Need Assessment Survey - Plastic Cluster, Aurangabad

1 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai

Need Assessment Survey ReportPlastic Cluster, Aurangabad

Survey byNIFT Mumbai

Supported byMCED Aurangabad,

NID Ahmedabad, & Design Clinic Scheme

by Ministry of MSMEs Govt. of India

2014www.designclinicsmsme.org


Design Clinic Scheme is a tested strategic model of design intervention, where a solution to an existing design problem is diagnosed and remedial steps suggested by a multi-disciplinary team of design experts. In this scheme, the value additions to an idea or a concept are imparted through interaction at a lesser cost to a specific industry/sector. It applies to a sector that requires intervention, like manufacturing etc. as the existing conventional models of design consultancy and training are not viable. These models bring design exposure to the door-step of industry clusters for design improvement, evaluation, analysis and adopting even long-term consultancy/design related intervention

The main objective of the Design Clinic is to bring the MSME sector and design expertise into a common platform, to provide expert advice and solutions on real time design problems, resulting in continuous improvement and value addition for existing products. It also aims at value added cost effective solutions. These Design Clinics in clusters of the country are to usher in a continuous competitive advantage to the MSMEs.

The broad activities planned under the scheme include creation of Design Clinics Centre along with four regional centres for intervention on the design needs of the MSME Sector. Further these centres will have linkages with engineering, management, design institutes of the country.

The scheme is under operation in a Public Private Partnership (PPP) Mode.

http://www.dcmsme.gov.in/schemes/DesignClinic.htm

FRONT COVERInjection Moulding at Darshan PlasticsMIDC, Waluj, Aurangabad

BACK COVERFinal Packing of finished products at Darshan Plastics MIDC, Waluj, Aurangabad


Contents

Synopsis 04Acknowledgement 05Need Assessment Survey 06

Introduction 07About DCS MSME 08 About MCED Aurangabad 10About NID Ahmedabad 11About NIFT Mumbai 12The PESTEl Analysis-Aurangabad 13SWOT analysis–Aurangabad 21Industry Attractiveness & Govt. Initiatives 22About the Plastic Cluster 24Intervention Pathway 25

Survey 26list of Participants 27

Annu Industries 29APM Plast 40Blue Star Engineers 60Concept Auto Packaging 72

SWOT analysis - Cluster 380Finding 383Recommendations 386

5 Day Workshop 390About the Workshop 391Schedule of the Workshop 392Day 1 394Day 2 395Day 3 396Day 4 397Day 5 398Design Briefs 399

References 401

Notes 402

Cool Engineering 81Darshan Plastic 91Electro Plast Industry 102Jayshree Enterprises 121Jyoti Industries 136Mitali Industries 146Moraz Plastic 163Mould Technology 166Plast Tech 180Rupesh Enterprises 189 Sejal Plastic 200Siddhi Polymers 214Snehal Plastic Industries 228Sunrise Auto Pack 241Sushma Industries 252Suyog Plastic 260Swagat Polymers 280Tirumala Industries 295Trimurti Polymers 311Ulka Plastic Industries 325V. P. Pet Polymer 336Varroc Polymer Pvt. ltd. (Tech.) 351Yogesh Plastic Industries 365

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Design Awareness Programme (DAP) is part of the Design Clinic Scheme, an initiative of the Ministry of Micro, Small & Medium Enterprises (MSME), Government of India (GOI) & National Institute of Design (NID).

The National Institute of Design, Ahmedabad, acts as the nodal agency for the Design Clinic Scheme. The Maharashtra Centre for Entrepreneurship Development (MCED) associated with National Institute of Fashion Tech-nology (NIFT), Mumbai; set up by Ministry of Textiles, Govt. Of India; to leverage the expertise of the institute in the arena of design education and its commitment to contribute to society.

The main objective of the Design Clinic Scheme is to provide a common platform for the MS&ME sector and Design experts for mutual sharing of ideas and form symbiotic relationship for creating sustainable growth envi-ronment for the MSME sector.

DAP initiative aims to evaluate real life issues and provide practical solutions for value addition in the current context while not ignoring the long term survival and growth potential.

Synopsis

Finished Products being packed at Snehal Plastic Industries, MIDC, Waluj, Aurangabad


We would like to express our sincere gratitude to Ministry of Micro, Small and Medium Enterprises (MSME), Government of India and National Insti-tute of Design (NID) Ahmedabad, for giving us the opportunity to be a part of the Design Clinic Scheme.

We would also like to extend our special thanks to The Maharashtra Centre for Entrepreneurship Development (MCED) to select us to do the project.

Our gratitude is also due to Mrs. Nilima R. Singh, Director-National Insti-tute of Fashion Technology, Mumbai for providing us guidance and support to successfully complete the report.

Our heartfelt thanks to all the Owners and workers of the units surveyed who took time out of their busy schedule and spent time in explaining the modus operandi of their business to us.

Acknowledgement

PET jar being manufactured at V. P. Pet Polymer, MIDC, Waluj, Aurangabad


The Plastic cluster at Aurangabad was contacted through MCED. An interview schedule was planned with all the unit owners who agreed to be a part of the survey.

Team:Mr. Saurabh KumarMr. Tanmay KandekarMs. lipi Choudhary

Objective: The primary objective of need assessment survey is to collate detailed cluster information in order to understand the business and supply chain issues like:

• Existing product design and packaging and scope of intervention or R&D for re-designing/ packaging changes or diversifying into different product categories.

• Current state of technology and scope of modernization• Visual identity and branding and other collaterals• Forward and Backward linkages for Marketing and Raw materials• Competitive structure and rivalry in the Industry• Infrastructure, ergonomics and environment factors• Manpower recruitment, availability of skilled labour, training and skill up‐

gradation opportunities.

Methodology:• Interview with unit owners (27 units).• Discussion with unit owner and workers.• Business Process observation.• Questionnaire survey of manufacturing units.• Self observation and analysis.

Need Assessment Survey

NEED ASSESSMENT PROCESS AND TOOlS

Expected outcome:This research aims to provide qualitative and detailed data of the plastic cluster to develop an understanding and generate insights into the business dynamics of the cluster. This would help identify the existing problems and future scope in the area for design intervention and business development.


Agricultural Sheet net being manufactured at Yogesh Plastic Industries, MIDC, Shendra, Aurangabad

IntroductionDCS for MSMEsMCEDNIDNIFTPESTEl AnalysisSWOT AnalysisIntervention Pathwaylist of ClustersInd. Attractiveness & Govt. Initiatives About the Plastic ClusterIntervention Pathway


PurposeTo increase awareness about the value of design and establish design learn-ing in MSMEs. To increase competitiveness of MSME products and services through design.

Objectives• To create a sustainable design ecosystem for the MSME sector through

continuous learning and skill development.• To promote use of design by MSMEs for developing products and services

that are market led.• To focus on building the design capability of MSMEs to enable them to

improve business performance as well as compete in the global market.

Key principles• Adopting a rigorous, yet applicant friendly, process.• Promoting and disseminating design concepts in regional or local languag-

es understood by the MSMEs. Establishing benefits without overwhelming the MSMEs.

• learning from other successful design-support programmes.• Establishing systematic processes for R&D in MSMEs.

Scheme descriptionFor easy percolation of design thinking and philosophy and maximum benefit for MSME units the Design Clinic Scheme is divided at 3 broader levels. These activities are helpful in smooth transition in to several levels of design inter-vention in industrial and business activities of MSMEs.

Design Awareness SeminarThe design sensitisation seminar is aimed to create a platform for MSME units

to improve the manufacturing competitiveness. The seminar will help MSME participants to interact with design experts/speakers to understand design methodology and benefits of design to MSME in their business, product, process, service and operations. To take design to a higher level of manufactur-ing functions, it is very important to develop an understanding of the design scenario and environment at an early stage of conception.

Design Awareness ProgrammeThe design awareness programme is focused on exploring industrial functions and activities to develop a holistic map of MSME clusters and units. The design expert/s will generate design information about products, market scenario, technology, communication, research and development, and various industrial functions along with human factor study for ergonomics, safety, convenience, learning and skill up gradation through design research. The programme will also provide design remedies for identified opportunities through the design clinic workshop.

The design awareness programme is conducted in two stages:• Need Assessment Survey• Design Clinic Workshop

Design ProjectsDesign projects are identified during the need assessment survey and discussed during the design clinic workshop. Project which require intensive design observation and interventions can be taken up as design projects with the help of design experts. The project can be related to design intervention in area of product/process /strategic areas where design can help in generating solutions and value for individual or group of MSMEs.

About DCS for MSMEs


Role of Design in Improving CompetitivenessDesign is an approach, process and methodology. Design is indented, purpose-ful, contextual, which is aimed to create advantage, distinction and futuristic outcome as a result. Design is systemic and holistic in nature, there fore helps in generating more creative, impactful and sustainable solutions. In manufac-turing, design is commonly associated with industrial product design – specif-ically the ‘aesthetics and appearance’ of a product at a surface level interaction. However, the application of design is much broader, for example designing for functional appeal, ease of manufacture, consumption and sustainability. De-signing may also be done for reliability or quality or business processes. Service designs are primarily to cater to customers experience of the delivered product and service.

The larger purpose of design is to do things in a better manner, to improve a situation and to make a positive difference. The role of design in business is to create value. A company can use the design process to add value to products, services, and the organisation. A well-designed product, service, or organisa-tion is always more valuable.

Design, innovation and growth are linked. Innovation and design are not simply about new products or technology. They are also about how to improve products for everyday use, leading to reduced costs, increased usability and new business opportunities. Design is recognised as an innovative discipline that can help MSMEs to sustain and grow in an increasingly competitive mar-ket.

About DCS for MSMEs


MCED has been a pioneer in espousing social and economic entrepreneurship since 1988. It is one of the foremost institute working in the areas of Entrepreneurship development.

MCED conducts special training programs, Seminars and skill development courses for young and budding entrepreneurs and encourages them to solve their problems in respective start-ups.MCED benefits the self employed people greatly by sharing the knowledge and success of the industry experts.

MCED has its offices all over Maharashtra. Beyond Maharashtra, MCED has offices in Delhi, Assam and Goa.

Need Assessments Survey Approach Process:Steps below are followed to meet the objective of Need Assessment Survey

• Questionnaire survey of Units.• Process Observation of the Unit.• Interaction with Unit management.• Opportunity areas finding.

About MCED Aurangabad


On April 7, 1958, Charles and Ray Eames presented the India Report to the Government of India. The India Report defined the underlying spirit that would lead to the founding of NID and beginning of design education in India. The Report recommended a problem-solving design consciousness that linked learning with actual experience and suggested that the designer could be a bridge between tradition and modernity. The Report called upon future de-signers to re-examine the alternatives of growth available to the country at that time.

Based on the recommendations made in the India Report, the Government of India with the assistance of the Ford Foundation and the Sarabhai family estab-lished the National Institute of Industrial Design, as it was originally called as an autonomous all-India body in September 1961 at Ahmedabad. This unique curriculum and revolutionary educational philosophy remain part of NID to the present day.Today the National Institute of Design is internationally acclaimed as one of the finest educational and research institutions for Industrial, Communication, Textile and IT Integrated (Experiential) Design. It is an autonomous institution under the aegis of the Ministry of Commerce and Industry, Government of In-dia and is recognised by the Department of Scientific and Industrial Research, Government of India as a Scientific and Industrial Research Organisation.The aim is to provide design intervention for craft, handloom, rural technol-ogy, small, medium and large scale enterprises, and outreach programmes for capability and institution building and sustainable livelihood, employment opportunities and economic growth.

NID has been a pioneer in industrial design education after Bauhaus and Ulm in Germany and is known for its pursuit of design excellence to make Designed in India, Made for the World a reality. NID’s graduates have made a mark in key sectors of commerce, industry and social development by taking role of catalysts and through thought leadership.

About NID Ahmedabad


National Institute of Fashion Technology (NIFT) is an institution of Design, Management and Technology. It was set up in 1986 under the aegis of the Min-istry of Textiles, Government of India and NIFT has been granted statutory status under the act of Parliament of India in 2006, empowering the Institute to award degrees and other academic distinctions.

In 2006, the Parliament passed the National Institute of Fashion Technology (NIFT) Bill, 2006, thereby receiving a statutory status and empowering the in-stitute to grant its own degrees and other academic distinctions. It also counts among the coveted list of an Institute of National Importance by the Parliament of India.

With its head office in New Delhi, NIFT has centers at Mumbai, Kolkata, Kan-gra, Gandhinagar, Hyderabad, Chennai, Bangalore, Raebareli, Patna, Shillong, Bhopal, Kannur, Bhubaneswar and Jodhpur where it offers four-year bachelor and two-year master programmes in the areas of Design, Management and Technology.

NIFT’s graduates have made a mark in key sectors of entrepreneurship, com-merce, industry and social development by taking the leading responsibilities as design and business leaders.

About NIFT Mumbai


A PESTEl analysis is a framework or tool used by marketers to analyse and monitor the macro-environmental (external marketing environment) factors that have an impact on an Industry/Organization.

Social Forces

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PESTEL stands for:• P – Political• E – Economic• S – Social• T – Technological• E – Environmental• l – legal

As the Plastic Cluster in Aurangabad is similar in its dynamics to an indus-try barring its size, the PESTEl analysis of Aurangabad becomes pertinent to identify the key variables that drive the Plastic Cluster.

The PESTEl Analysis - Aurangabad

POLITICAL

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History:A prime minister of the Muslim Kingdom of Ahmednagar, Malik Ambar established a town at a village called Khirki. later, his son Fateh Khan named the town as Fatehpur in 1626. Mohammad Bin Tughlaq tried to switch over the capital of his Delhi sultanate to Fatehpur in 14th century keeping in mind the strategic location of the town. The town was at the centre of India, and the region was considered the safest from the marauding armies of the Afghan and Central Asian raiders.

When Aurangazeb took over the Deccan kingdoms, he changed the name of the town to Aurangabad in 1653. Aurangazeb used the town as the strategic point to suppress the rising power of Shivaji. Aurangabad was taken over by the Nizam of Hyderabad after the death of Aurangazeb in 1707 that retained control till it was merged with Maharashtra in 1956.

Source: http://www.maharashtratourism.net


* Aurangazeb * Shuja, Aurangzeb, and Murad Bakhsh

Current Scenario: The BJP-Shiv Sena alliance is ruling the Aurangabad Municipal Corporation (AMC). Aurangabad comprises of 9 talukas and 1344 villages, covers an area of 10,107 sq km out of which 141.1 Sq. Km is urban area and 99,587 sq. Km is rural area. The population of around 36.95 lacs. There are no minerals availa-ble in Aurangabad. In Aurangabad district total forest area is 135.75 Sq.Km.

ECONOMIC

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Maharashtra Industrial Development Corporation established a number of industrial estates at various locations in and around Aurangabad, which con-tributed immensely to the economic growth and development of the area.

Key Economic Drivers: AurangabadIndustry Established Industries: Automobiles, Auto components, Pharmaceuticals,

Breweries, Food Products, Plastic, Rubber, Paper & Paper ProductsTourism World heritage sites of Ajanta, Ellora and other tourist destinations of

Daulatabad, Bibi-ka-Makbara attract large number of touristAgriculture Cotton, Sugar-cane, Maize, Bajra, Jowar, Soyabin, Sunflower, etc.Education Engineering, Management, Medical and vocational fieldsHealth Availability of ample medical facility with hospitals viz. Govt. Hospital, MGM

Hospital, Nandlal Dhoot Hospital, Dr. Hegdewar Hospital, Kamalnayan Bajaj Hospitals, Etc.

Present Industrial Status of Aurangabad:

Prominent Industries:•AutomobilesAssembly•AutoComponents•Beverages•Pharmaceuticals•WhiteGoods

The major industrial houses present are as follows:

• Videocon, Garware, Ajanta Pharma, Glenmark, lupin, Wipro, Orcid Pharma, Endurance Systems, Rucha Engg., Indo German Tool Room, Ceekay Daikin ltd., Cosmo Films, NRB bearing, Hindalco, Almex Aerospace, Can-pack India, Varroc, Dagerforst, FriogoriFico, Allana, Nath Seeds among others.

• Speciality in Automotive, Auto components, Pharmaceuticals, Breweries, Con-sumer durables, Plastic processing, Agriculture and Biotech. Among these Re-combinant Insulin Manufacturing Plant of Wockhardts (Wockhardt Biotech Park) is the largest Bio-pharmaceutical plant in India.

• The Shendra, Chikalthana and Waluj MIDC are prominent industrial zones on the outskirts of the city, with various major multinational groups having set up manufacturing or processing plant in and around the city.


Micro Small and Medium Enterprises (MSMEs):

Aurangabad has 3,405 medium and small scale units generating about 36,871 jobs with an investment of Rs. 404.86 Cr. It is estimated that by year 2020 these units will grow to 9000 nos, generating about 95,000 jobs with an investment of Rs. 1050 Cr.

Large Scale Enterprises in the District:

• Aurangabad has around over 195 units of large scale enterprises or Indus-trial Enterprises Memorandum (IEM) which has generated 80,500 jobs with total investments of Rs. 7,384 Cr.

23% 30%

7%29%

11%

21% 30%

8%29%

12%

Sector wise Units Contribution -2010 Sector wise Units Contribution -2020

Engineering

Manufacturing Machinery

Beverages & Food Products

Pharmaceuticals

Rubber & Plastic

Engineering

Manufacturing Machinery

Beverages & Food Products

Pharmaceuticals

Rubber & Plastic

• It is estimated that by year 2020 these units will grow to 343 units generat-ing over 1,95,000 jobs with total investment of Rs. 1,79, 590 Cr.


Currently has 5 MIDCs and 2 Growth Centres.•PlasticandRubberProducts

Comparative Analysis of Industrial Districts:

SOCIO-CUlTURAl

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The rule of the “ Satavahanas” witnessed the era of peace and prosperity and hence the district of Aurangabad then centered around Pratishthan the capi-tal of the Satvahanas for centuries together, became the hub of socio-cultural activities of the Deccan.

The Satvahanas gave incentive to trade and commerce and monopolised the Greeco-Roman markets as far textile goods namely Paithani the high-class silk-en sarees of Paithan is concerned.

The current day Aurangabad offers a wonderful opportunity to step back to past history. Ajanta and Ellora caves and Bibi-Ka-Makbara bring back the visi-tors to the past history of the town.


Aurangabad Caves Bibi-Ka-Makbara

Key Festivals and Fairs in Aurangabad:Ajanta and Ellora Festivals: It is the festival of classical dance and music under the backdrops of the Ellora Caves. The festival usually falls in March. The festi-val showcases best talents from across India. Maharashtra government organiz-es the festival.

Aurangabad Festival: Aurangabad Festival promotes the rich local culture, tal-ent, art and heritage of the city. The festival is organized to explore the hidden talents and to increase the vibrancy of this historic city. The festival generally falls in December. The Aurangabad Festival Committee organizes it.Buddha Jayanti: Buddha Jayanti is organized in the city as an important fes-tival. Community halls and public places are remained crowded for mass prayers. Religious processions are also taken out on this day.

Dussehra: Dussehra is celebrated for ten days. On the tenth day, a fair is held when people greet each other with offerings of ‘Apta’ leaves that symbolize good luck. Source: http://www.maharashtratourism.net

Current social scenario:Population: According to the census of 2011 the Male Vs Female population of Aurangabad is 1,928,156 Vs 1,767,772 respectively.Traffic is minimal, the roads are barely motorable and the errant traffic sense of

its residents is no different than in any other Tier II town.

However, the southern side is the face of new wealth: A stretch of sprawling bungalows dotting the streets. Jalna Road, an arterial road that connects the city, is the nerve centre. Practically everything is located in and around this stretch.

The evidence of prosperity and change are clearly visible; from the four-month-old 800,000 sq ft Prozone mall, which is the largest and only mall in the city, to dealerships of automobile brands like Skoda, Nissan and Maruti Suzuki and eateries and hotels like the Taj and lemon Tree.

In the last five years, the city has morphed well beyond its status as Maharash-tra’s tourism capital into a hotbed of industrial activity, primarily led by the automobile and engineering cluster. In more recent times, the growth has been spurred by agriculture and real estate development. Cotton farming has grown in the surrounding villages.

Farmers have thrived thanks to cotton prices hovering at an all time high of around Rs. 4,500 per quintal. Residential real estate prices have zoomed. Prop-erties were valued at around Rs. 20 lakh an acre in areas like Nashik Road, Old Bombay Road and Beed Road in 2006. Prices have risen five times in the last four years.

Source: http://forbesindia.com/article/on-assignment/the-value-hunters-of-au-rangabad

Emerging Socio Economic Trends•ItisemergingasaregionalhubonthelinesofPuneandNagpur•Attractinglargeinvestmentsinindustrial,Services&Tourismsectors•Thecityhasovertenlakhpopulationwithalarminggrowthprojections•Itisemergingasacentreforhighereducationandhealthfacilities•Rapidurbanizationandencouragingdevelopment•Enhancedsocialinfrastructure•Worldclasstouristdestinations,promotionstoindustrialsector


TECHNOlOGICAl

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The IT sector promotion was initiated in Aurangabad since year 2003 along with the formation of HTPI office and IT park in Chikalthana in vicinity to Pune and Mumbai.

Good educational base, existence of local IT units and industrial maturity of the city due to manufacturing segment, low cost of operation are plus point of the city for the future IT sector growth.

i) Currently, around 22 IT units are operational employee 2500 professionals. The city has 6 registered HTPI, 100% EOUs exporting services worth Rs, 7 crores per year to USA, Germany, Neatherland, among others.

ii) In past two years, BPOs have been established which are providing services in various languages to local customers and also to few international clients. Aditya Birla group, Vodaphone are extending services to their clients, through BPOs at Aurangabad.

The key machines used by the plastic cluster are:• Injection• Extrusion• Compressor

• Grinder

The key software used in the plastic cluster:• Tally(foraccounting)• MicrosoftExcelandWord

ENVIRONMENTAl

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The total area of Marathwada region is of 64,813 km. and is bounded by the Vidharbha region on the North, by Andhra Pradesh on the East and South-east, by Karnataka on the South and by Western Maharashtra on the West. The entire region is situated at an average height of about 300-650 m. above Mean Sea level gradually sloping from West to East, and is traversed by hill ranges origination from the Sahyadris in the West and the Satpudas in the North.The weather is generally dry and moderately extreme. The average day tem-perature ranges from 27.70 C to 38.00 C while it falls from 26.90 to 20.00C during night. Similarly summer and winter temperature also varies greatly. The highest during summer day being about 43.30C while the lowest during winter nights about 6.00C. Relative humidity is extremely low for major part of the year (between 35 to 50%) while it is highest (85%) during monsoon.


The rainy season is considered from middle of June to the end of September which is followed by a sultry period from about the end of September to the middle of November. The winter season commences from the middle of No-vember and ends by the end of the January followed by a dry hot summer from February to middle of June. Summers are in general full of gusty winds. The normal average rainfall is about 90 cm but is rather variable form year to year.

Aurangabad and Nanded districts covers more forest area than the others. There are Teak, Sandalwood, Anjan, Moh, Tembhurni, Ain and other kinds of trees in these forests. In Aurangabad district, Gautala is a well known sanctu-ary, Jayakwadi is also famous for bird sanctuary. Thorny scrub forests are hav-ing major trees like Bor, Babul, Aloe-voera etc. The major agricultural crops of the Marathwada region are Cotton, Oil seeds, Bajra, Jowar, Groundnut, Wheat, Safflower and irrigated crops like Sugarcane which is one of the important irrigated crop.

lEGAl

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MICRO, SMAll & MEDIUM ENTERPRISES DEVElOPMENT (MSMED) ACT, 2006

Definition of Micro, Small and Medium Enterprises :(a) Enterprises engaged in the manufacture or production, processing or pres-ervation of goods as specified below:

i. A micro enterprise is an enterprise where investment in plant and machin-ery does not exceed Rs. 25 lakh;

ii. A small enterprise is an enterprise where the investment in plant and ma-chinery is more than Rs. 25 lakh but does not exceed Rs. 5 crore; and iii. A medium enterprise is an enterprise where the investment in plant and machinery is more than Rs.5 crore but does not exceed Rs.10 crore.

Key initiatives by the Government:a) As per announcement made by the Governor in the Annual Policy Statement 2005‐06, a scheme for strategic alliance between branches of banks and SIDBI located in clusters, named as “Small Enterprises Financial Centres” has been formulated in consultation with the Ministry of SSI and Banking Division, Ministry of Finance, Government of India, SIDBI, IBA and select banks and circulated to all scheduled commercial banks on May 20, 2005 for implementation. SIDBI has so far executed MoU with 15 banks (Bank of India, UCO Bank, YES Bank, Bank of Baroda, Oriental Bank of Commerce, Punjab National Bank, Dena Bank, Andhra Bank, Indian Bank, Corporation Bank, IDBI Bank, Indian Overseas Bank, Union Bank of India, State Bank of India and Federal Bank).

b) Targets for lending to Micro and Small enterprises (MSE) sector by Domestic Commercial Banks and Foreign Banks operating in India.

c) Issue of Acknowledgement of loan Applications to MSME borrowers.

d) Banks are mandated not to accept collateral security in the case of loans upto Rs.10 lakh extended to units in the MSE sector. Banks are also ad-vised to extend collateral‐free loans upto Rs. 10 lakh to all units financed under the Prime Minister Employment Generation Programme of KVIC.

e) A composite loan limit of Rs.1 crore can be sanctioned by banks


to enable the MSE entrepreneurs to avail of their working capital and term loan requirement through Single Window.

f) Public sector banks have been advised to open at least one specialised branch in each district. As per the policy package announced by the Govern-ment of India for stepping up credit to MSME sector, the public sector banks will ensure specialized MSME branches in identified cluster/centres with preponderance of small enterprises to enable the entrepreneurs to have easy access to the bank credit and to equip bank personnel to develop requisite expertise.

g) UDYOG SETU:Objective: To establish new industries, give information & guidance regarding: •Variousrules&regulationsofGovt.•Variousincentiveschemes.•PermissionrequiredfromGovt./SemiGovt.Institutes•Clearancecertificates.•Variousservicesasperneedofapplicant.•Allaboveservicesatonecounter&withinpredeterminedtimelimit


Strength:1. Historical background of the District useful for Foreign Investor.2. Tremendous scope for ancillarisation of industries Especially in Engineering units3. Central location of India.4. Good communication system available.5. Good Transportation Connectivity available i.e. Road, Rail & Air, with all over India.6. A strong young first Generation Entrepreneurs in Aurangabad.7. Skilled & unskilled man power Available at very low cost.8. Good dealer network & logistic facility is Available.9. Educational Intuition like ITI/Engg. College/IGTR/ CIPET/MCED to facilitate and support to industries.10. Due to major financial institute running in Aurangabad, finance is made easily available to the Industries.

Weakensses:1. Poor Water Supply System.2. Improper maintenance of available Infrastructure3. lack of coordination with different Govt.. Depts.4. Inadequate Working Capital from F.I. & higher rate of interest.5. R & D / Technology up gradation Facilities are not available.6. low level of Business exports7. Awareness Camps/seminars are not organized so frequently.8. High level of skilled man power is not available

Opportunities:1. MIDC has plan to develop Additional MIDC’s in the region which creates good opportunities for industries. (MIDC - Maharashtra Industrial Development Corporation )2. Cluster development programme of Central Govt.. boost for creation of jobs

SWOT Analysis of District Aurangabad

/ skilled & unskilled man power.3. Expansion project of CIPET is playing vital roll for plastics mfg in the region.4. DMIC (Delhi Mumbai Industrial Corridor) Project develops the Region.5. Scope for tourism due to Historical background.6. Major Investment & Job creation due to State Govt.. Mega Project policy.7. Wide Scope for retail sector.

Threats:1. Shortage of Power.2. labour policy to be reviewed.3. Pollution (17th rank district)4. Non availability of Agriculture labour5. Dependency on large scale Industries for ancillary Industries.6. High costing of Industrial land.7. labour union problems. Experts from DIC (District Industries Centre ) document published online.


Industry Attractiveness & Government Initiatives - Aurangabad


DMIC Corridor


The cluster comprises of small and medium industries manufacturing product parts for various industries like Bajaj Auto, Crompton Greaves, Verroc group, Videocon, Tata Motors, Piaggio.

The cluster makes sub-components for the OEM’s (Original Equipment manu-factures ) and Tier 1 & Tier 2 suppliers. The products from the MSME units to their customers are tail lamp, foot rest cover, poly-wraps, pet jar, PVC irriga-tion pipes, automotive plastic components, water tank, case for mirror

The key machines used by the plastic cluster are: Injection, Extrusion, Com-pressor, Grinder etc.

The key software used in the plastic cluster are: Tally (for accounting), Micro-soft Excel and Word.

Institutions at Aurangabad•DistrictIndustriesCentre,Aurangabad•MaharashtraIndustrialDevelopmentCorporation(MIDC)•Micro,Small&MediumEnterprises–DevelopmentInstt.Aurangabad–Abranch office of MSME-DI, Mumbai.•MSME-ToolRoom,Aurangabad(IGTR)•NationalSmallIndustriesCorporation(NSIC)•MSME–TestingCentre,Mumbai.•BureauofIndianStandards(BIS)•EngineeringExportPromotionCouncil(EEPC)•SmallIndustriesDevelopmentBankofIndia(SIDBI)•IndianInstituteofTechnology,Mumbai(IIT)•MITCON•MaharashtraCentreforEntrepreneurshipDevelopment(MCED)•Govt.Engineeringcollege,Aurangabad

About the Plastic Cluster at Aurangabad

Associations & Firms•TheTinyIndustriesCo-operativeIndustrialEstateLtd•MarathwadaAssociationofSmallScaleIndustries&Agriculture(MASSIA)•ChamberofMarathwadaIndustriesandAgriculture(CMIA)

Category of companies in AurangabadCategory – 1 Suppliers of raw materialsCategory – 2 Plastic Component manufacturers (Tier 1, 2 or 3 suppliers)Category – 3 Part Assembly unitsCategory – 4 Precision Plastic product mfrs.Category – 5 Testing & Analysis unitsCategory – 6 Plastic products small manufacturers & retailers Category – 7 lead Firms (such as Bajal Auto ltd., Crompton Grieves ltd., Videocon, Varroc)Category – 8 Plastic Equipment SuppliersCategory – 9 Outsourcing Companies, Merchant & Traders, Market AgentsCategory – 10 Clearing Agents, CA firms, etc.

Salient features of cluster1. Good infrastructure with RCC buildings and-roads2. Frequent Job orders from customers3. Availability of Business education through MCED.4. Financial assistance from banks for Machines & Infrastructure.5. Sustained growth over the years6. Cluster association looks into welfare of all units.


ElICIT

EXPlORE

EXPAND

EVAlUATE

EMPOWER

Survey to arrive at SWOT for each unit and understand their future goals and aspirations

Workshops to identify their training needs and competencies to chalk out a customised growth plan by mutual consent

• Evaluation of success

• Consolidation of learning

• Modifying systems and processes wherever possible

Intervention on:• New Product development• Market linkages• Branding• Display• Sign-ages• Website development and

online marketing• Awareness about Govt. Rules,

Regulations and schemes• Common Facility Centres

• Forming associa-tions or groups to disseminate learning

• Documenting the success stories for reference by others as Best Practices

• To ensure that the cluster becomes sustainable

The 5-E process of Solution- Focused Intervention

Step 1: Eliciting - Obtaining a clear understanding of the Client’s goals at the outset of intervention.Step 2: Exploring – Delving deeper into issues to arrive at possible alternatives.Step 3: Expanding – Enabling the client to expand his success and resources to other areas and encouraged to “do the exception” more frequently.Step 4: Evaluating – Clients’ judgement is yardstick to evaluate the success of intervention.Step 5: Empowering – When desired results are achieved, the focus shifts towards empowering these people to maintain the changes on an ongoing basis by rou-tinely employing maintenance strategies on an ongoing basis.

Intervention Pathway


Turning Process at Mould Technology, MIDC, Waluj, Aurangabad

Survey - Plastic ClusterA total of 27 companies were surveyed

Colour Coding:The following pages have different coloured circles over the photographs to indicate the effectiveness of the process. These are colour coded and also vary in size to indicate relevancy.

Good process/product feature/practice

Decent process/product feature/practice, can be improved further

Needs immediate intervention


Need Assessment Survey - Plastic Cluster, AurangabadSr. no. Name of Unit Name of Proprietor/

OwnerProducts Unit Address Mail ID Contact No.

1 Annu Industries Vishal Panjabi Automotive Parts. F- 60, MIDC, Waluj, Aurangabad. [email protected] 92253646332 APM Plast Ajinkya Nandkumar

KawathekarEngineering Plastic Products Pl. no. ,A-42, B/2, Railway Sta-

tion,MIDC, [email protected] 9689737899,

98226832963 Blue Star Engineers Rajesh K. Sanghavi Plastics M. V. & Home Appli-

ances Parts.Plot NO. 96/13, Arihant, Pannal al Nagar,Osmanpura, A'bad.

[email protected] 9371135475, 9371135486

4 Concept Auto Pack-aging

Rahul S. Neele fully Auto on line Care Pack-ers.

F-16/4, MIDC Chikalthana, Auran-agabad

[email protected]

9405963499, 8888864242

5 Cool Engineering S. P. Kale Water Chillers, Industrial Re-frigerators

Plot No.23,MIDC,Station Road,Au-rangabad

[email protected]

9822019718

6 Darshan Plastic Ashok B. Thorat Plastic Injection mowded Com-ponents.

W-71, MIDC, Waluj, Aurangabad. [email protected]

8007800122, 8007800112

7 Electro Plast Industry Syed Shaukat Abdul Rauf

Inter Strage Tank Electro Plast Industries , K-49, MIDC, Waluj, A'bad.

[email protected] 9595463964, 9890217103, 7620077735

8 Jayshree Enterprises Shailendra Prataprao Baviskar

Plastic Injection Products Plot No.19, MIDE, Waluj, A'bad. [email protected]

8888805868

9 Jyoti Industries Atmajyoti Bapu Na-gare

Drip Irigation. D-107, Shendra MIDC,Aurangab-ad.

[email protected]

8928187703

10 Mitali Industries Pramila Kanha Kashide

Auto Components. Pl.no. 5-1, Opp. Good year tyre Midc, Waluj, A'bad.

[email protected]

9421683397, 9767100466

11 Moraz Plastic Vilas More In Process Yeshwant Nagar, Navle, Paithan [email protected]

9028173531

12 Mould Technology Bhalchandra Dhond-pant Bhandrao

Plastic Moulds & moulding Products.

Plot No. M-92/1, MIDC, Waluj, A'bad.

[email protected]

9370656737

13 Plast Tech laxman Irana Man-dkar

Appliances spare parts Plot no. C-252/6-A-4, MIDC, Waluj, A'bad.

[email protected]

9326206512

list of Participants


14 Rupesh Enterprises Godavari Dattrao Narwade

Plastic Mould & Dies Plot No. D-51/10, MIDC, Waluj, A'bad.

[email protected]

9881243938

15 Sejal Plastics Santosh Vajantrao Joshi

P. P. Mats Plot No. D-81, MIDC, Shendra, A'bad.

[email protected]

9370150700

16 Siddhi Polyweave Shashikant Nagnath-rao Ernale

P. P. Mats Plot no. l-18/1, MIDC, Waluj, A'bad.

[email protected]

9970053151

17 Snehal Plastic Indus-tries.

Bharat Hariba Shindi-kumate

Caster Wheel M-127, MIDC, Waluj, Aurangabad. [email protected]

8888837991

18 Sunrise Auto Pack Raju Suresh Neele Flyash Bricks. F-16/4, MIDC, near Gautamn Dalmill, Naregaon road Chikaltha-na, Auranagabad

[email protected]

8888864242

19 Sushma Industries Parvati Mahadeo Phunde

PVC Pipe Shendra MIDC, B-95, Aurangabad. [email protected]

9404012247

20 Suyog Plastic. Vinay Walandikar Agriculture , Electrical, Auto-mobile.

E-70/27, Waluj, Auranagabad. [email protected]

9923143839

21 Swagat Polymers Ashok R. Joshi Packaging Products Plot NO. 210, Saileela, Ulka nagari, Waluj, A,bad.

[email protected]

9822037318

22 Tirumala Industries Ajay Annasaheb Patharikar

Plastic Water Tank Plot no.H-5/41, MIDC, Chikaltha-na, Aubad.

[email protected]

9850963136

23 Trimurty Polythenes Misal Bhaskar Hariha-ranrao

Poly Bags & Sheets For India. Gut No. 48, Plot No. 12, Near MIDC, Waluj, A'bad.

[email protected] 9372005542

24 Ulka Plastic Industries Sachin S. Thete Krishi Pipe, polymers Sheets B-10, Add. Midc Jalna, A'bad. [email protected] 997565619325 V. P. Pet polymer. Jayshree N. Somase pet jars , pet bottels E-97, MIDC, Waluj, Aurangabad. info@vppetpolymers.

com9370146402

26 Varroc Polymer Pvt. ltd. Tech. Centre

Ritesh Solanke Seat Assembly, Air Forse, Body Parts & Mirrors.

M-138/139, MIDC, Waluj, Aurangabad

[email protected]

9673001597, 9673001490

27 Yogesh Plastic Indus-tries

Yogesh Vrajlal Parmar Plastic Shed net. Plot No. A-114/3, Five star MIDC, Shendra, Aurangabad

[email protected]

9403759542


01Ann

uIn

dustr

ies


Name of the Unit: Annu IndustriesAddress of the Company: F – 60, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9225364633 (Vishal Panjabi, Plant head)Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2010

Type of Company: Proprietorship

Company’s Specialization/Product/Services: Nylon automotive parts like chain cover, foot rest cover

Details of the Owners / Partners:

Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Mr Niraj Goel

55 yrs Owner Graduate

Company’s Initial Investment: 30 lacs

Loan/Financial Assistance taken since the start of the company: Not taken

Annu IndustriesMIDC, Waluj, Aurangabad

Vendor Code Details: It is available for Kumar elastomer Pvt ltd., Tata motors and PIAGGIO for products such as Tail lamps, chain cover and foot rest cover.

Types of Customer:Type Total number of

CustomersNames/List of Customers Products

ManufacturedAutomotive 2 Kumar Elastomer and Tata

Motors

Total number of Employees at the company: 45

Types of Business: As a Tier 2 Supplier to OEM for products such as Chain cover, foot rest cover, tool lamp

Area of the Unit: Plot area is 7000 sq. ft.

Certifications: TPM

Audit Reports: Yes

Types of Machines: 12 injection moulding, grinder, Mixer, etc.

Raw materials: Nylon

Warehouse/Storage of Raw material (Inventory Control Techniques)Order Quantity: As per customer requirementOrder Process: Direct from SupplierQuality Control: Yes as per requirement


Quality Control PlanProject Documentation Yes

Quality Control Procedure: (In house/ External agency)

Yes In-house• Visual Inspection• Finishing & Deflashing• Dimension Checking & other defects

Testing of Raw Materials (Incoming - Quality Control Techniques)

Yes• Weight measurement• Strength and moisture checking

Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)

N. A.

Name of Testing Labs (tie-ups for Finished Products)

N. A.

Testing of Finished Products Yes• Visual Inspection• Dimension & Weight measurement• De-flashing & Finishing

Marketing and BrandingEffectiveness of the company logo Medium

Brand Awareness in respective markets; whether B2B or B2C

Medium

Initiatives taken to promote the Brand and Respective expenses

N. A.

Exhibition/trade shows visits: Plexpo and PlastIndia as visitors

Online services Yes

Human Resource ManagementEmployment recruitment rules On The Basis of

• Education• Work Experience in which company• Asking questions• Practical test

Male & Female Employees: 43 Males & 2 Female

Covered under ESI/EPF/Gratuity: Yes

Contract Worker Policy: N. A.

Assistance required from Government in the following areas:• Expansion• Up-gradation• Subsidies on raw material, new product development and business devel-

opment Assistance by CIPET, IGTR, ITI, MCED Aurangabad: N. A.


Company’s main entrance and is very well maintained.

The exit gate for the finished products.


Company’s raw material area clean and well maintained. The raw materials are very well segregated as per their specification.


Raw material HDPE bags stacked neatly

The wooden panels used to stack the raw material bags


Good management practices to maintain display boards

Area for continuous inspection of sample products manufactured on a daily basis

Bags of finished goods ready to be transported to clients


The injection moulded parts

The injection moulded parts

Annealing process adds value to the injection moulded parts w.r.t. its strength

The posture of the workers for long hours will make them suffer from work-related diseases.


Different moulds ready for maintenance

Annealing process in case of bulk items

Table for maintenance needs maintenance

Scrap stored is ready to be transported for recycling


Spanner and Allen-key board needs regular checks

Moulds are maintained in place neatly


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement Space arrangement is a concernNew Product Development No in-house product development process

followedPackaging Need to improveMarketing Market awareness is a problem. No marketing

for business growthHuman Resource Good training initiatives for the workers

Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Need to developWebsite Need to develop better one

RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.

Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-

gency situations.

Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.

Product: Company is supplying 90% of its production to single company. To reduce the business risk Company need to diversify into other products instead of focus-ing on single company.

Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.

Marketing:• A company website needs to be developed on an urgent basis so that the

customer reach can be extended.• As the company need to venture into other products, it requires more pub-

licity on retail level. A proper branding strategy should be formalised to get maximum visibility in the market.

• The brand identity (logo) needs to be more creative, to make a place in the customers perception.

• A proper career growth plan should be formalised, so that the attrition rate is reduced.

• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.

• Company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the develop-ment process.


02APM

Plas

t


Name of the Unit: APM PlastAddress of the Company: Plot No. A-42 – B/2, B/3 & B/4 Aurangabad Co. Op. Industrial Estate, Railway Station, MIDC, Aurangabad. landline number: 0240 - 2331312Mobile Number: 9822683296, 9822683294, 9922920338, 9689737899Company e-mail id: [email protected] Website: N. A. Company started in: 1990

Type of Company: Partnership

Affiliated units/sister concern/subsidiary:Sr. No. Unit Name Product/Service Address Contacts1 A. R. Polymers P. U. Casting,

Epoxy castingC-252, V- 16, MIDC Waluj

N. M. Kawathekar & R. S. Deshpande


Sr. N

o.

Nam

e of

O

wne

r /

Prop

riet

or

/ Par

tner

s /

Dir

ecto

r

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 N. M. Kawathekar 58 Partner BSC 15 yrs [email protected]

9822683296

2 S. Y. Despande 60 Partner B. Com. With BAl N. A. 9822683296

Company’s Specialization/Product/Services:• Injection moulding of Eng. Plastics • Epoxy casting• P. U. casting

Details of the Owner/Director Family members:

Sr. N

o.

Fam

ily M

embe

r

Rel

atio

n to

the

Ow

ner o

f th

e C

ompa

ny

Age

(in

Year

s)

Educ

atio

nal Q

ualifi

catio

n

Wor

k Ex

peri

ence

pri

or to

jo

inin

g th

e C

ompa

ny

Invo

lved

in C

ompa

ny’s

busi

ness

act

iviti

es (Y

es/N

o)

Rol

e in

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 A. N. Kawathekar

Son of N. M. Kawathekar

23 B. E. - Yes Produc-tion

9689737899

2 R. S. Deshpande

Son of S. Y. Despande

28 B.E. M.B.A.

Yes Market-ing

9922920338

Company’s Initial Investment: N. A.

loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt.

AssistanceYear Purpose Amount (Rs.) Status (Active/

Closed)1 Deogiti Nagari Co. Op. 94-97 Ind. Shade Rs. 400000 Nil

C. C. Rs. 800000

APM PlastMIDC, Railway Station, Aurangabad


Vendor Code Details:Vendor Code

Customer Issued in

Products Supplied Last Audit by Customer

1 Crompton Greaves ltd. 1990 Guide bush for VI 19.01.20142 Easun Refolled ltd. Electric Component

3 Vijai Electric ltd. Guide bush

Production capacity of the Unit:Year Production capacity2013-2014 28050210 (20 M.T.)2013-2012 35529827 (23.787 M.T.)2012-2011 39389982 (24.171 M.T.)2011-2010 31405620 (20.741 M.T.)2010-2009 29553356 (18.476 M.T.)

Types of Customer:Type Total number

of CustomersNames/List of Customers Products

ManufacturedAutomotive 7 Kumar elastomers Pvt.

ltd., SM Auto, Vedant etc.Waher, bush, spacer, Plung, fender clamp

Household Appliances 1 Texas furniture BushOthers Electrical 4 CGl, BMC, Tushiba group Bush, coller, Cap,

indicator, clip, cover

Total number and list of Vendors or Suppliers:• Hitesh polymer• G.K. Sales Corporation• OM Engineering• Shree ram Polymos• Shriram Enterprises


Organization Chart:

Director & M. R.(Mr. N. M. Kawathekar)

Purchase & Store I/C

Molding Machine Operator

Finishing Operator

Marketing Manager Quality In-charge ProductionShift In-charge

Director(Mr. S. Y. Deshpande)

Production & Dispatch I/C

APM PLAST

Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Guide bush, switchgear

unit componentsCGl, Toshiba, ERl, BMC, S. M. Auto, Badve Eng.

As a Tier 2 Supplier to OEM Washer and auto parts Kumar elestomer Pvt. ltd.

Area of the Unit:Plot Area 1300 Sq. FeetTotal Built-up Area 1300 Sq. Feet

Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2009-2010 6820629 1387497 6475492010-2011 7325062 2224451 13526632011-2012 9444973 2815519 19332112012-2013 10024783 2412054 1395007


2013-2014 (expected) 1,12,00000 2700000 1550000

Certifications:Certification Description of the Certification Year taken in local AgentISO 9001 : 2008 Main Certificate No.

18355-2008-AQ-IND ; R. A. Rev. 02ISO 9001 : 2008

Sept. 2004 Diwan

Audit Reports:• ISO• CGl Audit report

Company Plant and Process FlowCompany’s Plant layout:

Types of Machines:

Sr. N

o.

Nam

e of

M

achi

ne

Qua

ntity

Mak

e of

m

achi

ne

Spec

ifica

-tio

n

Pric

e of

the

Mac

hine

Year

of

Purc

hase

Loan

/ by

Self

1. Semi Automatic injection moulding

1 Ramco 200 grams

N. A. 1990 N. A.

2. Semi automatic Plenger type toggle lock machin

1 WASPAN 60 grams

N. A. 1992 N. A.

3. Semi automatic injuction moulding machine

2 WASPAN 40 grams

N. A. 1994 N. A.

4. Semi Automatic moulding machine

1 Self Made 200 grams

N. A. 2010 N. A.

5. Semi automatic moulding machine

1 Self Made 70 grams

N. A. 2011 N. A.

6. Bench Grinder 1 N. A. N. A. N. A. 2000 N. A.7. Drill machine 1 N. A. N. A. N. A. 2000 N. A.8. Electrical oven 1 N. A. 3500

wattsN. A. 2000 N. A.

9. Electrical oven 1 N. A. 3000 watts

N. A. 2011 N. A.

Types of Hand Tools:Sr. No. Name of Hand Tool Quantity1 Screwdrivers 10 - 152 Pilers 3 - 43 Magnifier 14 Hammers 2 - 35 Driling Machine 2

Raw materials


Sr. N

o.

Raw

Mat

eria

l

Cur

rent

Rat

e (R

s. Pe

r Kg)

Spec

ifica

tion

Supp

lier’s

Nam

e

Min

imum

qua

ntity

mai

n-ta

ined

in th

e co

mpa

ny p

er

mon

th

Prod

uct M

anuf

actu

red

with

th

e m

ater

ial

Prod

uct S

uppl

ied

to (O

EM/

Tier

1 su

pplie

r/Ti

er2

Supp

li-er

/Tie

r 3 S

uppl

ier)

1 Nylon 205 N. A. Windsor 300-400 kg

Guide spring washer

2

2 Glass field B 145 N. A. Shriram Polymers

400-500 kg

Bush coller indicator

1

3 Nylon B 150 N. A. Hitech Polymers

300-400 kg

N. A. 2

4 PPCP 126 N. A. Shriram Polymers

250-300 kg

N. A. 1

Information of Workers, Supervisors, Managers and Staff for clean-ing:

Shift Timings: 8 A.M. to 8 P.M.

Number of Shifts per day: 2

Sr. N

o.

Nam

e of

wor

ker

Age

(yrs

)

Gen

der (

M/F

)

Wor

kers

/Sup

ervi

sor/

Man

ager

/Sta

ff fo

r cl

eani

ng

Qua

lifica

tion

Ope

ratio

n/ F

unct

ion

Year

s of e

xper

ienc

e in

In

dust

ry

Wor

king

hou

rs/d

ay

1 N M Kawathekar 58 M Director B SC 24 yrs2 S V Deshpande 60 M Director B Com 24 yrs

3 A N Kawathekar 23 M Production Manager

BE 6 months

4 R S Deshpande 28 M Marketing BE MBA

2 yrs

5 Nitin M Supervisor 10th 19 yrs6 Baban Jadhav M Supervisor 10th 16 yrs7 Abhijit

DeshmukhM Worker 10th 2 yrs

8 Rohit Batelu M Worker 10th 2 yrs9 Bhimrao Kolte M Worker 10th 3 yrs10 Devendra Kolte M Worker 10th 3yrs11 Karan Mahske M Worker 10th 14 yrs12 Rahul Kumawat M Worker 10th 2 yrs13 Dnyaneshwar

JadhavM Worker 10th 11 yrs

14 Jankiram Ram-dari

M Worker 10th 12 yrs

15 Chaya Tapre F Worker 7th 24 yrs16 Mina Kolte F Worker 7th 17 yrs

Functions/Operations in the company:Function / Operation Required

Qualifi-cation of workers

Required number of workers

Shortfall of workers

Number of hours /shift

Number of shifts/day

Plastic Moulding 10th 8 hrs 1

Machine operations:Sr. No.

Machine name No. of labors required per machine

Time required for process

Idle time per shift of 8 hrs

Wastage %

1 Serni automatic Plastic injection moulding machine

1 As per compo-nent

0.25%


Flow chart of Business Process:


Flow chart of Manufacturing Process:


Products manufactured at the Company:Sr. No.

Product Name Cost to Company

Price to Customers

Repeat Order

Supplied to

1 Washer 0.12824 0.1603 Yes Aurangabad, Pune, Delhi2 Plug 0.58072 0.7259 Yes Aurangabad3 Guide Spring 3.216 4.02 Yes Aurangabad, Pune4 Guide bush 11.4 14.25 Yes Aurangabad, Hyderabad5 Former 14 17.5 Yes Hyderabad6 Epoxy Bushing 640 800 Yes Aurangabad7 Bobbin 20 25 Yes Aurangabad8 Nylon insulator 124.8 156 Yes Aurangabad9 Cable Clip 84 105 Yes Banglore10 Flamge indicator 12.8 16 Yes Banglore

Quality Control PlanProject Documentation: Does the company maintain Documents for every Project?

Yes


In house


Raw material quality control done by the suppliers. Using test certificates at the MSME’s end

Name of Testing labs for Raw Mate-rials (tie-ups for Raw Materials)

S. N. Metallurgical

Name of Testing labs (tie-ups for Finished Products)

S. N. Metallurgical

Testing of Finished Products It is done in house by manually

Quality Standard for Product:Sr. No. Product name Specification Strictly followed (Yes/No)1 V4 – 3 1079 All dimensions Yes2 K 39217924 All dimensions Yes

3 CAP – 12kv - 005 All dimensions Yes

Quality Manual: Sequence of Interaction of Process

Design & DevelopmentWhat is Design? “Design is the creation of a plan or

convention for the construction of an object or a system. It is a strategic approach for someone to achieve a unique expectation”

Design Process of existing products (choose any top one product that is being manufactured at the company for a OEM or a Customer)

Design Process/Plan for a new Product innovation: APM Plast has decided plan for near future to acquire Horizontal injection moulding machine to produce plastic articals which are more than 250 gms by weight. M/S Easun Reyrolle ltd Bangalore has given concept to produce such items for them.

Secondaly as our current business is vendor base, we propose to produce households items such as plastic buckets, Mugs, jugs and Glass.

To work out this plan we needs assistance in acquiring machine of appropriate capacity additional land for machine and running capital to run the business.

We had already started one project of key holder for entering in to retail mar-ket prototype of this is being made. Final touches will be given by the 2nd week of Feb 2014


Budget allocated for Research & Development (Annually in Rs.)

Rs. 1.5 lacks for last year (2012-13)

IT/CAD/Softwares/CAM used in the Company

N. A.

Exhibition/trade shows visits:

Sr. N

o.

Exhi

bitio

n /

Show

Part

icip

ant /

V

isito

r

Last

atte

nded

(Y

ear)

Fees

(in

case

th

e co

mpa

ny

part

icip

ated

)

Bene

fits

1 Engg. Expo Participant 2011-12 26,000 Yes2 Plast Vision Visitor 2012-13 600 Yes3 Elecarama Visitor 2013-14 - Yes

Safety standards in the Company:Manufacturing Op-erations

Possible accidents / hazards

Safety measures in the company

Remedies / Medica-tion

Plastic Injection Moulding

Splash of overheated material

Preheating of materi-al, glows, shoes

First Aid Box, Medi-cal Checkup

Marketing and Branding:logo of company:

Effectiveness of the company logo Medium

Describe the Company’s Target Market: Automobile industry, switchgear industries


Medium


N. A.

Online services No

Company label:Sr. No.

Labeling type Label specification

Material used

Vendor name/ In house

Machine details if pro-duced In house

1 Printed Stickers N. A. Paper Address Advertisor N. A.

Company Packaging:Sr. No.

Packaging type Packaging specifications

Material used

Vendor name / In house

Machine details if produced In house

1 PP Bags PP - -2 Corrugated Box Paper Akansha Packs -

Finance & AccountsCostingCost Sheet: Washer NylonDESCRIPTION


ITEM CODE lDA00010DESCRIPTION Washer NylonVENDOR CODEVENDOR NAME APM PlASTPlACE AURANGABADMOD NO 0RM SPECIFICATIONS NylonCOlOUR NaturalRM RATE-BASIC Rs/Kg 205.00 RM RATE-lANDED Rs/Kg 215.65 UV STABIlISER %ge Rs/Kg 0 0.0000 UVS CHARGES Rs 0.0000 NET WEIGHT Grms 0.1400 RUNNER WEIGHT Grms 0.0900 MElTING lOSS %ge 2.5 0.0058 less UVS WEIGHT Grms 0.0000 GROSS WEIGHT Grms 0.2358 RM COST Rs 0.0508 CONVERSION COST DE-TAIlSMACHINE TONNAGE SEMI AUTOMATMACHINE SHIFT RATE Rs 650.0000 NO OF CAVITY 10.0000 CYClE TIME Sec 40.0000 EFFICIENCY - IN %ge 95.0000 PROD PER SHIFT 6840.0000 MOUlDING COST Rs/each 0.0950 FINISHING COST (Rs) Rs 0.0200 OTHERS

CONVERSION COST Rs 0.1150 0.0000 0.0000 0.0000

BOUGHT OUT ITEM COST Rs 0.0000 PROFIT (%ge) : RM 10 0.0051 PROFIT (%ge) :lABOUR 10 0.0115 I C C (%ge) 0 0.0000 SAlES TAX IMPACT (%ge) - 0.0000 REJECTION (%ge) 0 0.0000 PACKING 0.0200 TRANSPORT 0.0200 TOTAl COST --> 0.2225

-->--> 0.22

Raw material break upBASIC 205.0000 EXCISE 12 25.3380 TOTAl 230.3380 SAlES TAX 5 11.5169 TOTAl 241.8549 TURN OVER TAX 0 0.0000 SURCHARGE ON ST 0 0.0000 TOTAl 241.8549 OCTROI 2.75 6.6510 COlOURING (RS/KG) 0 0.0000 TRANSPORT AND HANDlING 4.0000 TOTAl 252.5059

lESS ST SET OFF 5 11.5169 lESS EXCISE CREDIT 100 25.3380

RM lANDED (RS/KG) 215.6510

Explain the Distribution Process. Backward Linkages and Forward Linkages (Supply Chain): Direct sale to customer. No distributor chain


Human Resource ManagementEmployment recruitment rules There are no special rules for recruit-

ment but for operator education is at least 10th pass.

Money charged (in Rupees) by contractors for each worker/staff in case the workers/staff are recruited through Contractors

Rs. 10,000

Training Policy for the new recruits and already employed with the company:For New Recruits For Already Employed

Machine Operator Competence review attached

And training needs

SupervisorManagerHelper/Cleaning Staff

leave Policies: N. A.

Overtime Policy: N. A.

Insurance/Medi-claim Policy: Covered under EsIC / Covered under WCT

Wage Rate Policy:Staff Wage Rate PolicyMachine Operator 150 – 250 Rs. Per day basicSupervisor 300 Rs. Per day basicManager 35000 Rs. Per MonthHelper/Cleaning Staff 150 – 200 Rs. per day

Salary Structure::Staff For Fresher (in

Rupees)With experi-ence of 3 years (in Rupees)

Training required, if yes then please mention the training


Machine Oper-ator

250 275 N. A. N. A.

Supervisor 400 600 N. A. N. A.Manager 3500 40000 N. A. N. A.Helper/Cleaning Staff

N. A. N. A. N. A. N. A.

Male & Female Employees:Staff Number

of staffProfile (Machine Operator / Su-pervisor / Man-ager / Helper / Cleaning Staff)

Hometown (Aurang-abad/Outside Au-rangabad but within Maharashtra/Outside Maharashtra)

Years of experience in the Com-pany


Male 10 Machine Opera-tor, Supervisor

Aurangabad N. A. N. A.

Female 2 N. A. N. A. N. A. N. A.

Covered under ESIC/EPF/Gratuity: Yes covered under ESIC


Compensation Plan for workers in case of injury or accidents: The company has taken policy from New India assurance co. for all workers

Views on Government Initiatives taken so far: The company is satisfied with the government support w.r.t. the subsidies, trainings, etc.

Assistance required from Government in the following areas:• For enhancement of sales / production the company needs


• One horizontal injection moulding machine of 200 T

Assistance by MCED, Aurangabad:• Entrepreneurship Development Programme is beneficial for our Managers• MCED always helps us by giving information about plastic clusters and

other surveys

SWOT Analysis of the CompanySTRENGTHS• Technical expertise and core

knowledge in plastic moulding polyurethane and epoxy mould-ing with more than 25 years of experience.

• Tailor made products as per cus-tomer demands.

• Supplying products to different types of industries which includes Automobiles, Electrical, Switch-gear, Packaging, Pharmaceutical, Furniture

WEAKNESSES• Horizontal moulding machine

and appropriate land is not avail-able.

• Plastic products weighting more than 200gms cannot be manufac-tured with current machinery

THREATS• Almost 70% of the business

comes from one customer.• lack of advanced technology and

production.

OPPORTUNITIES• To create ever growing demand of

heavy plastic products (more than 200gms) in nearby waluj, Paithan and shendra MIDC

• To supply epoxy and polyure thane parts weighting more than 5kg to switchgear industries.

Future Plan of the CompanyTime-lines

Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)

Benefits for the Company

6 months To manufacture components weighting more than 250gms for industrial as well as domestic market

Finance, land and Machinery

With increase in production ca-pacity sales will increase there by employment will be generated.

1 year N. A. N. A. N. A.3 years N. A. N. A. N. A.5 years N. A. N. A. N. A.

Product Design BriefDesign Brief

Design & development of new plastic products and estimated cost for the same up to 10 lacs to 30 lacs

Plan of the Design ProjectProduct Design Brief specifications Plastic injection moulded compo-

nents weighting 250 gms and aboveProposed Design Process N. A.Timeline 6 months June, 2014Budget Rs. 30 lacsTeam members & Skills Required N. M. Kawathekar / S. Y. Deshpande /

A. N. KawathekarBenefits for the Company Increase in product capacity will lead

to increase in sales


Proper management of raw material stock

Needs better arrangement as per the specification of the tools

Proper segregation of raw material stock

Proper display of sample material


The worker is trapped from all sides aswell as the sitting posture is notergonomically conducive

The space is very less around the worker and the machine parts are open which may cause injury to the worker

The wires are exposed to the heater which may case melting or short circuit

The size of the hopper funnel is small which requires multiple filling which

increases the total process time


Proper storage for moulds

Proper use of tool for finishing the moulded pieces

Proper display of the safety procedures and company’s progress reports

The cutting tool used for finishing is too small and can be unsafe for the worker


The place is unclean and disorganized to be accessed. The wiring is exposed.

The place is unclean


Proper safety measures adopted while handeling the product

The waste magement has to followed properly

The fire extinguisher is not easily accessible in case of emergency


The material stock in the store is not properly organised

The machine is not properly maintained w.r.t. the parts of the machine. The files are kept to close to the meter box and the heater.

The fire extinguisher is not placed properly. The store room is not easily accessible.


The water dispenser is unhy-gienic and there is no proper mechanism to dispose off the

wasted/accumulated water

The wash room is unclean and not properly maintained

The external facade is poorly managed as it reduces the visi-

bility of the company signage


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergo. Need to improvePlant layout Im-provement

• Space arrangement is a concern as the plant area is congested

• No use of Natural light• No Workstation or work arrangement for labours

NPD No in-house product development process followedPackaging Need to improveMarketing • Market awareness is a problem. No marketing for business

growth• Good branding material available• Sample swatches are available

Human Resource Focus on manpower training by chalking out customized train-ing programs and evaluation of the workers after undergoing the programs.

Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation

RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid

pre-mature wear and tear.

Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.

Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) luggage. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.

Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.


Marketing:• Branding exercise needs to be conducted on priority basis as the company

aspires to get into the household product segments. Trademark registration should be taken to protect equity and prevent litigation in future.

• There is a huge dependence on one customer which might harm the busi-ness in the long run. Increasing the customer base is mandatory for long term sustenance and growth.

• Assistance should be provided to the company to set up their stall in exhi-bitions to highlight their products to the retail and manufacturing partners.

• Re-structuring of the website to increase vendor accessibility.• As the company plans to get into retail consumer segments like plastic

buckets, jugs, mugs etc. it should develop its distribution channel to reach out to the right target market.


31

2

03Bl

ue St

arEn

ginee

rs


Name of the Unit: Rajesh K. SanghaviAddress of the Company: B-72, M.I.D.C., Waluj, Aurangabad, Pin: 431136, Maharashtra, Indialandline number: 0240 - 2556612, 2555855Fax : 0240 - 2555902Mobile Number: 9371135475, 9371135480Company e-mail id: [email protected]: www.sanghavigroup.co.in Company started in: 1998


Company’s Specialization/Product/Services:Engineering Plastic Products

Affiliated units/sister concern/subsidiary: N. A.


Sr. N

o.

Nam

e of

O

wne

r /

Prop

riet

or

/ Par

tner

s /

Dir

ecto

r

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Rajesh K. Sanghavi

40 Propri-etor

Me-chan-ical engi-neering

N. A. [email protected]

9371135475

Details of the Owner/Director Family members: Wife takes care of HR is-sues, 1 son in 10th, other in 6th

Blue Star EngineersOsmanpura, Aurangabad


Loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt.


Closed)1 MFSC - Machines 6,00,000 -2 SBI - Machines 2,00,00,000 -

Customer Details: Bajaj Automobiles, Niranjan Plastic, Videocon

Types of Customer: Automotive

Total number and List of Vendors or Suppliers:• Reliance• SRF• DCM


Types of Business: OEM

Area of the Unit: 8000 sq ft

Turnover of the Unit (in Rupees): Rs 10 crore/annum. The gross Profit is 18%-20% and the net profit is 3% - 4%

Certifications: ISO 9001:2008 Certified company and CRISIl


Company Manufacturing Process FlowRaw material

passed through Hopper

Injected through Screw

Barrel

Injected in Mould

Cooling

Types of Machines: Injection Moulding, Hopper, Mould Temperature & Mix-ers

Raw materials: Average cost of Raw materials is Rs. 100 to Rs. 250/kg• Poly-propylene• lDPE• HDPE• Nylon 6• Polycarbonate• ABS• Dupont

No. of Shifts/day: 2 (7am – 7pm and 7pm – 7am)

Quality Control Plan• No quality check done for Raw Material. Brand name is an indicator of

quality.• Plating is outsourced.• 80% - 90% importance given to Aesthetic look, Dimensions and Branding

are also checked.• 100% of the products are checked visually.

Design & DevelopmentR&D:• All the moulds are developed in-house. No outsourcing.

• After receiving the order, they study the drawings and check

Inquiry received from

Clients

Drawings are studied

Tolerance issues are

checked with Clients

Clearance taken from

Clients

Moulds are prepared

E.g. Metallic washers converted into Plastic washers, Exploration in market items like Industrial bobbin or spool. No specific budget allocated for R&D. Visited Switzerland for developing a mould.

Softwares used:Deven Infotech, softwares for TPM

Trade shows:Only attended but not participated.• Plastovision• Amtex• Chinaplast• PlastoIndia

Visited China to attend Trade Show.

Safety standards in the Company:All machines are safe and as per the specifications of safety norms.

Marketing and Branding:Logo of company:


Effectiveness of the company logo Medium. No need to focus on Brand-ing and Marketing as it is a B2B business and Brand awareness of the company is high in its target market.

Online services No

Company Label: Tags and labels are put on every part. Supplies are made in bins which have replaced corrugated boxes.

Human Resource Management• Total employee strength: 110• Hiring through references or HR contractor.• No qualification required for workers but compulsory for staff.• Weekly off on Friday.• No paid leave for workers.• 5-6 days leave for workers in Diwali, May 1st-labour Day and 2 more days

of leave during other festivals during the year. • All employees are covered under ESIC and yearly health check-up conduct-

ed on campus.• Training is imparted at regular intervals. 4 days of training per month. 12%

- 15% increment per annum. Career path for employees is being worked out and assessment will be made through software.

Views on Government Initiatives taken so far:• Govt. Is not bothered if the company has received payment from vendor or

not. There is no relaxation on interest rates or Sales tax or concessions in Excise Duty.

• Grants are enough. • All India Plastic Manufacturers Association is also working efficiently.• MASSIA cluster and CEPAT are working for their benefit.

SWOT Analysis of the CompanySTRENGTHS• Their Brand Awareness in the

B2B market as their capacity is always full.

WEAKNESSES• No new product development

mechanism• Marketing not in place

THREATS• Chinese products other than mo-

torcycles where the Japan based products sell better.

• Support from OE as there is com-plete dependence on OE market.

OPPORTUNITIES• New customers need to be ac-

quired.• New products need to be devel-

oped with existing machinery

Future Plan of the Company• Entryintothemarketforallelectricalmachines.• 2-3CopyrightedproductsforstrengtheningBrandIdentity.• DonotwanttogetintoRetailbusinessasitisacashbasedbusinessandrequires huge investment in marketing.


Mould for ice trays loaded on machine

Injection moulded ice-trays ready for finishing

Rejected and scrap Injection moulded ice-trays ready for reprocessing

Moulds neatly arranged on shelves


Finishing of injection moulded parts in progress

Safety precautions taken while de-flashing the parts

Packages of injection moulded parts are being stacked in carton boxes.

Finished parts are being packed in plastic sheets


Master samples on display

Marking on finished parts with screen printing technique

Screen printed parts drying under fan

Alternate and efficient method can be used for marking


Overhead cranes to lift the moulds

There are chances of slippages of the moulds. Need a better method to lift the moulds and shift.


Improper approach for feeding plastic granules in the hopper

Spoilage of raw material which changing the mould

liquid colour master-batch stored properly

Carton being readied for packing the finished parts


Fire extinguisher placed in the working area

Customer complaint board maintained on a daily basis

Finished goods packed and ready for transportation to the clients


Tiffin rack

Drinking water storage


FindingsProduct Design & ProcessTechnology High investment in technologyAesthetics As per the product requirementsQuality As per the product requirementsOperations As per the product requirementsWorkplace & Ergonomics Need to improvePlant layout Improvement Well PlannedNew Product Development No dedicated Product Development wingPackaging As per requirementMarketing Brand awareness is high in the B2B marketHuman Resource Satisfactory

Business DesignMarketing Satisfactorylogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Needs up-gradation

RecommendationsInfrastructure & Technology: Very well managed as per the cluster standards. However, since the company has the potential for becoming a national player, latest machinery and technol-ogy needs to be employed to be in sync with global standards.

Supply Chain & Operations: The company is efficiently handling it’s supply chain and operations but further streamlining might help since the company plans to diversify into different product categories in future.


Product: The company needs to set up a dedicated product development wing and even collaborate with Govt. bodies to take up consultancy projects for new product development. It can also look at producing cheaper variants of internationally successful products.

Human Resource: Although the company takes substantial initiatives to train its people, more investment in hiring experts might help in new product development process.

Marketing:The company is banking heavily on its brand awareness in the current target market. However, it should not become complacent as new competitors with greater marketing efforts might erode its equity in future.

Participation in trade shows and more online marketing might be effective solutions to tackle the issue.


31

2

04Co

ncep

t Aut

o Pa

ckag

ing


Name of the Unit: Concept Auto Packaging (Sister concern of Sunrise Autopack)Address of the Company: F – 16/4, MIDC, Chikalthana, Aurangabad, Pin: 431 210, Maharashtra, IndiaLandline number: 0 240 - 2482097Mobile Number: 8888864242, 95951 74242, 94222 94242Company e-mail id: [email protected]

Website: www.sunriseautopack.com Company started in: 2013


Company’s Specialization/Product/Services• PET Packaging machinery manufacturer & Bottling machine


Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Rahul Owner Grad-uate

4 -- 9405963499


Loan/Financial Assistance taken since the start of the company: Not takenProduction capacity of the Unit: 150 bottles per minutes

Types of Customer: B2B

Total number of Employees at the company: 15 Males (14) and Female (1)

Area of the Unit:Plot Area 8000 Sq. ft.Total Built-up Area 3600 Sq. ft.

Turnover of the Unit (in Rupees): N. ACertifications: No

Types of Machines: Buffing m/c, Milling m/c, Drilling M/c and lathe m/c, Welding machine

Raw materials: Stainless Steel, Mild Steel, High Density polymer

Quality Control PlanDocumentation of every Project

No


No

Concept Auto PackagingMIDC, Chikalthana, Aurangabad


Mineral Water Bottling Plants in production

Cardboard box is used as support


The worker climbs on the machine while assembly

Grinding

Power board is broken and is dangerous while in use


No safety gears used

Drilling process

Scrap material is not maintained properly.


Scrap material is not maintained properly.

loose wires hang around the machine. Needs maintenance.

Welding of machine is not even and smooth

No safety gears used


Raw material room is not lit properly. No facility for natural light.

There is not labelling on the racks for different items.


Magnet is used to separate the metal scrap material

Scrap material is not collected and packed very loose

Halogen light system is very loose and hangs in the working area.

Advertisement of different company is painted on the wall of the company


FindingsProduct Design & ProcessTechnology As per standardAesthetics Good Quality SatisfactoryOperations Safety kits are not provided to the operatorsWorkplace & Ergonomics NeededPlant layout Improvement • Space arrangement is a concern as there is

lot of congestion of machine.• No use of Natural light.

New Product Development Yes, R & D in process for bottling machineryPackaging Yes, goodMarketing Good market presence in bottling automationHuman Resource 1 year training is provided to new recruit

Business DesignMarketing Yes, need to improvelogo Design NoVisiting Card NoBrochures & leaflets NoWebsite Yes

Recommendations• As company has plan for huge expansion, company logo has to more

creative and need to be protected. it has good visibility in market, need to capitalise on that.

• Production layout is not so good. Sufficient space has to be kept between machinery so the better working condition.

• Very less safety precautions are taken by workers, this need to be improved

by providing gloves and other safety gears to workers.• The work area need to be cleaned regularly and scraps and used tools re-

moval process has to be planned. • Need to focus on regular maintenance and servicing of machines to avoid

pre-mature wear and tear.• There is an urgent need for the certification of the company as this will

improve the image of the company in the market. For this proper record keeping in all departments is needed.

• No testing is done on the product during production, so proper quality control procedures need to be formed.


31

2

05Co

olEn

ginee

ring


Name of the Unit: Cool EngineeringAddress of the Company: Plot no 23, MIDC, station Road, Aurangabad, Maharashtra, IndiaLandline number: 0240-2321065Mobile Number: 9822019718Company e-mail id: [email protected] No.: 0240-2335968Website: www.coolengineering.co.in Company started in: 1990


Company’s Specialization/Product/Services• Custom made machinery, fabrication of refrigerators, chillers


Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

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rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

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Em

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1 S. P. Kale 54 Partner BCom 0 - 9822019718

2 Ajay Sathe - Partner 0 - -


Cool EngineeringMIDC, Station Road, Aurangabad

loan/Financial Assistance taken since the start of the company:Sr. No.

Bank Name / Govt. Assistance

Year Purpose Amount (Rs.) Status (Ac-tive/Closed)

1 Bank of Maharashtra 2013 Machineries 60 lacs Cash credit

Total number and List of Vendors or Suppliers: Two

Total number of Employees at the company: 7 (All males)



Certifications: ISO9001

Competitors: Bluestar and Voltas

Machines & raw materialsTypes of Machines: Compressor, Bending m/c, spot welding, drilling, grinder

Raw materials: Stainless steel sheets, copper tube and pipes

Quality Control PlanProject Documentation: yes


Does the company maintain Documents for every Project?

Yes


Yes


Yes


No


N. A.

Testing of Finished Products Yes

Exhibition/trade shows visits

Sr. N

o.

Exhi

bitio

n /

Show

Part

icip

ant /

V

isito

r

Last

atte

nded

(Y

ear)

Fees

(in

case

th

e co

mpa

ny

part

icip

ated

)

Bene

fits

1 Canton, China Visitor 1993 N. A. N. A.2 Singapore Visitor N. A. N. A.

Marketing and Brandinglogo of company:



Medium


N. A.

Online services Yes




Shift timing: 9 AM to 6 PM (One shift)

Salary Structure: Machine Operator (4000-5000), Supervisor (7000-8000) and Manager (10000)




opment


Assistance by CIPET, IGTR, ITI, MCED Aurangabad: N. A.

SWOT Analysis of the CompanySTRENGTHS• Service quality is very good• Quick and personalized service

WEAKNESSES• No skilled worker• Marketing not in place

THREATS• Chinese manufacturers are

providing the similar products at lower prices and better quality and eventually winning the cus-tomer base

OPPORTUNITIES• New product development in the

household category • Focusing the new customer base

by developing new product




6 months Improve the aesthetics of productImprove marketing efforts

N. A. N. A.

1 year Venturing into new product categoriesNew machineries like ultra low temperature and cold chain ma-chines

N. A. N. A.

Product Design Brief: N. A.


The entrance of the main unit area.

The main work area of the unit.

The gas cylinders are lying in the middle of the walk way in the work area.



The posture of the worker for long hours will make them suffer from work-related diseases.

The open work area at the entrance of the unit.

The open work area at the entrance of the unit.


The tools rack is cluttered. Needs proper arrangement procedures.

Sheet metal work done manually.


The tools are seen unattended in the working area.

Clutter and scrap is seen around the machine area

The gas cylinders are lying in the middle of the walk way in the work area.

First-aid box


The work area needs maintenance. Tools lying unattended.

Raw material area

lot of waste and scrap is seen around the unit area.


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement Space arrangement is a concern as the plant

area is congestedNew Product Development In-house product development process fol-

lowedPackaging Need to improveMarketing Market awareness is a problem. No marketing


Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Need to developWebsite Needs up-gradation


Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space

allocation to provide for ease of movement of workers during daily and emer-gency situations.


Product: As the company is planning to get into household products, it can also explore product diversification in the home appliances.


Marketing:• A website need to be up-graded on urgent basis so that the customer reach

can be extended.• As the company is venturing into other products, it requires more public-

ity on retail level. A proper branding strategy should be formalised to get maximum visibility in the market.

• A logo needs to be more creative, to make a place in the customers percep-tion.



• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.


31

2

06Dar

shan

Plas

tics


Name of the Unit: Darshan PlasticsAddress of the Company: W – 71, Near Kamgar Chowk, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 8007800122Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2002


Company’s Specialization/Product/Services• Automobile lighting parts• Indicator parts


Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

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er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

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rien

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rior

to

star

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join

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the

Com

pany

Pers

onal

Em

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Phon

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r

1 Mr. Ashok Thorat - Partner B. E. Mech.

- - -

2 Mrs. Thorat - Partner BSC - - -

Darshan PlasticMIDC, Waluj, Aurangabad


Vendor Code Details: For Varroc and Videocon

Production capacity of the Unit: 2.5 tons per day in 2013-14


CustomersNames/List of Cus-tomers

Products Manufactured

Automotive 1 Varroc Automotive partsConsumer Products 1 Videocon


Types of Business: As a Tier 2 supplier to Automotive parts to Varroc


Turnover of the Unit (in Rupees): Rs. 25 crores in 2012-13 and the expected amount is Rs. 27.5 crores in 2013-14

Certifications: KMS TS16949 and Total Productive Maintenance (TPM)

Audit Reports: Yes from its customers

Types of Machines: Injection moulding, pad printing, ultrasonic welding


Raw materials: Polycarbonate, acrylic, ABS, Nylon, PP

Business Process FlowProcurement of raw material

Preparatory process- Preheating

Ultrasonic welding

De-flashing

Packing

Inspection of raw material

Production

Final Inspection

Pad Printing

Dispatch


Yes


Yes


Yes


N. A.


N. A.

Testing of Finished Products • Visual Inspection• Dimension & Weight measurement• Deflashing & Finishing

Design & DevelopmentDesign Process/Plan for a new Product innovation

No


N. A.


No




Describe the Company’s Target Market: Targeting Irrigation components & Automobile Industry

Exhibition/trade shows visits: No


Medium


No

Online services No

Packaging materials: Polybags, PP boxes, Plastic bins

Human Resource ManagementShift Timings: 9 AM to 5:30 PM

Number of Shifts per day: 2 two for operators (12 hours), three for engineers (8 hours) and general shift ( 9 am to 6:30 pm) for other staff

Overtime Policy: Payment according to overtime hours

Insurance/Medi-claim Policy: Yes


Contract Worker Policy: No

Career Graph Plan for Employees: Growth & continues development under motivation & guidance

Retention Policies and Welfare Schemes: Insurance Policies

Assistance required from Government in the following areas:• Guidance about new product development • Awareness about the new schemes and training programs organized by

various agencies

SWOT Analysis of the CompanySTRENGTHS• Composite moulding• Manufacturing of complex prod-

ucts

WEAKNESSES• 80 % business depend on only

one customer• No new product development

mechanism

THREATS• No threat as such as the product

is more complex and need huge investment for the new entrant

OPPORTUNITIES• New customers need to be ac-

quired.• New products need to be devel-

oped with existing machinery• Enter into mould manufacturing

Future Plan of the CompanyTimelines Plan Assistance required by the

Government (Finance/Training/Design Assistance, etc.)


6 months New plant of size 10000 Sq ft under construction

N. A. N. A.

1 year New product develop-ment

N. A. N. A.



Company’s work area is clean and well maintained


Company’s raw material area clean and well maintained. The raw materials are very well segregated as per their specification.

Company’s main entrance and is very well maintained.


The worker climbs the machines to pour the plastic granules in the hopper. Need to improve the this practice.

Injection moulded parts


The injection moulded parts are getting finished.

The injection moulded tail light covers.

The injection moulded tail light covers are nice packed and stacked.


Separate and well defined Inspection table. The area needs to better lit.

The pieces are inspected, packed and later arranged separately in boxes.

The pieces are inspected and finished at the site of its production.


Separate and well defined area for keeping boxes of finished goods.

The mould under maintenance.

Whenever needed the mould is shifted in the work area on a trolley.


The moulds are kept at its specified location. The tool-board is not in use.

The moulds are kept at its specified location.

The finished products are ready to be transported.


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations SatisfactoryWorkplace & Ergonomics Satisfactory Plant layout Improvement Satisfactory New Product Development No in-house product development process



Business DesignMarketing No marketing initiative logo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Need to develop


Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-

gency situations.


Product: No new product development process is carried out. Company should look out for the new products that can be manufactured with the existing facilities to increase the customer base rather than depending on single customer.


Marketing:Company is supplying products to only single company Verroc. The company should increase its customer base to reduce the risk on the business.

As there is no marketing activity by company, it should start its branding in the market. A website should be formed as early as possible and advertisement should be given to various web portals like indiamart.com and alibaba.com to get more visibility in the market.

As company has plan for huge expansion, company logo has to more creative and need to be protected.


2

31

07El

ectro

Plas

t In

dustr

ies


Name of the Unit: Electro Plast IndustriesAddress of the Company: K-49, MIDC, Waluj, Aurangabad, Pin: 431136, Maharashtra, Indialandline number: 0240-2040186Mobile Number: 919890217103Company e-mail id: [email protected] No.: 0240-2040186 Company started in: 1992


Company’s Specialization/Product/Services:• llDPE Water Tanks ranging from 300 l to 5000 l



Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Shaukat Syed 48 Owner Graduate 25 yrs [email protected]

9890217103


Sr. N

o.Fa

mily

Mem

ber

Rel

atio

n to

the

Ow

ner o

f th

e C

ompa

ny

Age

(in

Year

s)

Educ

atio

nal Q

ualifi

catio

n

Wor

k Ex

peri

ence

pri

or to

jo

inin

g th

e C

ompa

ny

Invo

lved

in C

ompa

ny’s

busi

ness

act

iviti

es (Y

es/N

o)

Rol

e in

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Shaffiqunissa Ansari

Wife 47 Grad-uation

N. A. No N. A. N. A. 9890217103

2 Ramsha Daughter 21 Grad-uation

N. A. No N. A. N. A. 9762718333

3 Altamash Son 22 BBA N. A. No N. A. [email protected]

9762718333


loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt. Assistance Year Purpose Amount (Rs.) Status

(Active/Closed)

1 MSFC 1995 Term-loan 3 lacks Closed

Vendor Code Details: N. A.

Electro Plast IndustriesMIDC, Waluj, Aurangabad


Production capacity of the Unit:Year Production capacity2013-2014 1445000 lTR2013-2012 1150000 lTR2012-2011 1050000 lTR2011-2010 850000 lTR2010-2009 700000 lTR



ManufacturedConsumer Products 16 Girdhar Tiles, laxmi Hard-

ware, Gurukripa Sanitary, etc.

Water Tanks

Total number and list of Vendors or Suppliers:• Rotoflow Polymer• Parshwanath Plastigrind• Alkemy India• Pooja Polymer


Types of Business:Business Type Products Products supplied toAs Supplier to Retailers Water Tanks Sanitary & hardware Distributors

Area of the Unit (in Square feet):Plot Area 510 Sq. mtr.Total Built-up Area 230 Sq. mtr.

Organization Chart:

Sales & Marketing Manager (Mr. Rajeev Kumar)

Operator 1

Operator 2

Casuallabour

Casuallabour

Casuallabour

Casuallabour

Casuallabour

Casuallabour

Sales Exe. 2Sales Exe. 1 Accountant Production Supervisor

(Shift 1)

Production Supervisor

(Shift 2)

Security Staff

Driver

Production Manager(Mr. Gajanand Ganjre)

Proprietor - Shaukat Syed

Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2009-2010 2000000 100000 550002010-2011 2400000 128000 640002011-2012 2900000 180000 920002012-2013 3400000 225000 1100002013-2014 (expected) 3800000 350000 128000

Certifications: N. A.

Audit Reports: N. A.


Business Competitors:Sr. No.

Competitor’s name

Competitor’s Prod-uct Specialization

Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Supplier / Tier 3 Supplier

1 Ram Polymers Water Tanks N. A.2 Sarita Tank Water Tanks N. A.3 Spintex Group Water Tanks N. A.4 Saraswati Water

TankWater Tanks, PVC Pipes

N. A.

5 Harsh Industries Water Tanks N. A.


Extrusion

Section

Raw Material

Storage

Storage for

Finished Goods

Rotomoulding

Machine

Parking

Tank

Wastage

Storage

Toilet

Office

Chiller

Pulverizer

Powder

Storage

Types of Machines

Sr. N

o.

Nam

e of

M

achi

ne

Qua

ntity

Mak

e of

m

achi

ne

Spec

ifica

tion

Pric

e of

the

Mac

hine

Year

of

Purc

hase

Loan

/ by

Self

1. Extrusion 1 Raj Engineering, India

110 Mm 7 lakh 2003 By Self

2. Cutter 2 Raj Engineering, India

Cc-1541 50 Thousand 2003 By Self

3. Mixer 1 Raj Engineering, India

35 Hp Motor Qm-F9

1.5 lakh 2003 By Self

4. Grinder 1 Khalil, India 20 Hp Motor Pd-1100m

50 Thousand 1992 By Self

5. Pulveriser 1 Naroto, India 300 Mm Disc 5 lakh 2011 By Self6. Pulveriser 1 Plasmec, India 600 Mm Disc 20 lakh 2012 By Self7. Box- Type 1 Naroto, India 4 Hp Motor

With A/C Drive

8 lakh 2003 By Self

Types of Tools

Sr. N

o.

Nam

e of

M

achi

ne

Qua

ntity

Mak

e of

m

achi

ne

Spec

ifica

tion

Pric

e of

the

Mac

hine

Year

of

Purc

hase

Loan

/ by

Self

1. Hand Grinder

2 Hitachi, India PD 100M 27000 2012 By Self

2. Hand Drill 1 Hitachi, India CC 40 8200 2010 By Self

3. Welding Machine

1 Delt-Ton, India PQ-190 36500 2011 By Self

4. Buffing Tools

1 Idea, China Em-300 17500 2012 By Self

Raw materials


Sr. N

o.

Raw

Mat

eria

l

Cur

rent

Rat

e (R

s. Pe

r Kg)

Spec

ifica

tion

Supp

lier’s

Nam

e

Min

imum

qua

ntity

mai

n-ta

ined

in th

e co

mpa

ny p

er

mon

th

Prod

uct M

anuf

actu

red

with

th

e m

ater

ial

Prod

uct S

uppl

ied

to (O

EM/

Tier

1 su

pplie

r/Ti

er2

Supp

li-er

/Tie

r 3 S

uppl

ier)

1 llDPE Granule

Rs. 130/KG

4.2 MFI, 0.939G /CC

GAIl 5MT Water Tank Hard-ware retailers

2 Master Batch Rs. 300 /KG

UV Polyone 200 KG Water Tank N. A.

3 Diesel Rs. 62/ lTR

Indian Oil

IOCl 250 lTR Water Tank

Information of Workers, Supervisors, Managers and Staff for cleaning:

Shift Timings: 8AM to 8PM and 8PM to 8AM


Sr. N

o.

Nam

e of

wor

ker

Age

(yrs

)

Gen

der (

M/F

)

Wor

kers

/ Su

perv

isor

/M

anag

er /

Staff

for

clea

ning

Qua

lifica

tion

Ope

ratio

n / F

unct

ion

Year

s of e

xper

ienc

e in

In

dust

ry

Wor

king

hou

rs /

day

1 Wagmare 38 M Operator 12th Pass 12 Years 12 Hour2 Dhani Ram 32 M Helper Matric 5 Years 12 Hour3 Ram Babu 37 M Operator Matric 10 Years 12 Hour4 Shankar 44 M Operator 12th Pass 17 Years 12 Hour5 Mukesh 38 M Operator 12th Pass 7 Years 12 Hour

6 Suresh 28 M Helper Matric 8 Years 12 Hour7 laxmi Devi 32 F Helper Matric 4 Years 8 Hour8 Babu Ram 35 M Helper Matric 5 Years 12 Hour9 Shobha Rani 28 F Helper Matric 5 Years 8 Hour10 Gajanan 29 M Supervisor Graduate 8 Years 12 Hour11 Mobin 25 M Accountant Matric 4 Years 12 Hour12 Mujfar 28 M Sales Graduate 8 Years 12 Hour13 Kavri Devi 34 F Causal 10th Pass 3 Years 8 Hour14 Gouri Shankar 52 M Causal 10th Pass 12 Years 8 Hour15 Rajiv 43 M Sales Graduate 19 Years 12 Hour16 Mera Rani 38 F Causal 10th Pass 4 Years 8 Hour17 Maane 27 M Driver 12th Pass 7 Years 12 Hour18 Patil 35 M Security 12th Pass 4 Years 12 Hour

Functions/Operations in the company:Function / Operation

Required Qualification of workers





Marketing & Sales MBA, Graduate 3 1 1Accounting Graduate, Relevant

Experience1 1 1

Production Graduate, Diploma, Unskilled

12 2 2





Wastage %

1 Extruder 2+2 Continuous 30 Min 1%

2 Pulverizer 2+1 Continuous 40 Min 1%3 Rotomoulding

Machine2+2 Continuous 120min 5%




Price to Customers

Repeat Order

Supplied to

1 lDPE Water Tank

Rs 3.00/litre

Rs 3.60/litre

Yes Aurangabad, Pune, Delhi

Quality Control PlanProject Documentation: Does the company maintain Documents for every Project?

No


• Standardized Manufacturing Process• Inspection At Pelletizing Stage For

Colour • Inspection Of Powder After Pulveri-

zation For Correct Mesh Size• Inspection Of Final Product Tank For

Aesthetics, Pinholes, leakages.• Inspection For Patches And Delami-

nationTesting of Raw Materials (In-coming - Quality Control Tech-niques)

Product Purchased From Reputed Su-pliers like Gail. Certificate Of Quality Received With Consignments. Occasional Testing at CIPET

Name of Testing labs for Raw Materials (tie-ups for Raw Mate-rials)

CIPET Aurangabad


In-house testing

Testing of Finished Products Inspection of Final Product Tank For Aesthetics, Pinholes, leakages.Inspection For Patches And Delamina-tion

Quality Standard for Product:Sr. No. Product name Specification Strictly followed (Yes/No)1 Water T-anks Non ISI product

manufactured

Design & DevelopmentWhat is Design? “Design as per dictionary definition

is a plan or drawing produced to show the look and function of a product to be manufactured.”

Design Process of existing products: When the company entered market there were existing established players who had already standardized product design. But at that most tank manufac-turers were using Mild steel moulds in which surface finish of resultant prod-uct was not good.

Electro Plast was one of the few companies who started making tanks in Stain-less steel moulds in which inner surface is very smooth and tanks were also with good surface finish.

The process followed for existing product is studying the accepted norms/de-sign in the industry. Then finding out advantages and disadvantages and then working for improvements required.

Design Process/Plan for a new Product innovation: For any new design the process followed is studying the accepted norms/de-sign in the industry. Then finding out advantages and disadvantages and then working for improvements required in association with machinery manufac-turers and mould manufacturers.



No specific budget allocated. Mini-mum Rs. 25000 per year


Help of outside agencies taken. In house designing facilities not availa-ble

Exhibition/trade shows visits: N. A.




Remedies / Medica-tion

Electrical operations Fire Fire extinguishers

Marketing and BrandingBrand of the Company: POlO

logo of company:

POlO Tank is a brand by Electro Plast Industries


Describe the Company’s Target Market: Hardware and Sanitary equipment Retailers


Medium


N. A.

Online services No

Company label: N. A.

Company Packaging: N. A.

Finance & AccountsCosting: Raw MaterialRaw Material Quantity

(Kgs)Rate (Rs.) Amount (Rs.)

GAIl (Plastic Granules) 100 125 12500Masterbatch 2180 360Processing Charges 102 8 816Total Amount 13676Per Kg cost of making llDPE Powder 134This is per Kg powder cost which is used in water tank 134 per kg

Costing: Water Tank making Cost (1000lts)Items Quantity (Lts) Rate AmountDiesel 2 64 128Powder 21 134 2814Processing Charges 50 50Total Amount 2992This is 1000 lts of water tank cost Rs. 3 per ltr


Human Resource ManagementEmployment recruitment rules Educational qualifications should

be as per job requirement. Previous experience considered. Background check through references given by employee and previous employer


No involvement of contractor. Direct hiring.


Machine Operator Give 10 Days Training in Plant N. A.Supervisor Give 10 Days Training in Plant N. A.Manager Give 10 Days Training in Plant N. A.Helper/Cleaning Staff Give 10 Days Training in Plant N. A.

leave Policies:For New Recruits For Already Employed

Machine Operator Every Friday, local holidays Every Friday, local holidaysSupervisor Every Friday, local holidays Every Friday, local holidaysManager Every Friday, local holidays Every Friday, local holidaysHelper/Cleaning Staff Every Friday, local holidays Every Friday, local holidays

Overtime Policy: Not Required

Insurance/Medi-claim Policy: NIl

Wage Rate Policy:

Staff Wage Rate PolicyMachine Operator Rs. 300/shiftSupervisor Rs. 10000/monthManager Rs. 15000/monthHelper/Cleaning Staff Rs. 280/shift

Salary Structure::Staff For Fresher

(in Rupees)With experience of 3 years (in Rupees)



Machine Operator 280/shift 300/shift On job training N. A.Supervisor Never

employed10000/month

N. A. N. A.

Manager NA 15000/month

N. A. N. A.

Helper/Cleaning Staff 260/shift 280/shift N. A. N. A.

Male & Female Employees:Staff Number of

staffProfile (Ma-chine Operator / Supervisor / Manager / Helper / Clean-ing Staff)

Hometown (Aurangab-ad/Outside Aurangabad but within Maharash-tra/Outside Maharash-tra)

Years of experience in the Com-pany


Male 14 18 including all Aurangabad Min 3 years N. A.Female 4 N. A. N. A. N. A. N. A.

Covered under ESI/EPF/Gratuity: No

Compensation Plan for workers in case of injury or accidents: Company takes responsibility for any medical assistance required in case of injury or accidents


Career Graph Plan for Employees: Solely on education background and expe-rience merit

Retention Policies and Welfare Schemes: Bonus once in a year

Views on Government Initiatives taken so far: Although there are various schemes implementation is very poor. The paper work is very cumbersome. Moreover there is a lot of red tape and corruption involved.

Assistance by CIPET, Aurangabad: low testing rates for SSI

Assistance by IGTR, Aurangabad: Not Aware

Assistance by ITI, Aurangabad: Not Aware

Assistance by MCED, Aurangabad: Not Aware

SWOT Analysis of the CompanySTRENGTHS• Good product & market

knowledge• low operating cost• Good market credibility• Inhouse powder production

facility

WEAKNESSES• Non-availability of funding at

attractive interest rates hampering expansion activities

• Unorganized sector in rotomoulding industry

• Supply radius limited to only 300km

THREATS• Newer technologies like blow

moulded tanks having higher output rates affecting in short term

• Excessive credit offered by bigger companies due slump in demand

OPPORTUNITIES• Knowledge regarding machinery

and experimentation with newer manufacturing processes has opened machinery manufacturing as a new avenue

Future Plan of the CompanyTimelines Plan Assistance required

by the Government (Finance/Training/Design Assistance, etc.)


6 months Planning to launch tanks with new attractive design

N. A. N. A.

1 year Rotomoulding Machin-ery manufacturing

• Susbisdy for new ma-chinery

• lower electricity rates

Higher profits for asset creation and employee welfare

3 years • Pulverizer manufac-turing

• Conversion to Pvt ltd company




5 years PET jar manufacturing plant




Product Design BriefDesign Brief 1

New machinery manufacturing plan proposed. New energy efficient design which will save upto 10% of energy heating costs conversion of certain parts of machine to stainless steel from mild steel and introduction of pilot burners.

Design Brief 2

New pulverize manufacturing unit planned with segmented discs which will reduce machine disc cost drastically. Special segments to be made of hardened steel and chrome plated which shall reduce wear and tear.

Plan of the Design ProjectProduct Design Brief specifications

Change of material for certain parts, introduction of pilot burners


Proposed Design Process Design already developedTimeline Upto 31st Dec’14Budget Rs. 8 lac per machineTeam members & Skills Required

Proprietor Shaukat Syed has good contacts with machine shop operators, as he has been always interested in new developments in machinery.

Benefits for the Company lateral marketing concept. We will get into products already associated with our current product market. Net profit Margins are better in machinery, which help create new assets for future expansion and provide funds for employee welfare.


Improper and strenuous way of lifting plastic granules

heavy bags. This is also ergonomically inappropriate.

Children in the working area should be avoided at any time.

Gas cylinders are kept in the open and in the working area.


Open wires all around the heaters. These may cause fire and if not attended properly this may give electricity shocks to the workers if these wires come in contact with the workers.


The gap between the wall and the rotomoulding machines is very less to walk through.


The Cooling plant has been made in-house using the water tank produced at the unit.

Mr. Syed Shaukat posing with his design of a new rotomoulding machine. The machine is being designed and developed completely in-house.


The clutter of pipes seen around the cooling plant.

The window is being used as storage space for the heater cover panels leaving not enough space for the fresh air and light to come in the working area.


The plastic lids are kept outside and in open on their arrival from it’s suppliers. This may soil the lid or damage before it is sent to the retailers.

No proper placement for the fire extinguisher unit.


Need urgent attention for the proper wiring to avoid fire or any kind of accident.

The items out of use is kept in the regular working area. Need proper arrangement.

Area for storing drinking water. The area should be dry and clean.


The items out of use is placed in the working area. Need proper arrangement.

The company’s logo is seen incomplete. Need proper maintenance.

The company’s logo needs to be printed more accurately.

The company’s entrance gate needs maintenance.



area is congestedNew Product Development No in-house product development process


for business growthHuman Resource Training initiatives for the workers need to

improve

Business DesignMarketing Needs to improvelogo Design Needs to developVisiting Card Needs to developBrochures & leaflets Need to developWebsite Need to develop

RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear and thus the productivity of machines can be im-proved. More amount to be spent on research and development work to devel-op new products which are smaller in size and can cater to larger market.


Financials: n order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.

Product: Company currently producing only one type of product, it should venture into other categories to reduce the business risk. Product testing should be done at various levels and report can be prepared to increase customer confidence.

Human Resource: To reduce Employee attrition rate, the salary levels need to be revised to attract better skilled manpower.Proper training should be formalised to improve the skill of the workers.

Marketing:• A website need to be developed on urgent basis so that the customer reach

can be extended.• It requires more publicity on retail level. It urgently requires a modifica-

tion in a logo so that customers identity the product with the company. A proper branding strategy should be formalised to get maximum visibility in the market.


• A company should participate in trade fairs and exhibition related to plas-tics to attract new customers



31

2

08Jay

shre

eEn

terpr

ises


Name of the Unit: Jayshree EnterprisesAddress of the Company: Plot No. M-19, MIDC, Waluj, Aurangabad Maharashtra, IndiaLandline number: N. A.Mobile Number: 8888805868

Company e-mail id: [email protected]

Website: NA Company started in: 2011


Company’s Specialization/Product/Services• Auto Component • Furniture & House hold products


Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Shailendra Prataprao Baviskar

27 Proprietor MMM (Finance)

4 Years [email protected]

8888805868

Jayshree EnterprisesMIDC, Waluj, Aurangabad

loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name /

Govt. AssistanceYear Purpose Amount (Rs.) Status (Ac-

tive/Closed)1 State Bank of

India2011 C. C. 1000000 Active

Vendor Code Details:Sr. No. Customer Issued

inCriteria/Guidelines to become the Vendor

Products Supplied

1 Badve Engineering ltd. 2011 ISO Certification Plastic Moulded2 Rohit Exhaust Systems

Pvt ltd2011 ISO Certification Plastic Moulded

3 Darshan Plastic 2011 ISO Certification Plastic Moulded

Production capacity of the Unit:Year Production capacity2013-2014 60%2013-2012 90%2012-2011 70%2011-2010 30%



ManufacturedAutomotive 2 Badve Engineering ltd.,

Darshan PlasticsPlastic Moulded Prod-uct


Household Products

1 Rohit Exhaust Systems Pvt ltd

Plastic Moulded Prod-uct

Organization Chart:

Proprietor(Shailendra Baviskar)

Quality Head (Babasahbh Tupe)

Operator: 1. Sanjay Dushing2. Gajanan Nikas

ladies (Deflashing)1. Sharada Nikas2. Sangita Rajput

Production Head (Sanjay Kumbhar)

Accountant(Jiven Kadam)

Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Platina Tail Cap, D-105

Tail CapBottom Cap

Badve Engineering ltd. -VRubber

Rohit Exhaust Systems Pvt ltdAs a Tier 2 Supplier to OEM K G Cover Darshan Plastic

Area of the Unit:Plot Area 6000 Sq. feet.Total Built-up Area 2700 Sq. feet.

Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2010-2011 4,70,580/- 1,86,692/- 1,86,692/-2011-2012 23,15,471/- 8,64,420/- 2,29,404/-

2012-2013 70,53,916/- 12,82,738/- 5,09,712/-

2013-2014 (expected) 60,00,000/- 10,00,000/- 4,00,000/-

Certifications:Certification Description of the Certification Year taken inISO 9001:2008 The Quality Management System 22 April 2013


Competitor’s name

Competitor’s Product Spe-cialization


1 Mitali Enterprises Plastic InjectionMoulding Products

Tier 1 supplier

2 Tulja Enterprises Plastic Moulding & painting Shop

Tier 1 supplier


SemiFinishedGoods area

FinishedGood area

RawMaterialRoom

Office

Injection Moulding M/c 2

Working table 1

Working table 2

Injection Moulding M/c 1

Main Gate

Hea

ting

M/c

Coolingtower

Room for workers

Garden area


Types of MachinesSr

. No.

Nam

e of

M

achi

ne

Qua

ntity

Mak

e of

m

achi

ne

Spec

ifica

-tio

n

Pric

e of

M

achi

ne

(Rs.)

Year

of

Purc

hase

Loan

/ by

Self

1 Injection Moulding M/c 01 Jet Master, Taiwan 180 Ton 12,00,000 2011 Self

2 Injection Moulding M/c 01 Hy-Plast, India 150 Ton 8,00,000 2011 Self

3 Vertical Injection Moulding M/c

01 Niranjan, India 60 Ton 3,50,000 2012 Self

4 Heater 01 S. V. Enterprises, India

- - - -

One Crane is available which has a capacity of 3 tons.

Raw materials

Sr. N

o.

Raw

Mat

eria

l

Cur

rent

Rat

e (R

s. Pe

r Kg)

Spec

ifica

tion

Supp

lier’s

N

ame

Min

. qua

ntity

m

aint

aine

d in

th

e co

mpa

ny/

mon

th

Prod

uct M

an-

ufac

ture

d w

ith

the

mat

eria

l

Prod

uct

Supp

lied

to

(OEM

/Tie

r 1

supp

lier/

Tier

2 Su

pplie

r/Ti

er

3 Su

pplie

r)

1 Polypropylene Copolymer (PPCP)

113 Plastic Gran-ules

Poly Gran India Pvt ltd

3 Ton House hold

Tier 1

2 Acrylonitrile Butadiene Styrene (ABS)

130 Plastic Gran-ules

Badve En-gineering

4 Ton Auto Comp

Tier 1

Sr. N

o.

Wor

kers

/ S

uper

-vi

sor/

Man

ager

/ S

taff

for

clea

ning

Qua

lifica

-tio

n

Ope

ratio

n / F

unct

ion

Year

s of

expe

rien

ce

in In

dus-

try

Wor

king

ho

urs /

da

y

1 Supervisor 12th 3 Yrs 8 hrs2 Accountant B. Com. 1 Yr 8 hrs3 Operator 12th 2 yrs 8 hrs4 Operator 10th 2 Yrs 8 hrs5 ladies 10th 2 Yrs 8 hrs

6 ladies 10th 2 Yrs 8 hrs

Business Process Flow chartReceive

Order from Customer

Generate Inter-nal Order

Check raw Material & Pig-ment Availability

Allocate job into Pro-duction Schedule

Allocate Machine

Issue Production Order to Factory

Set Mould into allocated Ma-chine and do Sample Run

Check Acceptability of First-run Samples

Check Availability of Packaging

Quality Check Sample

Commence Production Run against Internal Order Sheet

No

A

Yes


Manufacturing Process Flow

Start

Receiving of Raw Material

Pre drying of Raw Material

De-flashing

Despatches

Packing

Inspection

Final Inspection

Injection moulding





Wastage %

1 Injection Mould-ing Machine

02 45-60 min 30 min 1%


Product Name Cost to Company Repeat Order

Supplied to

1 Platina Tail Cap 4.92 Yes Badve Engineering ltd2 D-105 Tail Cap 5.99 Yes Badve Engineering ltd3 K G Cover 1.6 Yes Darshan Plastics4 Bottom Cap 1.24 Yes Roht Exhust Systems Pvt ltd5 Angle Nut 2.19 Yes Roht Exhust Systems Pvt ltd6 Washer 0.23 Yes Roht Exhust Systems Pvt ltd

Quality Control PlanProject DocumentationDoes the company maintain Documents for every Project?

Yes


• Inward inspection for raw material check sheet also available.

• After production of component initial-ly it is inspected by machine operator itself & forward it to packing area.

• For dispatch of product pre-dispatch inspection is done and PDIR is given with every invoice.


CIPET



• Badve Engineering ltd.-V • Aurangabad Auto Cluster

Testing of Finished Products • Finish product checked dimensional as well as visually checking is carried out in house.

• We are having some of measuring instrument

Quality Standard for Product:Sr. No. Product name Specification Strictly followed1 Platina Tail Cap • NoFlash

• ShrinkageYes

2 Bottom Cap • Shrinkage• ColorVariation

Yes

Exhibitions/trade shows

Sr. N

o.

Exhi

bitio

n /

Show

Part

icip

ant /

V

isito

r

Last

atte

nded

(Y

ear)

Fees

(in

case

th

e co

mpa

ny

part

icip

ated

)

Bene

fits

1 Plast Expo (Pune) 2012 Free Market opportunity2 Plexpo (gujarat) 2013 100 Market opportunity3 Plast Vision 2014 300 Market opportunity

Safety standards in the CompanyManufacturing Op-erations



Remedies / Medication

Manufacturing Fire Fire Extinguisher First Aid


Effectiveness of the company logo High


Medium

Do you operate Online? No

Finance & AccountsPricing:Pricing of plastic product mainly depends upon its weight and type of machine requires to produce that part.

Component name: Motor CoverSr. no. Description Unit1 Name of moulder -- Jayshree Ent.2 Component Wt. Gms. 25.0003 Runner Wt. Gms. 2.0004 Shot Wt. Gms. 52.0005 Reco Wt. with 2% loss Gms. 25.5006 RM Rate Rs. 130 3.3157 M/C used Tons 150.00


8 M/C tarrif Rs./shift 1200.009 Cost of preheating Rs./shift 0.0010 Cycle time Sec. 30.0011 No. of shots/8 hrs shift due to lower volume Nos. 96012 No. of cavity Nos. 213 No. of pieces/shift Nos. 192014 Prod. by efficiency@90% % 172815 Moulding cost Rs. 0.69416 Finishing cost Rs. 0.00017 Prod. with 1% Rej Rs. 0.0118 Total cost of moulding comp. Rs. 0.6919 Total effective cost Rs. 4.00920 Profit 10% on effective cost Rs. 0.41021 Total cost of component Rs. 4.41022 ICC on RM - 3% 0.09923 Reprocess cost per piece Rs. 0.00024 Packing cost Rs. 0.05025 Transportation cost Rs. 0.04026 Final rate with RM per piece Rs. 4.60

Distribution Process:Finished product dispatched to customer by transport or customers directly purchased from our factory premises by their own vehicle.

Human Resource ManagementEmployment recruitment rules

• Minimum 3 yrs of work experience • Good manpower handling skill• Well knowledge of plastic injection Moulding Machine

Leave Policies:Staff Leave PolicyMachine Operator Inform before 10-15 days

Supervisor Inform before 10-15 daysManager Inform before 10-15 daysHelper/Cleaning Staff Inform before 10-15 days

Overtime Policy: Overtime is given as per their working hours

Insurance/Medi-claim Policy: United India Insurance company

Wage Rate Policy: As per their skill

Salary Structure:Staff For Fresher (in Rs.) With experience of 3 years (in Rupees)Machine Operator 150/shift 190/shiftSupervisor 200/shift 250/shift


of staffProfile (Machine Operator / Super-visor / Manager / Helper / Cleaning Staff)

Hometown (Aurang-abad/Outside Au-rangabad but within Maharashtra/Out-side Maharashtra)

Years of experience in the Company


Male 5 1 Supervisor, 1 Accountant, 1 Production Head, 2 Operator

With-in Maharashtra 2

Female 2 De-flashing With-in Maharashtra 2

Views on Govt. Initiatives taken so farAssistance required from Government in the following areas:• Electricity Rate Very High Compare to other State• Government Scheme is not aware of new business men• Road Facility is not good for transport • Develop New Plastic industries

Assistance by CIPET, Aurangabad:


• CIPET regularly arrange training for labour also give knowledge about new technology in plastic industry

Assistance by IGTR, Aurangabad:• Manufacturing of Moulds

Assistance by ITI, Aurangabad:• Helping in recruitment of New Employees (Technical)

Assistance by MCED, Aurangabad:• Help in development and design in association with Design Consultants

SWOT Analysis of the CompanySTRENGTHS• Excellent product quality• Prompt service• Customer Satisfaction

WEEKNESSES• Insufficient Funds• Un-skilled labour

THREATS• Competitor sale product on lesser

amount• Credit sale recovery

OPPORTUNITIES• To achieve zero customer returns.• To achieve 100 % compliance of

deliveries on scheduled time • To improve machine up time.• Reduction in internal non-

conformities.• Maintain clean & tidy work place.


Plan Assistance required by the Govt. (Finance/Training/Design Assistance, etc.)


6 months Design & development Finance Improvement in turnover

1 year Purchase new machine Finance Improvement in turnover

3 years Expansion of new unit Finance Improvement in turnover

5 years Increase more machine Finance Improvement in turnover

Product Design BriefDesign Brief It is an automobile part used in head light area of

two wheeler


Plastic injection moulded component

Proposed Design Process N. A.Time-line 6 monthsBudget Rs. 15-20 lacksTeam members & Skills Required

Two skilled person

Benefits for the Company Growth in profit as we will supply directly to main customer


The entrance needs maintenance

The gap between the wall and the machine is blocked because of the pipes hanging loosely


The glass is damaged and the process is not visible.

The marking for the switches is not properly shown. It needs urgent attention and maintenance. Overall the machines needs maintenance


The marking for the switches is not properly shown. It needs urgent attention and maintenance.


The floor needs maintenance


Security camera in the work area but not functioning

The raw material room is not lit properly


The tool board is not well maintained

The packaging area of the unit is well maintained

The windows in the work area is not clean. Need to be maintained properly.

Temporary arrangement at the cooling plant.


FindingsProduct Design & ProcessTechnology As per standardAesthetics As per the product requirementsQuality As per the product requirements Operations Need to improveWorkplace & Ergonomics Workplace need to be properly managedPlant layout Improvement Need to be more efficiently managedNew Product Development No in-house product development process

followedPackaging Yes, satisfactoryMarketing Not much visibility in marketHuman Resource Training is provided to new recruit

Business DesignMarketing No marketing, need to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Need to create a website



Very less safety precautions are taken by workers, this need to be improved by providing gloves and other safety gears to workers.

Financials: n order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.



Marketing:Company is supplying products to only single company Badwe Engineering. The company should increase its customer base to reduce the risk on the busi-ness. As there is no marketing activity by company, it should start its branding in the market. A website should be formed as early as possible and advertise-ment should be given to various web portals like indiamart.com and alibaba.com to get more visibility in the market. As company has plan for huge expan-sion, company logo has to more creative and need to be protected.

Quality Control:A quality control procedure has to be formed as there is no formal testing is done on products; products only checked visually for quality


31

2

09Jy

oti

Indu

stries


Name of the Unit: Jyoti Industries (sister concern of Sushma Industries)Address of the Company: D – 107, MIDC, Shendra, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 8928187703, 9404012247, 9822193777Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2007



Company’s Specialization/Product/Services: Drip Irrigation Pipes

Affiliated units/sister concern/subsidiary: Sushma Industries


Sr. N

o.

Nam

e of

O

wne

r /

Prop

riet

or

/ Par

tner

s /

Dir

ecto

r

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Atmajyoti Bapu Nagare

22 Owner B. A. [email protected]

8928187703

loan/Financial Assistance taken since the start of the company:

Jyoti IndustriesMIDC, Shendra, Aurangabad

Sr. No. Bank Name / Govt. Assistance


1 Khamgaon Urban Cooperative Bank ltd

2007 Building and Machinery

17.5 lacs Active, Current EMI approx. Rs22000/- per month



ManufacturedAgricultural/Irrigation

1 Biggest customer Rajput from Naregaon, Custom-ers from Pachur, Paithan, Jalgaon, Nanded, Beed etc

DripperIrrigation pipes with Dripper

Total number and List of Vendors or Suppliers: Vendors from Jalgaon for Dripper


Area of the Unit: 800 sq. mt

Turnover of the Unit (in Rupees):Year Annual Turnover2009-2010 40 lacs2010-2011 45 lacs2011-2012 50 lacks


2012-2013 75 lacks2013-2014 (expected) 1 crore

Certifications: ISO

Types of Machines: Extrusion Machine, Coiling Machine, Grinder and Mixer

Types of Tools: Complete tool box

Business Process FlowSample is shown

Production begins

Quality Inspections & Finishing

Quality and rates are negotiated and finalize

Sorting and packaging

Dispatch

Quality Control PlanProject Documentation:Does the company maintain Documents for every Project?

Yes


• Visual Inspection• Finishing • Dimension Checking & other defects

Testing of Raw Materials (In-coming - Quality Control Tech-niques)

• Weight measurement• Strength and moisture checking• Brand name is an indicator of quality

Name of Testing Labs for Raw Materials (tie-ups for Raw Ma-terials)

N. A.


N. A.

Testing of Finished Products • Visual Inspection• Dimension & Weight measurement

Safety standards: Fire extinguisher and First aid box is inside the factory premises and all medical expenses are reimbursed.



Company’s Target Market: Farmers


High


Promotion through Direct Meetings, Branding on Key Chains, Calendar, Watches given as gifts


Online services Not yet


Sr. N

o.

Exhi

bitio

n /

Show

Part

icip

ant /

V

isito

r

Bene

fits

1 Exhibition Participant Knowledge about new machines2 Training on new machines

handling organized by CIPETParticipant

Human Resource ManagementShift Timings 9 AM to 6 PM


Employment recruitment rules Direct Interview and referrals

Leave Policies: • WeeklyoffonFriday• Holi-2Days• 26thJan• 1stMay• Dussehra• Diwali

Salary Structure: Rs. 5000 to 12000 for Machine operators

Assistance required from Government in the following areas:• More awareness for programmes and training workshop initiatives run by

the government• Discount the VAT charges

SWOT Analysis of the CompanySTRENGTHS• Quality of products• Brand awareness• Cheaper products as lesser no. of

people employed which results in cost cutting

WEAKNESSES• Competitors using better ma-

chines• Availability of trained manpower

THREATS• Increase in rates of electricity

OPPORTUNITIES• Support from government &

other initiatives for development of the firm

Future Plan of the CompanyTime-lines Plan6 months Manufacturing of Solution and Dripper1 year Insurance and Mediclaim for employees

Increase in no. of machines5 years Making all the products required for operations In-house. No procure-

ment from vendors.

Market expansion to target markets out of Maharashtra.



Raw material

Extrusion moulding for Irrigation pipes

Company board at the entrance

Raw material


Online Drip extrusion line

Granules mixer

Grinder for the scrap material

Online Drip extrusion line


Cooling tower

Compressor unit

Roll of Irrigation pipe.

Rolls of Irrigation pipe.


Step to feed granules in the hopper

Automatic pipe rolling machine

Tool box


Main entrance of the company

Mosquitoes breeding in the cooling tower (since the plant has stopped for maintenance)

Financial institution’s sticker on the machine

Rooms for the workers inside the campus.


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergonomics Need to improvePlant layout Improvement Well plannedNew Product Development No in-house product development process

followedPackaging As per requirementMarketing Brand awareness is high. Kisan PVC Pipes is a

well known brandHuman Resource Needs improvement


RecommendationsInfrastructure & Technology: Needs to make greater investment in machinery in future to keep pace with the market needs and for scaling up the business.

No software is being used currently. But technology will have to be adopted to manage the business efficiently.


Financials: Three major sectors where the company’s products are used: i) Irrigation, ii) Drinking Water and iii) Electrical. In order to provide regular funding, the company may be linked to the respective corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.

Product: As the company is planning to become self-sufficient in all the products re-quired for business, they need to undergo product training and even evaluate the feasibility of entering into all the categories vis-a-vis outsourcing the prod-ucts. The balance needs to be worked out.

Human Resource: Currently the number of employees is only 10. Three members of the family manage the business operations. The company perceives it to be a cost advan-tage. However, the outlook needs to change and more number of qualified people need to be hired to strengthen the business and enter into new markets.

Marketing:The company is banking heavily on its brand awareness in the current target market. However, it should not become complacent as new competitors with greater marketing efforts might erode its equity in future. Participation in trade shows and more online marketing might be effective solutions to tackle the issue.


2

31

10M

itali

Enter

prise

s


Name of the Unit: Mitali EnterprisesAddress of the Company: Plot No. S-1, opp. Good year tyre, MIDC, Waluj, Aurangabad Maharashtra, IndiaLandline number: 0240-2554011Mobile Number: 9767100466Company e-mail id: [email protected] website: N. A. Company started in: September 2010


Company’s Specialization/Product/Services: Plastic injection Moulding




Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Pramila Kanha Kashide 34 Partner BA 3 Years - 09421683397

2 Santosh Mukinda Sirsat 27 Partner BA 5 Years - 09767100466

Mitali EnterprisesMIDC, Waluj, Aurangabad


Sr. N

o.Fa

mily

Mem

ber

Rel

atio

n to

the

Ow

ner o

f the

Com

-pa

ny

Age

(in

Year

s)

Wor

k Ex

peri

ence

pr

ior t

o jo

inin

g th

e C

ompa

nyIn

volv

ed in

Com

-pa

ny’s

busi

ness

ac

tiviti

es (Y

es/N

o)

Rol

e in

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Milind Kanha Kashide

Brother 27 5 years Yes CEO [email protected]

09767100466




1 State Bank of Hyderabad 2011 Machine 20 lacs 12 lac2 State Bank of Hyderabad 2011 Cash Credit 18 lacs

3 State Bank of Hyderabad 2013 Machine 19.75 19.75


Customer Issued in

Criteria/Guidelines to become the Vendor

Products Supplied

1 Badve Engineering ltd.

2012 ISO Certified Plastic Moulded

2 Darshan Plastics 2012 ISO Certified Plastic Moulded

3 Tulja Enterprises 2013 ISO Certified Plastic Moulded




ManufacturedAutomotive 3 1. Badve Engineering ltd

2. Darshan Plastics3. Tulja Enterprises

Plastic Moulded Prod-ucts

Total number and List of Vendors or Suppliers:• Total Supplier - 04 nos• Badve Engineering ltd• Swagat Plymers• Shri Vyankatesh Plymer• Poly Gran India Pvt ltd.

Organization Chart:

Milind Kashide(CEO)

Shift I operators:-1. Ramesh Kapde

2. Anil Dhule

Shift II Operators:-1. Ramnath Dhage

2. Vishnu Kulte

Account Head(Narayan Bhagure)

Quality Head Raju Rudrakshwar

Production Head Sanjay Katolkar

Mrs. Pramila Kashide (MD)

Area of the Unit:Plot Area 3000 Sq. feetTotal Built-up Area 2000 Sq. feet

Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Cowling BM 150 BOXER Plati-

na Side Cover Cap COWlING MIDDlE ASSlY

Badve Engineering ltd

As a Tier 2 Supplier to OEM K G CASEJ D CAPChain Cover

1. Tulja Enterprises2. Darshan Plastics

Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2011-2012 36.15 10.22 0.232012-2013 102.90 15.76 1.442013-2014 (expected) 150 N. A. N. A.

Certifications:Certification Description of the

CertificationYear taken in

Local Agent

ISO 9001:2008 Quality Management Sys-tem

2013 Ajit Rajendra

Audit Reports: ISO 9001:2008


Competitor’s name

Competitor’s Product Spe-cialization


1 Sanjay Plastics Plastic Mould-ed Products

Tier 2

2 Vipra Plastics Plastic Mould-ed Products

Tier 2

3 Gajanan Indus-tries

Plastic Mould-ed Products

Tier 2


Company’s Plant layout

Semi finish goods area

Finished goods area

Store Room

Open Space

Toilet

Machine No. 3 (300 Tons)



Electric Board

Shutter 1 Shutter 2

Semi finished Area

Office Space

Main Gate

Shut

ter 1

Types of Machines

Sr. N

o.

Nam

e of

M

achi

ne

Qua

ntity

Mak

e of

m

achi

ne

Spec

ifica

-tio

n

Pric

e of

th

e M

a-ch

ine (

Rs.)

Year

of

Purc

hase

Loan

/ by

Self

1. Plastic Injection Moulding

1 Electronic a/India

180 tons 10 lacs 2011 Self

2. Plastic Injection Moulding Machine

1 Jit / Philip-pines

300 tons 20 lacs 2012 loan

3. Plastic Injection Moulding Machine

1 Haitian / Vietnam


Types of Tools

Sr. N

o.

Nam

e of

M

achi

ne

Qua

ntity

Mak

e of

m

achi

ne

Spec

ifica

-tio

n

Pric

e of

the

Mac

hine

(R

s.)

Year

of

Purc

hase

Loan

/ by

Self

1. Spanner Set 02 Engineering approach

All types Rs.8000/- 2013 Self

2. Other tools - local market All types Rs.10000/- 2013 Self

Raw materials

Sr. N

o.

Raw

Mat

eria

l

Cur

rent

Rat

e (R

s. Pe

r Kg)

Spec

ifica

tion

Supp

lier’s

Nam

e

Min

imum

qua

ntity

m

aint

aine

d in

the

com

pany

per

mon

th

Prod

uct M

anu-

fact

ured

with

the

mat

eria

l

Prod

uct S

uppl

ied

to

(OEM

/Tie

r 1 su

ppli-

er/T

ier2

Sup

plie

r/Ti

er 3

Sup

plie

r)

1 PPCP 115/kg

MI 3530 lokesh Plasto Chem

1.5 ton Plastic Mould-ed item

Tier 2

2 ABS 1.5 Tons

HI121U Badev En-gineering ltd.

2 tons Plastic Mould-ed item


Shift Timings: 8am to 4pm, 4pm to 12am & 12am to 8am


Sr. N

o.

Nam

e of

wor

ker

Age

(yrs

)

Gen

der (

M/F

)

Wor

kers

/ Su

-pe

rvis

or/M

an-

ager

/ St

aff fo

r cl

eani

ng

Qua

lifica

tion

Ope

ratio

n /

Func

tion

Year

s of e

xper

i-en

ce in

Indu

stry

Wor

king

hou

rs

/ day

1 Milind Kashide

27 M CEO B.E. All 5 yrs 8 hrs

2 - - - Accountant (staff)

MBA Account-ing

3 yrs 8 hrs

3 - - - Supervisor BA Shift incharge / supervi-sory

8 yrs 8 hrs

4 - - - Worker 9th Machine Operator

5 yrs 8 hrs

5 - - - Worker HSC Machine Operator

5 yrs 8 hrs

6 - - - Helper SSC Helper 3 yrs 8 hrs7 - - - Worker HSC Machine

Operator4 yrs 8 hrs



Required number of work-ers




Design & development of plastic products

DME BE

02 0 8 hrs 1

Business Process FlowCustomer Enquiry

Decide rate based on machine capacity and cycle time of operation

Attend Meeting of negotiation

Take Input from Customer

Offer quotation

Receiver purchase order followed by mould

Start Production

Get the sample approved from customer

Submit sample piece

Manufacturing Process FlowMachine operations:

Sr. No.




Wastage %

1 Injection Mould-ing Machine

02 55-60 min 30 min 1%


Process Flow DiagramSr. No.

Operation Check Points Process Flow Dia-gram

Resp.

1 Receiving of Raw material

Raw material Grade as per Purchase order. Bags free from wet & torn Condition.

Store In-charge

2 Storage of Raw Material

Maintain FIFO Store In-charge

3 Pre drying of Raw material

Predrying Temp. & Time as per predrying chart

Material loading Op-erator

4 Injection Moulding

Visual & Dimensional parameters of compo-nent

Shift Super-visor & QA Inspector

5 Deflashing As per reference sample Operator

6 Final Inspec-tion

Free from visual, dimensional & printing defects.

Inspector

7 Packing as per standard packing chart

Operator

8 Despatches Free from transit dam-age

Despatch Supervisor



Price to Customers

Repeat Order

Supplied to

1 Cowling boxer BM 150 38 44.08 Yes Badve Engineering ltdAurangabad

2 Platina Cap 3.30 3.87 Yes Badve Engineering ltdAurangabad

3 K G Case 4.20 4.75 Yes Darshan PlasticsAurangabad

4 J D Cap 1.2 1.45 Yes Darshan PlasticsAurangabad

5 Cowling Middle Assly 10.30 11.67 Yes Badve Engineering ltdAurangabad

Quality Control PlanProject Documentation Does the company maintain Documents for every Project?

No

Quality Control Proce-dure: (In house/ Exter-nal agency)

• Inward inspection is carried out for raw material as well as for insert and other check sheet also available.

• After production of component initial-ly it is inspected by machine operator itself & forward it to packing area.

• for dispatch of product pre-dispatch in-spected is done and PDIR is given with every invoice.

Testing of Raw Materi-als (Incoming - Quality Control Techniques)

• Mostly raw material is supplied by cus-tomer so visually inspection is done.

• If any problem occurs in raw material processing we immediately inform to customer so that they will report it to their respective supplier.


CIPET


Aurangabad Auto Cluster

Incoming Parts

Transporta-tion

StorageOpem. & in-spn. together

OperationPacking Delay


Testing of Finished Products

• For finish product dimensional as well as visual checking is carried out in house

• We are having some of measuring in-strument such as a) Vernier Calliperb) Filler Gauagec) Thread Gauage

Quality Standard for Product:Sr. No. Product name Specification Strictly followed1 K G Case Air Filter No Shrinkage

No Warpage Scratches on insertYes

2 Cowling BM 150 No Scratches, No Weld lineNo shrinkageNo Warpage

Yes

Design & DevelopmentBudget allocated for Research & Development (Annually in Rs.)

15 - 20 lacs


N. A.


Sr. N

o.

Exhi

bitio

n /

Show

Last

at

tend

ed

(Yea

r)

Fees

(in

case

th

e co

mpa

-ny

par

tici-

pate

d)

Bene

fits

1 Plast India 2012 Free -2 Plexpo 2013 100 Heavy discount

in spare part3 Advantage Maharashtra Expo 2014 Free -





Manufacturing Fire Fire Extinguisher First Aid Kit


Effectiveness of the company logo Medium. No need to focus on Brand-ing and Marketing as it is a B2B business and Brand awareness of the company is high in its target market.

Describe the Company’s Target Market: Auto Auxillary manufacture


High


• Online marketing• Most Important satisfactory

customer• Person to person marketing

Online services No

Company Packaging: Supplied by Customer


Finance & AccountsProduct Pricing: Product Pricing of plastic product mainly depends upon its weight and type of machine requires to produce that part.Item Name Unit CapMaterial - PPCPColour - NaturalNet Wt. gms 1.0Runner gms 15Shot wt. gms 1.47Process loss % 1%Recon Wt. gms 1.0Raw Matl. Cost Rs/Kg 127.00Raw Matl. Cost / piece Rs/piece 0.1RM Profit 3% 0.01Net RM Cost per PC 0.14M/C used Tonns 180M/C tariff Rs/shift 1980cavity nos 32Cycle time secs 48Prod. per shift nos/shift 19200Production @ 90% effeciency nos/shift 17280Moulding cost Rs/piece 0.1Rejection @ 3% Rs/piece 0.00Profit 10% on Conv Cost Rs/piece 0.01Moluding Cost Rs/piece 0.13Cost of RM + Conv Rs/piece 0.27Mould Cost(One year) Rs/piece 0.04Inspection cost Rs/pieceFreight cost Rs/pieceTotal Component cost Rs/Piece 0.31

Terms & Conditions# - Freight & Packing cost is not included.# - Above price is basic price Ex. our Works. Other taxes will be as applicable.# - For supply of components payment within 30 days after dispatch from our end.

Distribution process: Finished product dispatched to customer by transport or customers directly purchased from our factory premises by their own vehi-cle.

Human Resource ManagementEmployment recruitment rules Competence requirement of supervisor:

1. Minimum 8 yr of work experience2. Good manpower handling skill3. Well knowledge of plastic injection moulding.

Training Policy for the new recruits/already employed with the company:For New Recruits For Already Employed

Machine Operator Work Experience Work ExperienceSupervisor Work Experience Work ExperienceManager Work Experience Work ExperienceHelper/Cleaning Staff N. A. N. A.

Leave Policies:Staff Leave PolicyMachine Operator Inform before 10-15 daysSupervisor Inform before 10-15 days

Manager Inform before 10-15 daysHelper/Cleaning Staff Inform before 10-15 days


Insurance/Medi-claim Policy: United India Insurance Company


Wage Rate Policy: As per the skill

Salary Structure:Staff For Fresher

(Rs.)With experience of min. 3 years (in Rupees)


Machine Operator 150/shift 190/shift YesSupervisor 200/shift 250/shift YesManager 300/shift 400/shift YesHelper/Cleaning Staff 120/shift 150/shift Yes


of staffProfile (Machine Oper-ator / Supervisor / Man-ager / Helper / Cleaning Staff)

Hometown (Aurangabad/Outside Aurangabad but within Maharashtra/Out-side Maharashtra)


Male 08 Operator Outside Aurangabad but within Maharashtra

1.5 years

Female N. A. N. A. N. A. N. A.

Covered under ESI/EPF/Gratuity: N. A.


Assistance required from Government in the following areas:• Various schemes to be informed by any communication medium• Reduce Electricity rate• Reduce water rate

Assistance by CIPET, Aurangabad: Various training is carried out in CIPET for worker.

Assistance by IGTR, Aurangabad: N. A.

Assistance by ITI, Aurangabad: N. A.

Assistance by MCED, Aurangabad: Many Entrepreneur development training

and other useful workshop is carried out.

SWOT Analysis of the CompanySTRENGTHS• Customer satisfaction• Quality Material• Good reputation among customer

WEAKNESSES• Number of competitor• Unskilled labour• Insufficient capital



OPPORTUNITIES• Export the product• Scope in own product




6 months Design & development Finance Improvement in turnover

1 year Purchase new 450 tons machine

Finance Improvement in turnover

3 years Expansion of new unit Finance Improvement in turnover

5 years Increase more machine Finance Improvement in turnover


Proposed product is having heavy requirement in market

Design Brief 2

It is an automobile part of two wheeler.

Design Brief 3

Very few manufacturer are their for proposed product and supply to direct market will give more profit


Design Brief 4

Cost of product will be very less for direct customer.


It is an automobile part used in head light area of two wheeler

Proposed Design Process Study and designing and researching according to actual available sample

Time-line 06 monthsBudget Rs. 15 to 20 lacsTeam members & Skills Required

Team includes 05 Members• Industrial Designer (two)• Technical Engineer (Two)• Marketing



The main building of the unit.

Pile of boxes folded and kept right in-front of the entrance

The reception area of the unit

Raw material is arranged well


Raw material: PP by Reliance Industries

Raw material: ABS by lG Chem.


Workers assembling the Air filter Case


Workers masking the front cowl for finishing purpose

Well maintained tool board

Quality inspection in progress


The fire extinguisher is not easily visible.

Good practice of maintaining separate area for tiffin area.


Separate and well maintained area for keeping boxes of finished goods.

Security camera in the work area but not functioning

Well defined for raw materials


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement • Space arrangement is a concern as the

plant area is congested• No use of Natural light

New Product Development No in-house product development process followed

Packaging Need to improveMarketing • Market awareness is a problem. No

marketing for business growth• Good branding material available• Sample swatches are available

Human Resource • Good training initiatives for the workers







Marketing:• Website need to be developed to showcase the product portfolio and con-

nect to the buyers and customers.• Branding exercise needs to be conducted on priority basis as the company







31

Claims:

An improved safety shaving disposal razor comprising:

• at least one disposal blade sandwich assembly• at least one sandwich assembly holder• at least one piece of shaving blade• a flap• at least one pivot pin or rivet

13M

oraz

Plas

tics


Name of the Unit: Moraz PlasticsAddress of the Company: Yeshwant Nagar, Navle, PaithanLandline number: N. A.Mobile Number: 9028173531Company e-mail id: [email protected] Website: N. A. Company started in: In process

Type of Company: Proprietership

Company’s Specialization/Product/Services: Safety razor


Details of the Owners / Partners: Vilas More

Abstract of the Innovation:The present invention [particularly discloses the said safety is fold-able device which is mainly used in saloon and parlours for shaving purposes. It comprises of a flap meant for accommodation the disposable blade sandwich assembly along with the sandwich assembly holder. The disposal blade sandwich assembly is snap fitted in the sandwich assembly holder. The sandwich once snap fitted cannot be removed for changing the blade and if any body tries to do so, the snap breaks from its base, thereby avoiding its further use or reuse by inserting a new blade or further use or reuse of said

Moraz Plastic (Innovator)Paithan, Aurangabad

disposable blade sandwich assembly.

Thus it provides a safety to the user which avoids spreading of various dan-gerous and incurable diseases like AIDS, Hepatisis, etc. which are likely to be spread because of the residues remains on the razor blade assembly through infection and contamination while conducting shaving different persons.

Note: limited study has been conducted on this unit as the product develop-ment is in progress.


12M

ould

Tech

nolo

gy


Name of the Unit: Mould TechnologyAddress of the Company: W – 74 MIDC Waluj, Aurangabad, MaharashtraLandline number: N. A.Mobile Number: 9370656737 Company e-mail id: [email protected]

Website: N. A. Company started in: 2009


Company’s Specialization/Product/Services: Mould Making and products manufacturing



Sr. N

o.

Nam

e of

Ow

ner

/ Pro

prie

tor /

Pa

rtne

rs /

Di-

rect

or

Age

(yea

rs)

Stat

us (O

wne

r /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

peri

-en

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail

Id.

Phon

e nu

mbe

r

1 Bhalchandra Bhandare

40 Owner Diploma in Mechanical Engineering

10 -- 9370656737

Mould TechnologyMIDC, Waluj, Aurangabad




Year Purpose Amount (Rs.)

Status (Active/Closed)

1 Shyamrao Vithal Co op bank

2010 Purchase of machinery

25 lacs Paid

2 Bank of Maharashtra 2013 18 lacs Cash credit

Customer Details: Sanjay technoplast, Savera moulding, Varroc, Videocon, Ultima plastics, Higher appliances and Aurangabad Electricals ltd.

Production capacity of the Unit: 8-10 moulds/month

Types of Customer: OEM, Tier 1, 2 and 3 suppliers to OEMs.

Types of Business: OEMs in Aurangabad and Ranjangaon

Turnover of the Unit (in Rupees):Year Annual Turnover2009-2010 40 lacs2010-2011 1 crore2011-2012 1.5 crores2012-2013 1.6 crores2013-2014 (expected) 2 crores


Certifications: ISO certificate in 2010

Business Competitors:• Kishor Industries• Marvel Moulds

Machineries & raw materialsTypes of machineries:• Surface grinder• Drilling machine• Milling cum Drilling machine• Vertical milling machine (Rough milling)• Vertical milling machine (for parallelity)• lathe machine• Injection moulding machine• Grinding machine• Buffing machine• VMC (CNC) machine• EDM machine• Compressor

Raw materials: P-20, Mild steel, OHNS, Copper for moulds and ABS, PP & HIPs for production

Human Resource ManagementShift Timings: 7 am to 7 pm

Total number of Employees at the company: 10 Males ( for Machine opera-tors, tooling & assembly) & 2 Females (for Packing job)

Salary Structure: Rs. 5000 to 7000 for Machine operators & Rs. 10000 for supervisors

Covered under ESI/EPF/Gratuity: N. A.

Compensation Plan for workers in case of injury or accidents: N. A.

Career Graph Plan for Employees: N. A.

Retention Policies and Welfare Schemes: N. A.

Assistance required from Government in the following areas: Taxation need to be simplified w

R&DBudget allocated of Research & Development (Annually in Rs.): 7-10 lacs

Exhibition/trade shows visits (mention name and place): Yes, attended Plas-tvision as a visitor in 2013




Medium


Online services No

Company Label • Company ‘OK’ labels for cardboard boxes• Injection moulded parts being packed

in plastic bags and further packed in cardboard boxes

• Polythene bags for injection moulded parts

SWOT Analysis of the CompanySTRENGTHS• Skilled workers, so always ready to

accept the new challenges• Ready to spend on the innovations• Positive attitude towards the

challenges

WEAKNESSES• Attrition rate is high• More time required to train the

new operator

THREATS• Frequent rate changes of the raw

material, leads to variation in the prise

OPPORTUNITIES• New product development in

the household category




6 months N. A. N. A. N. A.1 year Purchase of machinery

1 VMC and 1 EDMYes N. A.

3 years N. A. N. A. N. A.5 years N. A. N. A. N. A.


Poultry related injected moulded product made with injection moulding technology


Injection moulded parts, almost 50 parts

Proposed Design Process N. A.Time-line 12 monthsBudget Rs. 10 lacs plus the mould expenditure is 1 croreTeam members & Skills Required





lathe machine for rough machining

No safety gears used while working on the machine.

The scrap is not collected properly.


Centre table for finishing workFinishing process

Surface grinder for achieving parallelity


Vertical milling machine (Computer numerical control)

Mould part is being machined


The work area for moulds assembly as seen from the top. Mould parts and tools scattered all over the working area and walk way.

Machine area is not clean and it can become a big hygiene issue.

The machine parts and scrap material lying unattended around the machines


Centre table (bench work) for fitting, assembly, filing and finishing work.

Vertical table top height-gauge in use


The marking for the switches is not shown. It needs urgent attention and maintenance.

Injection moulding area is cluttered and needs proper arrangement for moulds space management.

The machine is not maintained. Needs regular maintenance and the floor needs to be maintained.

The floor needs to be maintained.


Metal part inserts for inhjection moulded parts

Runner and spruce being removed from the Injection moulded parts

Part de-flashing in progress. No safety measures followed

The posture of the worker for long hours will make them suffer from work-related diseases.


Injection moulded parts being packed in plastic bags and further packed in cardboard boxes

Company ‘OK’ labels for cardboard boxes






Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Need to develop




Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) Poultry. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.



Marketing:• A website need to be created on urgent basis so that the customer reach can

be extended.• As the company is venturing into other household products like mugs, it

requires more publicity on retail level. A proper branding strategy should be formalised to get maximum visibility in the market.






31

2

13Pl

ast T

ech


Name of the Unit: Plast TechAddress of the Company: C-252/6 A4, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9326206512




Company’s Initial Investment: Rs. 50000

Company’s Specialization/Product/Services• Spare parts of appliances


Sr. N

o.

Nam

e of

Ow

n-er

/ Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wne

r / P

artn

er)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 laxman Mandkar

42 Owner N. A. 8 years in Videocon

[email protected]

9326206512

Plast TechMIDC, Waluj, Aurangabad



of CustomersNames/List of Cus-tomers


Household Products

- - Plastic Moulded Product

Area of the Unit:Plot Area 1700 Sq. feet.Total Built-up Area 1350 Sq. feet.

Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2010-2011 40,00,000/- N. A. N. A.2011-2012 60,00,000/- N. A. N. A.2012-2013 42,00,000/- N. A. N. A.2013-2014 (expected) 50,00,000/- N. A. N. A.

Certifications: None

Types of Machines: Injection moulding, (3 vertical, 2 horizontal), grinding m/c, cooling plant

Raw materials: PP, Nylon, plastic, High impact polystyrene


Safety standards in the CompanyManufacturing Operations




Manufacturing Fire No Fire Extinguisher No first Aid




Medium





Workers: Makes (8) and Females (2)

Insurance/Medi-claim Policy: United India Insurance companyWage Rate Policy: As per their skill. Machine operators are paid Rs. 8000/mth

Shift Timings: 7 am to 7 pm and 7 pm to 7 am

Views on Govt. Initiatives taken so farAssistance required from Government in the following areas:• Electricity Rate Very High Compare to other State• Government Scheme is not aware of new business men• Road Facility is not good for transport

Assistance by CIPET, IGTR, ITI, MCED Aurangabad: None

SWOT Analysis of the CompanySTRENGTHS• Excellent product quality• Prompt service• Customer Satisfaction

WEEKNESSES• Insufficient Funds• Un-skilled labour



OPPORTUNITIES• To achieve zero customer returns.• To achieve 100 % compliance of

deliveries on scheduled time • To improve machine up time.• Reduction in internal non-

conformities.




1 year Purchase new machine


2 years Expansion of new unit




The working area as seen from top


Injection moulding machine

The injection moulded parts on zig to set the shape

Runner and spruce being removed from the Injection moulded parts

Oil leakage and the scrap on the machine.



The glass is damaged and the process is not visible.

Cloth is tied on the screw to maintain proper injection of raw material.


Hopper is tied with strings to the machine and is also difficult for the workers to feed raw material in the feeder fitted much higher than their reach.

Waste material and scrap material is seen inside the machine

The moulds area is not maintained properly. Water spillage is seen near the moulds


Safety precautions taken while de-flashing the parts


The cardboard box material for product packaging


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Safety kits are not provided to the operatorsPlant layout Improvement Space arrangement is a concern as the plant


followedPackaging Need to improveMarketing • Market awareness is a problem. No

marketing for business growth• No branding material available

Human Resource Focus on manpower training by chalking out customized training programs and evaluation of the workers after undergoing the programs.


RecommendationsInfrastructure & Technology:Machines are not maintained properly. Water spoilage near moulds may rust

the mould, so more intense cleaning operation need to be carried out. Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.



Product: There is no initiative on the new product development so R&D activities need to be carried out for product diversification.

No certification has been taken for the process or product. This needs to be tackled on priority basis

Human Resource: Training period for workers to be increased to avoid the wastage of raw mate-rial, as well as other training on regular basis to be carried out to up-grade the skill of workers.

Marketing:No marketing activities are carried out by the company, no branding is done. So to increase market share or to acquire more customers, proper market-ing activities need to be carried out. A website needs to be designed. Various exhibitions need to be visited by company official and a stall may be put up for awareness among customers.

Considering the long term plan , own transport vehicle need to be purchased for carrying the finished goods so that the transportation cost can be reduced.


2

31

14Ru

pesh

Enter

prise

s


Name of the Unit: Rupesh EnterprisesAddress of the Company: Plot No. D–51/10, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: 0240-2476895Mobile Number: 9881243938Company e-mail id: [email protected]

Website: N. A. Company started in: April 2006


Company’s Specialization/Product/Services• Automobile components• Electrical Components• Appliances Components• Plastic Packing components• Pharma Packing


Sr. N

o.N

ame

of O

wn-

er /

Prop

riet

or

/ Par

tner

s /

Dir

ecto

r

Age

(yea

rs)

Stat

us (O

wne

r / P

artn

er)

Educ

atio

nal

Qua

lifica

tion

Pers

onal

Em

ail

Id.

Phon

e nu

mbe

r

1 Godavari Dattarao Narwade 36 Owner SSC [email protected]

9881243938

Rupesh EnterprisesMIDC, Waluj, Aurangabad


Sr. N

o.Fa

mily

Mem

ber

Rel

atio

n to

the

Ow

ner o

f the

C

ompa

ny

Age

(in

Year

s)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

join

ing

the

Com

pany

Invo

lved

in

Com

pany

’s bu

si-

ness

act

iviti

es

Pers

onal

Em

ail

Id.

Phon

e nu

mbe

r

1 Dattarao Narwade

Spouse 42 ITI, HSC

11 Yes [email protected]

9881243938

Company’s Initial Investment: 27.55 lacs

Loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name /


tive/Closed)1 State Bank of

Hyderabad2010 Term loan 15.75 lacs N. A.

2 State Bank of Hyderabad

2010 Cash Credit 3.00 lacs N. A.

Affiliated units/sister concern/subsidiary:Sr. No

Unit Name Product / Service Address Contact

1 Nitesh Enter-prises

Mfg. Plastic moulding dies, break liner, press tool, Jigs fixtures

Plot No. 79, CIDCO Service Indl. Area, Au-rangabad

9881243938



Production capacity of the Unit:Year Production capacity2013-2014 85 qt.(Proj Sales Rs. 25.00 lacs)2013-2012 70 qt.(Sales Rs. 19.55 lacs)2012-2011 78 qt.(Sales Rs. 23.45 lacs)2011-2010 72 (Sales Rs. 19.51 lacs)2010-2009 60 (Sales Rs. 16.65 lacs)



ManufacturedAutomotive 15 Snehal Autoparts, Shri Ganesh

Ind., Samarth tool• Dies, Press tool

dies

Total number and List of Vendors or Suppliers:• Design steel Pvt. ltd. - Waluj, Aurangabad• Gaurav Enterprises - Waluj, Aurangabad• Shree Sai Cutting tools - Waluj, Aurangabad• Trigon Enterprises - Pune

Total number of Employees at the company: Worker 3 (Supervisor: 01, Oper-ator: 02, Helper: 01)

Types of Business: Tier 2 supplier

Area of the Unit (in Sq. Ft.):Plot Area 650Total Built-up Area 650

Turnover of the Unit (in Lacs):Year Annual Turnover Gross Profit Net Profit2011-2012 23.45 9.86 3.05

2012-2013 19.55 9.33 3.32

2013-2014 (expected) 25.00 11.90 4.20


Office

VMC Machine

Entry Gate30 feet MIDC Road

Working Table

Finished Goods

Surface Grinder

Bathroom

RawMaterial

Bench Grinderlathe

Machine

Milling Machine

Comp-ressor

Types of Machines

Sr. N

o.N

ame

of

Mac

hine

Qua

ntity

Mak

e of

m

achi

ne

Spec

ifica

-tio

n

Pric

e of

th

e M

a-ch

ine

Year

of

Purc

hase

Loan

/ by

Self

1 Milling M/c 1 Kirloskar, India 1mtr X 400mm X 350mm

3.50 lacs 2006 Self

2 Surface Grinding M/c

1 Bhurji Machine Tools, India

500mm X 270MM

1.75 lacs 2006 Self

3 Bench Grinder 1 Rajkot , India 0.15 lacs 2006 Self4 VMC M/c 1 Parattech,

Taiwan900mm X 600mm X 550mm

22.50 2010 Term loan of 15.75


Types of ToolsSr

. No.

Nam

e of

M

achi

ne

Qua

ntity

Mak

e of

m

achi

ne

Spec

ifica

-tio

n

Pric

e of

the

Mac

hine

(R

s.)

Year

of

Purc

hase

Loan

/ by

Self

1. Hand Grinder 1 Max India, India 4 inch Grinder 0.02 2011 Self

2. Hand drill 1 Max India, India 5 mm drilling 0.02 2011 Self

3. Air blow 1 Prakash, India 0.02 2011 Self4 Bench Grinder 1 Rajkot, India 200mm X

31.75mm X 20mm

0.15 2009 Self

5 Pencil Grinder 1 Hitachi, India 6 mm

Raw materials

Sr. N

o.

Raw

Mat

eria

l

Cur

rent

Rat

e (R

s. Pe

r Kg)

Supp

lier’s

Nam

e

Min

imum

qua

n-tit

y m

aint

aine

d in

the

com

pany

pe

r mon

th

Prod

uct M

anu-

fact

ured

with

the

mat

eria

l

1 Mild Steel, WPS (Die Steel), OHNS (Oil Hardening Non Shrinking Die Steel), EN-31 (high carbon alloy steel), EN-8 (medium carbon steel), Copper

AVG. Rs. 1000

Design steel pvt. ltd, Gaurav Enterprises, Shree sai cutting tools, Trigon Enter-prises

Rs. 1.50 lacs Dies, Moulds, Jigs, Fixtures

Information of Workers, Supervisors, Managers and Staff for cleaning

Sr. N

o.N

ame

of

wor

ker

Age

(yrs

)

Gen

der (

M/F

)

Wor

kers

/ Su

perv

isor

/M

anag

er /

Staff

Qua

lifica

tion

Ope

ratio

n /

Func

tion

Year

s of

expe

rien

ce in

In

dust

ry

Wor

king

ho

urs /

day

1 Dattarao Narwade 42 M Supervisor HSC, ITI Supervisor 18 82 Jadhav S.A. 30 M Operator SSC M/c Operator 10 83 Shingade A.S. 41 M Operator Dip. Mech M/c Operator 16 84 Santosh Gadekar 32 M Helper SSC Helper - 8







Designing of plastic moulds, jigs, fixtures

BE DME 02 02 8 1

Business Process Flow

Acquired Purchase Order From Customer

Design & Drawings as per customer requirement

Raw Material Purchase

Cutting

Turning

Milling & Grinding

Drilling

Wire Cutting

VMC Machining

Heat Treatment

Assembly

Dispatch


Manufacturing Process FlowRaw Material Purchase

Cutting

Turning

Milling & Grinding

Drilling

Wire Cutting

VMC Machining

Heat Treatment

Assembly

Dispatch


Machine name No. of labours required per machine



Wastage %

1 Milling Machine 01 As per product (Min. 1hr or max.8 hr)

N. A. 6%2 VMC Machine 01 N. A. 2%3 Surface Grinder 01 N. A. 2%



Price to Customers

Repeat Order

Supplied to

1 Dies Moulds, Jigs, Fixtures

1.07 lacs 1.32 lacs Yes Automobile, plastic in-dustries @ Maharashtra


No


As per customer requirement


Raw material quality control done by the suppliers

Name of Testing Labs for Raw Mate-rials (tie-ups for Raw Materials)

N. A.


N. A.

Testing of Finished Products It is done in house by manually or done by outside

Design & DevelopmentWhat is Design? N. A.

Design Process: Presently design process not done.

Design Process / Plan for a new Product innovation:Design process will be done in house by using technical & qualified employee, and we will developed new design in plastic Agricultural products, household & other products.


Rs.15,00,000/- (proposed plan for development)


Presently used DElCAM software for VMC machining programme


Exhibition/trade shows visits:Sr

. No.

Exhi

bitio

n /

Show

Part

icip

ant /

V

isito

r

Last

atte

nded

(Y

ear)

Fees

(in

case

th

e co

mpa

ny

part

icip

ated

)

Bene

fits

1 Advantage Maharashtra Expo 2014

Dattarao Narwade

2014 Not participated

New design & development


Effectiveness of the company logo

Medium. No need to focus on Branding and Mar-keting as it is a B2B business and Brand aware-ness of the company is high in its target market.

Describe the Company’s Target Market:Export the product and develop new products in automobile & plastic & other industries.


Medium


N. A.


Company Label & Packaging: N. A. (Not required for moulds)

Finance & AccountsCosting for Die weight 150kgsSr. no. Description Rs.1 Cost of raw material 0.352 +Processing cost 0.623 +labour Cost (wages) 0.104 Total Cost to company 1.075 Margin 0.256 Selling Cost 1.32

Distribution Process:Finished material dispatched to customer by transport or customers directly purchased from our factory premises.


No any specific recruitment rules. Employee’s selection on their skilled and work efficiency.


Machine Operator Work experience / trail run Work experienceSupervisor Work experience Work experienceManager Work experience Work experienceHelper/Cleaning Staff Work experience Work experience

Leave Policies: 4 days in month and Public holiday for All.

Overtime Policy: Staff Leave Policy


Machine Operator Wages per hourSupervisor Wages per hourManager Salary per hourHelper/Cleaning Staff N. A.

Insurance/Medi-claim Policy: N. A. (Proposed to start)

Wage Rate Policy:Staff Wage Rate PolicyMachine Operator On work experience or fixed on Rs.6000-7000 p.m.Supervisor On work experience or fixed on Rs.9000-10000 p.m.Manager On work experience or fixed on Rs.10000-12000 p.m.Helper/Cleaning Staff Helper / cleaning fixed Rs. 3000-4000 p.m.

Staff Rs.6000 - 7000 p.m.

Salary Structure:Staff For Fresher (in Rs.) With experience

of 3 years (in Rs.)Training required, if yes then please mention the training

Machine Operator

6000-7000 p.m. 7000-8000 p.m. Practical work done

Supervisor 9000-10000 p.m. 10000-12000 p.m. HRMManager 10000-12000 p.m. 11000-13000 p.m. Business Management train-

ingHelper/Clean-ing Staff

4000-6000 p.m. 6000-8000 p.m. For staff - as per post training


of staffProfile (Machine Operator / Supervisor / Manager / Helper / Cleaning Staff)

Hometown (Aurangabad/Outside Aurangabad but within Maharashtra/Outside Maharashtra)


Male 04 Supervisor / Manager / Staff

Aurangabad 2 yrs - 3 yrs

SWOT Analysis of the Company

STRENGTHS• Good reputation among customer• Huge works order in hands• Use pure raw material for produc-

tion, not mix any default material like other customer

WEAKNESSES• Unskilled labour• Insufficient capital

THREATS• Competitor sale produce in lesser

amount• Recovery of Credit Sales

OPPORTUNITIES• Export the products• Design & Develop new Products




6 months ISO Certification -- Develop material quality

1 year Design & develop new products

Finance / Training / Design Assistance

Acquired new work orders

3 years Export sales Finance Export order

Product Design BriefDesign Brief Design & development of new plastic products

Plan of the Design ProjectProduct Design Brief specifications Various types of Plastic productsProposed Design Process N. A.Time-line 2 - 3 yrsBudget Rs. 15,00,000/-Team members & Skills Required 03Benefits for the Company Develop new products


Vertical Milling Machine

CNC Wire-cut


Better Scrap collection process need to be introduced.

The moulds are lying unattended on floor


The compressor is right at the entrance blocking the entrance

The entrance of the unit is not well lit



plant area is congested• Proper use of Natural light








Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII, FICCI and build associations with design insti-tutes, national innovation foundations, etc.

Product: Close tie up needed with companies in FMCG, household products manufac-turers, medical products and relevant industries. New product development and business process needs to be top priority.









31

2

15Se

jal P

lastic


Name of the Unit: Sejal PlasticAddress of the Company: D -81, MIDC, Shendra, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9370150700





Company’s Specialization/Product/Services• Woven Plastic Mats & Mandap Rolls


Sr. N

o.

Nam

e of

Ow

n-er

/ Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wne

r / P

artn

er)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Santosh Vajantrao Joshi

46 Owner Engineer Produc-tions

- - 9370150700

Sejal PlasticMIDC, Shendra, Aurangabad

Loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt. Assistance Year Purpose Amount (Rs.) Status1 Mortgage of Plot and Building - - 30 lacs Not Closed2 Transferred by MIDC as a Tri-

party Agreement- land - -

Production capacity of the Unit: Mat size=4 ft*6 ft; 1 machine produces 80 mats. Total 960 mats produced in a day.



ManufacturedConsumer Products

N. A. Main markets in Hyderabad, Bangalore and Mumbai

N. A.

Area of the Unit: 800 sq metres

Turnover of the Unit (in Rupees):The expected amount is Rs. 65-70 lacs

Types of Business (give product’s name and its buyer): Mats and Mandap Rolls. Main markets in Hyderabad, Bangalore and Mumbai

Types of Machines: Injection moulding, (3 vertical, 2 horizontal), grinding m/c, cooling plant. A total of 12 local made machines: Avg Price- Rs 1.2 lacs to 2.5 lacs produces 3.5 kgs of mats/hour

Raw materials: Avg Cost of Virgin Material = Rs 55/kg. The main raw materi-als are Polypropelene, Tapes, Cotton and Nylon


Business Competitors: Total No.: 40, the main competitors being Sapna, Satyam ad general Mats

Organization ChartBoss

Manager

Supervisor Supervisor

21 workers

Business process - flow chartProducts manufactured

Transported to local hubs like Shendra/Waluj/ Chikalthana

Wholeseller

Retailer

Design & DevelopmentWhat is Design? Quality in focus, useful to consumers,

aesthetic appeal and longer shelf life


Design software outsourced from Sholapur




Medium


Exhibition/trade shows visits (mention name and place): Not attended till date

Packaging: 80 mats in one High Density Propylene is used

Pricing:Tax Calculation, VAT, Income Tax, Daily Accounts are done by a hired CA. CA is paid Rs 4000/- to 5000/- per month.Cost = Raw Material+ Power+ labor+ Operating Expenses\

Price= Cost+ Profit




Overtime Policy: Generally 1.5 times of regular salary but overtime not al-lowed for more than 4 hours

Employees: 25

Insurance/Medi-claim Policy: Nil

Wage Rate Policy: As per their skill. Machine operators are paid Rs. 8000/mth

Shift Timings: 7 am to 7 pm and 7 pm to 7 am

Leave Policies: Government leaves are given to workers

Salary Structure: Rs. 250/day for 25 days in a month for Machine operators and Rs, 12000 for supervisors.

Views on Govt. Initiatives taken so farCommunication of Govt. initiatives is not done properly. Most of the times they are not aware about the schemes. They are not aware about the process or even whom to approach.

Assistance required from Government in the following areas:Transportation of laborsAssistance in payment cycleWater supply issues

Assistance by CIPET, IGTR, ITI, MCED Aurangabad: None

SWOT Analysis of the CompanySTRENGTHS• Experience in the business• Marketing Expertise• Quality of products manufac-

tured

WEEKNESSES• Unskilled labors• Absenteeism due to lack of con-

veyance issues

THREATS• Break in Payment Cycle• Recession in the Industry

OPPORTUNITIES• Design and Raw Material

Improvement

Future Plan of the Company

Time-lines Plan6 months Streamline operations1 year Purchase new machine2 years Expansion of new unit

Product Design Project Brief: N. A.


No name plate on display

Extrusion process for making hollow strips


A lot of clutter is seen in the working area. The floor needs maintenance

Continuous water leakage in the work area.


Bundling of strips in progress. A lot of wastage is seen.

The work area around the machine is not free and clean.


A lot of wastage seen around the work area

The scrap is not properly collected


A lot of clutter and wastage seen around the work area


Sharp shaving blades is used for finishing the edges of the plastic mat.


Hot-wire cutting machine for the mats Stitching machine to close

the edges of the mat


The package design is not appealing. The brand name is not easily readable



Sharp shaving blades is seen thrown on the floor unattended

Scrap material is thrown at the entrance


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality Needs up-gradationOperations As per the product requirementsWorkplace & Ergonomics Need to improvePlant layout Improvement Well plannedNew Product Development No dedicated Product Development wingPackaging As per requirementMarketing Brand awareness is high in the B2B marketHuman Resource Needs to improve

Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Needs up-gradation

RecommendationsInfrastructure & Technology: There is a need to invest in premium and more technologically advanced machines as product differentiation is the key to achieve competitive growth in this market. Technology can also enable the company to enter into online operations which it has still not explored.

Supply Chain & Operations: Exploring new raw material vendors and tapping new customers is essential for increasing the market share and be competitive in the industry.


Product: The company needs to set up a dedicated product development wing and even collaborate with Govt. bodies to take up consultancy projects for new product development.

It can also look at creating new patterns and weaves. Product diversification into the Home Decor industry will enable the company to enter into new mar-kets and de-risk business by reducing dependence only on one or two product categories.

Human Resource: Investment in manpower training, adopting safety measures and providing insurance/medi-claim facilities is crucial. Moreover, the company also needs to chart out career progression path to retain talent.

Marketing:The company is banking heavily on its brand awareness in the current target market. However, it should not become complacent as new competitors with greater marketing efforts might erode its equity in future.

Participation in trade shows and online marketing might be effective solutions to tackle the issue.


31

2

16Sid

dhi

Polyw

eave


Name of the Unit: Siddhi PolyweaveAddress of the Company: Plot No: l-18/1, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 09970053151Company e-mail id: [email protected]: N. A. Company started in: 2012


Company’s Specialization/Product/Services: Plastic Mats



Sr. N

o.N

ame

of O

wne

r /

Prop

riet

or /

Part

-ne

rs /

Dir

ecto

r

Age

(yea

rs)

Stat

us (O

wne

r /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

peri

ence

pr

ior t

o st

artin

g/jo

inin

g th

e C

om-

pany

Pers

onal

Em

ail

Id.

Phon

e nu

mbe

r

1 Shashikant Nagnathrao Ernale

44 Owner BE Me-chani-cal

Sapna Polyweave & Chandra Mats for 12 yrs

[email protected]

09970053151

Siddhi PolyweaveMIDC, Waluj, Aurangabad


Sr. N

o.Fa

mily

Mem

ber

Rel

atio

n to

the

Ow

ner o

f the

C

ompa

ny

Age

(in

Year

s)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

join

ing

the

Com

pany

Invo

lved

in

Com

pany

’s bu

si-

ness

act

iviti

es

Pers

onal

Em

ail

Id.

Phon

e nu

mbe

r

1 Kavita Shashikant Ernale

Wife 36 B. Com. N. A. Accounts N. A. N. A.


Loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt.

AssistanceYear Purpose Amount

(Rs.)Status (Active/Closed)

1 State Bank of India 2012 Machineries 50 lacs Taken 24 lacs20 lacs CC

Production capacity of the Unit:Year Production capacity2013-2014 7.5 lacs worth of Plastic Mats monthly



ManufacturedHousehold Products

Many Distributors across India

Kerala, Karnataka, Aurangab-ad(RM Sales, Super Kirana) and Ferry wallas (door to door selling)

Plastic Mats


Total number and List of Vendors or Suppliers: 8 Suppliers from Hyderabad, Umnabad in Karnataka


Organization Chart

Proprietor

Jobber (1)

Extruder Operator (2)

Parker (1)

Weaving Operator (4)

Packaging (2)

Types of Business: OEM. Plastic mats are supplied to the Dealers across India

Area of the Unit: 750 Sq. mtr. Built-up area is 49% of the total area.

Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2013-2014 (expected) 90 lacs N. A. 5% - 8%

Certifications: None

Business Competitors: Total 40 Mat companies in Aurangabad district

Sr. No.

Competitor’s name



1 Sapna Polyweave Mats OEM2 Kesona Mats Mats OEM3 Chandra Mats Mats OEM

Types of Machines

Sr. N

o.N

ame

of

Mac

hine

Qua

ntity

Mak

e of

m

achi

ne

Pric

e of

th

e M

a-ch

ine

Year

of

Purc

hase

Loan

/ by

Self

1 Mixer 1 Tejal Engineering, Aurangabad 60000 2012 loan

2 Grinder 1 Tejal Engineering, Aurangabad 15000 2012 loan

3 Compressor 1 Skyline distributor, Aurangabad 67000 2012 loan4 Extruder 5 Tejal Engineering, Aturangabad 450000 2012 loan5 Weaving Machine 8 Tejal Enginrreing waluj, Pooja

Enginering, Chikalthana1350000 2012 loan

6 Cutting machine 1 Tejal 20000 2012 loan7 Stitching Machine 1 12000 2012 loan8 Joining machine 1 Yamoto 25000 2012 loan

Types of Tools: Grinding machine, Scissors, Blades

Raw materials: low Density Polypropylene from Hyderabad company, HDPE Bags, PP Bags, Tapes and Yarns- low Density Polypropylene

Information of Workers & Staff:

Shift Timings: 7 AM to 7 PMNumber of Shifts per day: 2Male & Female Ratio: 9 Males & 1 Females


Sr. N

o.

Nam

e of

w

orke

r

Age

(yrs

)

Gen

der

(M/F

)

Wor

kers

/ Su

perv

isor

/M

anag

er /

Staff

1 Raju Piwal 35 M Jobber2 Ramdas Shinde 32 M Extruder Operator3 Shankar Pujari 34 M Extruder Operator4 Pratap Rajput 25 M Weaving Operator5 Chandra Rajput 21 F Parker (Pipes collection and putting in weaving section6 Sharma 30 M Weaving Operator7 Jitendra Patil 23 M Weaving Operator8 Swapan

mandavgadh33 M Weaving Operator

9 Namdev Kalwani

31 M Packaging

10 Daneshwar Kalwani

36 M Packaging

Quality Control PlanProject Documentation Yes. In-house Quality Control Procedure: (In house/ External agency)

The raw materials are sourced from reliable vendors. Hence, no quality check is done


Weight and Quality reading is taken on an hourly basis at the extruder machine.

Design & DevelopmentWhat is Design? Design means Innovation

Design Process/Plan for a new Product innovation: Designs and patterns are outsourced due to cost implications.


No


Tally for Accounts and Microsoft Office

Exhibition/trade shows visits: Plast India as a visitor

Safety measures: Fire Extinguisher & First Aid available in the work area

Marketing and Branding:Describe the Company’s Target Market: Middle class households


Medium


Word of Mouth Publicity

Online services No

Company Label: Company Branding is done on the bags and on the taped margins of the mats.

Pricing: RM+ labor+ Electricity+ Overheads+ Profits = Price

Human Resource ManagementEmployment recruitment rules Direct Recruitment


Leave Policies: Weekly off and additional 20 days in the year


Insurance/Medi-claim Policy: None

Salary Structure: An average of Rs. 10000 per month. Rs. 300/day for 26 days in a month.

Views on Government Initiatives taken so far:The Govt. subsidies have not been availed so far but would now like to take advantage of the same.

Assistance required from Government in the following areas:• Financial Aid• lower Interest Rate• Awareness about new Technology and quality of Raw Materials

SWOT Analysis of the CompanySTRENGTHS• Good quality Product at low

price• Hard-working team

WEAKNESSES• Financial backing is weak• Margins are very thin (operat-

ing at 5%-8% while it should be around 10%)

• Safety measures• No security at the unit• No design team

THREATS• Prices are moderate. Competitors

sell mats at lower prices.

OPPORTUNITIES• Good market opportunity• Huge demand (currently not able

to fulfil the market demand)

Future Plan of the CompanyTime-lines Plan6 months Tying up with Govt. bodies for availing the benefits of Govt. schemes.

Introduce virgin materials in manufacturing Plastic Mats1 year Plant expansion : Expansion by investing in 8 more machines3 years 5 cr turnover to be achieve5 years Diversification in other engineering product line


No name plate on display

Extrusion process for making hollow strips





The space in the plant is not utilized efficiently

A lot of wastage seen around the work area. The spillage of water is a big issue all around the work area


Bundling of strips in progress. A lot of wastage is seen.

The scrap is not properly collected


The scrap to be properly collected

The scrap to be properly collected. The tools are lying around on floor unattended


Sharp shaving blades is used for finishing the edges of the plastic mat.


The work area around the machine is not free and clean.


Hot-wire cutting machine for the mats


Stitching machine to close the edges of the mat

The package design is not appealing. The brand name is not easily readable

Finished rolls of plastic mats



Water is removed from inside of the hollow pipes used in the plastic mats

Area around the compressor is filled with granules bags. There is no free space around it.


31

2

17Sn

ehal

Plas

tic

Indu

stries


Name of the Unit: Snehal Plastic Industries (10 years back was Sachin Plastic Industries)Address of the Company: M – 127, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9325212359, 8888837992Company e-mail id: [email protected] No.: N. A.Website: www.snehalplasticindustries.bizporto.com Company started in: 1993


Company’s Specialization/Product/Services• Injection Moulding (Castor wheel)•Details of the Owners / Partners:

Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Bharat Sindi Kumate

N. A. Owner High School

1 N. A. 08888837991

Company’s Initial Investment: 35000

Snehal Plastic IndustriesMIDC, Shendra, Aurangabad


Bank Name / Govt. Assis-tance


1 Bank of Baroda N. A. Expansion 80 lacks 15 lacs Paid

Production capacity of the Unit: 5000 Castor Wheel per day


CustomersNames/List of Custom-ers


Automotive 2 Sanjay Techno Products • Mirror for two wheeler

• Protective Packing for shafts & gears

Agricultural/Irrigation

1 Disha Industries Dripper

Household Products

1 Yashoda Industries Washing Machine Components

Industrial Appliances

2 • Yashoda Industries • lunar Ele. Pvt. ltd.

TV Parts Refrigera-tor Parts

Pharmaceutical 1 Navketan Pharmaceuti-cal Pvt. ltd.

Bottles

Total number and List of Vendors or Suppliers: Two



Organization Chart:

Owner(Bharat Sindikumate)

Machine operator Service & main-tenence staff

Accountant & Admin staff

Snehal Plastic Industries

Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Castor Wheel, Spare

Part of Cooler, Mixer and some part of light

Vidieocon, K-stars, Bajaj, Wipro lighting


Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2012-2013 2.5 crores N. A. 30 lacs (aprox.)

2013-2014 (expected) 3.5 to 4 crores N. A. N. A.

Certifications: ISO9001

Business Competitors: Twenty-five

Machines & raw materialsTypes of Machines: Buffing M/c, Milling M/c, Drilling M/c and lathe M/c

Raw materials: Acrylic, GPPS, PP, PPCP, HD, HD block, Nylon, etc.


No


No


No


No


N. A.

Testing of Finished Products Takes place at the buyers place

Quality Standard for Product:Sr. No. Product name Specification Strictly followed1 Pulsar Housing Free from Flash, Welding flow

marks, silver marks Yes

2 612 Holders Free from defect and flash Yes3 Automotive casting Free from silver marks flash Yes4 Dripper Free from flash Yes5 Bottles Free from damage and over deflash-

ingYes

6 Protective Sleeves Free from flash Yes

R & DBudget allocated for Research & Development (Annually in Rs.)

N. A.



N. A.

Exhibition/trade shows visits

Sr. N

o.

Exhi

bitio

n /

Show

Part

icip

ant /

V

isito

r

Last

atte

nded

(Y

ear)

Fees

(in

case

th

e co

mpa

ny

part

icip

ated

)

Bene

fits

1 Goregaon, Mum-bai

Visitor 2013 N/A Information about latest Technology




Medium


N. A.

Online services Yes







opment Assistance by CIPET, IGTR, ITI, MCED Aurangabad: N. A.

SWOT Analysis of the CompanySTRENGTHS• Quality – satisfactory customers• Advanced technology• Experienced & trained staff• Development strategies and plans

WEAKNESSES• Financial crunch• No own factory land

THREATS• Development of the firm’s new

design & components (copying) by other competitors.




CostingThe cost of the unit product depends on the design and quality required by the customers. Basic costing depends on the following components such as Raw material cost + pigment (master batch) cost + runner cost + cavity cost + machine shift cost + machine tonnage cost + cycle time (as per hours) + (-) efficiency + finishing + packaging + 5% to 10 % profit + cost of imported component (if applied)




6 months Purchasing of new land for factory premises and new product development

Finance & Design Assistance Growth of sales & promotion

1 year ISO certification, Building infrastructure development

Finance Better Produc-tivity and build trust and value in market

3 years New product develop-ment and machinery

Finance Growth of sales & promotion




New filter development for 2-wheeler vehicles to increase the mile-age, life and pick up of the vehicle.

Design Brief 2

New design and development of castor wheels

Plan of the Design Project

Product Design Brief specifications

Injection moulded parts


Timeline 1 yearBudget Rs. 15 lacsTeam members & Skills Required

Team includes 5 Members• Designer (2)• Technical Engineer (2)• Marketing (1)

Benefits for the Company It will create brand value inhale confidence and more profitability


Raw material bags






There is no enough light to do the finishing job such as de-flashing.

The finished items are being packed and weighed


Clutter seen around the working area

The bags are being readied for transportation

The shelves are not properly marked. It is difficult to find the items from the clutter.

The grinder is kept on floor. Needs proper care to avoid any accident


The tool board is not well maintained

The moulds needs to be arranged properly to avoid damage to the mould and avoid accidents with the working area.


Annealing method developed in-house


Oil spillage seen around the machine.



The finished products are loaded on thwe tempo to be transported to the clients

The unit has maintained a beautiful garden within the campus

The walk way is occupied with the items produced and the scrap material






Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Needs to improve





Product: Company is dependent on only one type of product, it should think about venturing into other products with the existing setup of machineries to reduce the business risk.


Marketing:• Website need to be up-graded on urgent basis so that the customer reach

can be extended.• The company requires more publicity on retail level. A proper branding

strategy should be formalised to get maximum visibility in the market.• The logo needs to be more creative, to make a place in the customers per-

ception.• A proper career growth plan should be formalised, so that the attrition rate

is reduced.• Emphasis should be given on the putting the stall in the exhibitions to cre-

ate awareness among probable customers.• The Company can tie-up with the trade bodies, which give funding for

the new product development, this will be very beneficial to speed up the development process.


31

2

18Su

nrise

Auto

Pac

k


Name of the Unit: Sunrise AutopackAddress of the Company: F – 16/4, MIDC, Chikalthana, Aurangabad, Pin: 431 210, Maharashtra, IndiaLandline number: 0 240 - 2482097Mobile Number: 8888864242, 95951 74242, 94222 94242Company e-mail id: [email protected]

Website: www.sunriseautopack.com Company started in: 2008


Company’s Specialization/Product/Services• PET Packaging machinery manufacturer & Bottling machine


Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Raju Neele Owner Grad-uate

4 -- 8888864242



Production capacity of the Unit: 150 bottles per minutes

Types of Customer: B2B

Total number of Employees at the company: 15 Males (14) and Female (1)


Turnover of the Unit (in Rupees): Rs. 1.5 crores in 2012-13 with a net profit of 4 lacs

Certifications: No

Types of Machines: Buffing m/c, Milling m/c, Drilling M/c and lathe m/c

Raw materials: Stainless Steel, Mild Steel, High Density polymer


No


No

Sunrise Auto PackMIDC, Chikalthana, Aurangabad



No


N. A.


N. A.


Design & DevelopmentDesign Process/Plan for a new Product innovation

No


N. A.


No



Exhibition/trade shows visits: Yes as participant


Medium


No

Online services No

Human Resource ManagementShift Timings: 9 AM to 5:30 PM


Insurance/Medi-claim Policy: No


Contract Worker Policy: No

Career Graph Plan for Employees: Growth & continues development under motivation & guidanceRetention Policies and Welfare Schemes: Insurance Policies

Assistance required from Government in the following areas:• Guidance about new product development • Awareness about the new schemes and training programs organized by

various agencies





6 months Capacity increase, purchase of Blow moulding machine

Yes N. A.

1 year Purchase of injection moulding machine

Yes N. A.



The workers are too close to each other and to adjacent machines.

No safety gears used while working on the vertical milling machine.




Turning process


The posture of the workers for long hours will make them suffer from work-related diseases. Also, the machines parts are seen unattended in the working area.


The main switch board is not maintained.


Drawing prepared by the workers

Drawing in progress


Wires are seen hanging loosely around the main switch board leading to a risk of accident and fire.

The flat grinding belt has temporary arrangements.

The ready parts are spread all over the floor.

The table is temporarily built to carry out maintenance and finishing work


The scrap is not collected properly.

The work area as seen from the top.

Tool table is cluttered.


FindingsProduct Design & ProcessTechnology As per standardAesthetics Good Quality SatisfactoryOperations Safety kits are not provided to the operatorsWorkplace & Ergonomics NeededPlant layout Improvement • Space arrangement is a concern as there is

lot of congestion of machine.• No use of Natural light.

New Product Development Yes, R & D in process for bottling machineryPackaging Yes, goodMarketing Good market presence in bottling automationHuman Resource 1 year training is provided to new recruit

Business DesignMarketing Yes, need to improvelogo Design NoVisiting Card NoBrochures & leaflets NoWebsite Yes

Recommendations• As company has plan for huge expansion, company logo has to more

creative and need to be protected. it has good visibility in market, need to capitalise on that.

• Production layout is not so good. Sufficient space has to be kept between machinery so the better working condition.

• Very less safety precautions are taken by workers, this need to be improved

by providing gloves and other safety gears to workers.• The work area need to be cleaned regularly and scraps and used tools re-

moval process has to be planned. • Need to focus on regular maintenance and servicing of machines to avoid

pre-mature wear and tear.• There is an urgent need for the certification of the company as this will

improve the image of the company in the market. For this proper record keeping in all departments is needed.

• No testing is done on the product during production, so proper quality control procedures need to be formed.


2

31

19Su

shm

aIn

dustr

ies


Name of the Unit: Sushma Industries (sister concern of Jyoti Industries)Address of the Company: D – 95, MIDC, Shendra, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 8928187703, 9404012247, 9822193777Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2007



Company’s Specialization/Product/Services: PVC Pipes

Affiliated units/sister concern/subsidiary: Jyoti Industries


Sr. N

o.

Nam

e of

O

wne

r /

Prop

riet

or

/ Par

tner

s /

Dir

ecto

r

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Parvati Mahadeo Funde

45 Owner 9th std. [email protected]

9404012247, 9822193777



Year Purpose Amount (Rs.)

Status (Active/Closed)

1 Khamgaon Urban Cooperative Bank ltd

2007 Building and Machinery

17.5 lacs Active, Current EMI approx. Rs. 22000/- per month



ManufacturedAgricultural/Irrigation

1 Biggest customer Rajput from Naregaon, Customers from Pachur, Paithan, Jalgaon, Nanded, Beed etc

PVC Pipes

Production capacity of the Unit: 75mm- 6m length- 150 units; 32mm- 6m length- 175 units


Area of the Unit: 800 sq. mt

Turnover of the Unit (in Rupees):Year Annual Turnover2009-2010 40 lacs2010-2011 45 lacs2011-2012 50 lacks

2012-2013 75 lacks

2013-2014 (expected) 1 crore

Business Competitors: Kanak

Sushma IndustriesMIDC, Shendra, Aurangabad


Certifications: ISO

Types of Machines: Extrusion machine, Mixer, Heater, Firing, Injection, Cut-ter, Socket, Grinder, Screen Printing

Types of Tools: Complete tool box

Raw Materials: PVC Granules, Titanium, Carbon, Master Batch, Calcium, Wax

Business Process FlowSample is shown

Production begins


Quality and rates are negotiated and finalize

Sorting and packaging

Dispatch

Quality Control PlanProject Documentation:Does the company maintain Documents for every Project?

Yes


• Visual Inspection• Finishing • Dimension Checking & other defects


• Weight measurement• Strength and moisture checking• Brand name is an indicator of quality


N. A.


N. A.


Safety standards: Fire extinguisher and First aid box is inside the factory premises and all medical expenses are reimbursed.



Company’s Target Market: Farmers


High


Promotion through Direct Meetings, Branding on Key Chains, Calendar, Watches given as gifts


Online services Not yet

Packaging: The packaging is open and a minimum of 10 pipes are bundled/tied together


Sr. N

o.

Exhi

bitio

n /

Show

Part

icip

ant /

V

isito

r

Bene

fits

1 Exhibition Participant Knowledge about new machines2 Training on new machines

handling organized by CIPETParticipant

CostingRaw Material cost + 15% Mark-up

Human Resource ManagementShift Timings 9 AM to 6 PM


Employment recruitment rules Direct Interview and referrals

Leave Policies: • WeeklyoffonFriday• Holi-2Days• 26thJan• 1stMay• Dussehra• Diwali

Salary Structure: Rs. 5000 to 12000 for Machine operators

Assistance required from Government in the following areas:• More awareness for programmes and training workshop initiatives run by

the government• Discount the VAT charges

SWOT Analysis of the CompanySTRENGTHS• Quality of products• Brand awareness• Cheaper products as lesser no. of

people employed which results in cost cutting

WEAKNESSES• Competitors using better ma-

chines• Availability of trained manpower

THREATS• Increase in rates of electricity



Future Plan of the CompanyTime-lines Plan6 months Manufacturing of Solution and Dripper1 year Insurance and Mediclaim for employees

Increase in no. of machines5 years Making all the products required for operations In-house. No procure-

ment from vendors.

Market expansion to target markets out of Maharashtra.



Stock of pipes kept near the entrance

Financial institution’s mention on the wall inside the unit

Group of workers separates the stones and metals from the scrap of plastic pipes


Extrusion machine for the plastic pipes

Storage area for finished plastic pipes

Heating the plastic pipes

The heated pipe is put on die to increase the diameter of the plastic pipe


Damaged plastic pipes during production because of power cuts

The fire extinguisher is hidden behind the bags of raw material. Need to make it easily accessible in case of emergency.

Company’s own transport vehicle with company’s branding on it.

Company’s own calender for branding purpose.


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergonomics Need to improvePlant layout Improvement Well plannedNew Product Development No in-house product development process

followedPackaging As per requirementMarketing Brand awareness is high. Kisan PVC Pipes is a

well known brandHuman Resource Needs improvement


RecommendationsInfrastructure & Technology: Needs to make greater investment in machinery in future to keep pace with the market needs and for scaling up the business.

No software is being used currently. But technology will have to be adopted to manage the business efficiently.


Financials: Three major sectors where the company’s products are used: i) Irrigation, ii) Drinking Water and iii) Electrical. In order to provide regular funding, the company may be linked to the respective corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.

Product: As the company is planning to become self-sufficient in all the products re-quired for business, they need to undergo product training and even evaluate the feasibility of entering into all the categories vis-a-vis outsourcing the prod-ucts. The balance needs to be worked out.

Human Resource: Currently the number of employees is only 10. Three members of the family manage the business operations. The company perceives it to be a cost advan-tage. However, the outlook needs to change and more number of qualified people need to be hired to strengthen the business and enter into new markets.

Marketing:The company is banking heavily on its brand awareness in the current target market. However, it should not become complacent as new competitors with greater marketing efforts might erode its equity in future. Participation in trade shows and more online marketing might be effective solutions to tackle the issue.


2

31

20Su

yog

Plas

tics


Name of the Unit: Suyog PlasticsAddress of the Company: E – 70/27, MIDC, Waluj, Aurangabad, Pin: 431136, Maharashtra, IndiaLandline number: 9923143839Mobile Number: 9923143839Company e-mail id: [email protected] No.: N. A.Website: www.suyogplastics.com Company started in: 2008


Company’s Specialization/Product/Services• Automobile components• Electrical Components• Appliances Components• Plastic Packing components• Pharma Packing



Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Vinay Walandikar

24 Partner BBA, MBA

2 Years [email protected]

09923143839

2 Anand Walandikar

21 Partner B.Tech - [email protected]

07798267067


Sr. N

o.Fa

mily

Mem

ber

Rel

atio

n to

the

Ow

ner o

f th

e C

ompa

ny

Age

(in

Year

s)

Educ

atio

nal Q

ualifi

catio

n

Wor

k Ex

peri

ence

pri

or to

jo

inin

g th

e C

ompa

ny

Invo

lved

in C

ompa

ny’s

busi

ness

act

iviti

es (Y

es/N

o)

Rol

e in

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Vaibhav Walandikar

Brother 18 12th - No No - 09404001539

2 Sudha Walandikar

Mother 51 Bcom, llB

- No No - 09960411602

3 Prakash Walandikar

Father 61 Bsc, Msc

- No No - 09421405614



Suyog PlasticsMIDC, Waluj, Aurangabad




1 SBI 2012 C. C. 2400000 Active2 SBI 2013 C. C. Extended 3500000 Active

3 SBI 2013 Term loan 2400000 Active


Customer Issued in

Criteria/Guidelines to become the Vendor

Products Supplied

Last Audit by Customer

1 Sanjay Techno Products Pvt ltd

2010 ISO Certified Automo-bile

8 months

2 Forcas Impex Pvt ltd

2010 ISO Certified Electrical 1 year

3 Devgiree Forging Pvt ltd

2009 ISO Certified Packaging 2 months

Production capacity of the Unit:Year Production capacity2013-2014 150 M / Tons - Year2013-2012 125 M / Tons - Year2012-2011 100 M / Tons - Year2011-2010 75 M / Tons - Year2010-2009 50 M / Tons - Year



ManufacturedAutomotive 2 Sanjay Techno Products • Mirror for two

wheeler• Protective Packing

for shafts & gearsAgricultural/Irrigation

1 Disha Industries Dripper

Household Products

1 Yashoda Industries Washing Machine Components

Industrial Appliances

2 • Yashoda Industries • lunar Ele. Pvt. ltd.

TV Parts Refrigerator Parts

Pharmaceutical 1 Navketan Pharmaceutical Pvt. ltd.

Bottles

Total number and List of Vendors or Suppliers:• Devgiri Foreign (Aurangabad)• Navketan Research and Development Pvt. ltd. (Aurangabad)• Sanjay Techno Products Pvt. ltd. (Aurangabad)• John fowler Ocular lens Pvt. ltd. (Aurangabad)• SOM AutoTech Pvt. ltd. (Aurangabad)• l M Wind Power (Bangalore)• Forcas Impex Pvt. ltd. (Ahmednagar)• Nirmal Industries Controls Pvt. ltd. (Mumbai)• Kalyani Thermal Systems ltd. (Pune)• Bharat Forge ltd. (Pune)• Yashoda Industries (Ahmednagar)• FCI OEN Connectors Pvt. ltd. (Cochin)


Organization Chart:

Partners

Skilled SkilledUnskilled Unskilled

Manager Accounting Quality In-charge

Production In-charge

Suyog Plastics


Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Navketan Pharma

FCIOENBottlesRubber Bands

As a Tier 2 Supplier to OEM STPPlYashoda

Automobile componentsHousehold Appliances

Area of the Unit:Plot Area 5500 Sq. mtr.Total Built-up Area 3000 Sq. mtr.

Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2009-2010 12 lACS 7 lACS 1 lACS2010-2011 36 lACS 12 lACS 1.8 lACS2011-2012 161 lACS 52 lACS 3 lACS

2012-2013 148 lACS 50 lACS 3.25 lACS

2013-2014 (expected) 200 lACS 65 lACS 4.5 lACS

Certifications:Certification Description of the Certification Year taken in Local AgentISO Certified Quality 9001 – 2008 2013 TUV India



Competitor’s name Competitor’s Product Specialization

Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Sup-plier / Tier 3 Supplier

1 Vishwas Moulders Automobile2 Marwel Industries Home Appliances3 Darshan Plastics Automobiles4 S R Plastics Irrigation


Scrap area

Workers

Room

Toilet

Finished

Goods area

Dispatch

area

EntranceParking

Security

Accounts &

Office

M/C

1

M/C

2

M/C

3

M/C

5

M/C 6

M/C

4

Finishing

area Raw Material

area


Types of MachinesSr

. No.

Nam

e of

Mac

hine

Qua

ntity

Mak

e of

mac

hine

Spec

ifica

tion

Pric

e of

the

Ma-

chin

e (R

s.)

Year

of P

urch

ase

Loan

/ by

Self

1. Injection Moulding

1 Rana and sons Engg Pvt ltd




80 tons 4.5 lacs 2008 Self





1 UA Polyplast Pvt ltd

150 tons 6.5 lacs 2010 Self


1 Cincinatee Mi-lacron



1 Ferromatik Mi-lacron


Types of Tools

Sr. N

o.

Nam

e of

Mac

hine

Qua

ntity

Mak

e of

mac

hine

Spec

ifica

tion

Pric

e of

the

Ma-

chin

e (R

s.)

Year

of P

urch

ase

Loan

/ by

Self

1. Weighing 2 Sharp Machines Heating Pur-pose

30000 2008 Self

2. Grinder 2 Rana and sons Engg Pvt ltd

Recycling Pur-pose

45000 2008 Self

3. Oven 2 Rana and sons Engg Pvt ltd

Heating 30000 2008 Self

Raw materials

Sr. N

o.

Raw

Mat

eria

l

Cur

rent

Rat

e (R

s. Pe

r Kg)

Spec

ifica

tion

Supp

lier’s

Nam

e

Min

imum

qua

ntity

mai

n-ta

ined

in th

e co

mpa

ny p

er

mon

th

Prod

uct M

anuf

actu

red

with

th

e m

ater

ial

Prod

uct S

uppl

ied

to (O

EM/

Tier

1 su

pplie

r/Ti

er2

Supp

li-er

/Tie

r 3 S

uppl

ier)

1 PPCP 108 Used for auto parts

Polygram India Pvt ltd

4500 kg Mirror housing, 6/2 Holders

STPPl

2 Derlin 105 Used for house-hold parts

Apex Poly-mers

2000 kg Yashoda Industries

3 Nylon 6/6 150 Used for auto parts

ShreeRam Polymers

7000 kg Casing Gas caps

STPPl

4 HDPE 110 Used for agri-parts

A. M. Traders

1000 kg Dripper Sleeves Bottles

Disha Ind. Devgiri Forging Navketan Pharma

Warehouse/Storage of Raw material (Inventory Control Techniques)

Order Quantity: As per customer requirement

Order Process: As per production Planning

Quality Control: ISO 9001:2008




Sr. N

o.

Nam

e of

wor

ker

Age

(yrs

)

Gen

der (

M/F

)

Wor

kers

/ Su

perv

isor

/M

anag

er /

Staff

for

clea

ning

Qua

lifica

tion

Ope

ratio

n / F

unct

ion

Year

s of e

xper

ienc

e in

In

dust

ry

Wor

king

hou

rs /

day

1 Gajanan Ghuge

26 M Manager Graduate Inhouse Manage-ment

7 12 hrs/day

2 A Deshpande 60 M Accounts Manager

Graduate Accounting 35 12 hrs/day

3 Suresh Ubale 26 M Quality Manager

Graduate Quality Checking

8 12 hrs/day

4 Gajanan Shilvant

28 M Prod. Man-ager

Graduate Production Incharge

10 12 hrs/day

5 Rakesh Rajput 23 M Supervisor 12th Pass Supervision 4 12 hrs/day6 Raju

Mahendrakar25 M Supervisor 12th Pass Supervision 5 12 hrs/day

7 Gajanan Kachgunde

24 M Worker 12th Pass Worker 5 12 hrs/day

8 Kamlesh Rajput

19 M Worker 10th Pass Worker 4 12 hrs/day

9 Ankush Kale 23 M Worker 10th Pass Worker 4 12 hrs/day10 Pramod Rajput 19 M Worker 10th Pass Worker 6 12 hrs/day11 Nirmal Rajput 19 M Worker 10th Pass Worker 4 12 hrs/day12 Nathulal

Rajput21 M Worker 10th Pass Worker 2 12 hrs/day







Store Keeping & Accounting

Graduate 2 0 12 hrs/day 1

Quality Inspection Graduate 1 0 12 hrs/day 1Production Incharge Graduate 1 0 12 hrs/day 1

Factory Inhouse Manager


Business Process FlowCustomer

Mould Designing & Manufacturing


Component Finalizing

Component Manufacturing

Dispatch

Manufacturing Process FlowRaw Material (Plastic Granules)

Injection of melted Plastic Granules

Quality inspections & Finishing

Raw Material Heating

Cooling

Finished Goods

Machine operations:


Sr. No.




Wastage %

1 Injection Molding M/C 1

1 30 Seconds 0 5%


1 18 Seconds 0 5%


1 14 Seconds 0 5%


2 40 Seconds 0 5%


1 10 Seconds 0 5%


1 180 Seconds 0 5%



Price to Customers

Repeat Order

Supplied to

1 Pulsor Mirror Housing Rs. 5.86 5.99 Yes STPPl2 Automotive Rs. 4.35 4.45 Yes STPPl3 Decotrim Rs. 0.61 0.71 Yes Yashoda Industries4 612 Holder Rs. 1.06 1.10 Yes Disha Industries5 Dripper Rs. 0.28 0.35 Yes Disha Industries6 Bottles Rs. 7.99 8.20 Yes Navketan Pharma7 Protective Sleeves Rs. 12.25 12.40 Yes Devgiri Forging

Quality Control Plan




ingYes



Yes. Quality control is process by which entities review quality of all factors involve entities review quality of all factors in-volved in production.Documentation includes testing of prod-ucts to uncover defects & reporting to management to make decision to allow product release. Possible quality defects of a component are noted & steps are taken to reduce or make quality defects. Master samples of each are kept & referred in case of a quality issue in a component.


• Visual Inspection• Finishing & Deflashing• Dimension Checking & other defects


• Weight measurement• Strength and moisture checking


N. A.


N. A.

Testing of Finished Products • Visual Inspection• Dimension & Weight measurement• Deflashing & Finishing


Design & DevelopmentWhat is Design? “Plan or drawing produced to show the look &

function of a component before it is built or made”

Design Process:

Feasibility

Research

Market Demand

Developing Design

Engg. and other Processes

Market Value

Developing Concept

Design Documentation

Development

Approved of Developed Design

Production


50 - 60 lacs


N. A.


Sr. N

o.

Exhi

bitio

n /

Show

Part

icip

ant /

V

isito

r

Last

atte

nded

(Y

ear)

Fees

(in

case

th

e co

mpa

ny

part

icip

ated

)

Bene

fits

1 Plastivision, Mumbai

Visitor 2013 250 Knowledge of advanced technologies

2 Maha Advantage Expo, Aurangabad

Visitor 2014 300 Knowledge of advanced technologies





Injection molding process

Getting in contact with melted plastic granules

Shield, gloves & machine safety

First Aid Kit

Grinding Splitting of plastic gran-ules

Gloves & face shield provided

First Aid Kit

Oven Burn marks due to high temp inside oven

Providing of gloves First Aid Kit




Describe the Company’s Target Market: Targeting Irrigation components & Automobile Industry


High


• Online marketing• Most Important satisfactory customer• Person to person marketing

Online services Yes

Company label:Sr. No.

Labeling type

Label specification

Material used



1 Stick Paper label showing company name production & quality aspect

Automobile components

Sanjay Techno Products

Moulding ma-chines 60, 80, 100, 150, 500 tons

2 Stick Paper label showing company name production & quality aspect

Dripper Disha Industries Moulding machine 100 tons


Packaging type

Packaging specifications

Material used



1 Gunny Bags Gunny Bags of standard size



Moulding machines 60, 80, 100, 150, 500 tons

2 Boxes Boxes of standard size




3 Polythene Bags

Blue & white colored




4 Gunny Bags Gunny Bags of standard size

Dripper Disha Industries Moulding machine 100 tons

Finance & AccountsCosting: Calculating weight of components + Raw material charges + Moulding cost + Inspection / deflashing cost + Profit + Packing / Transportation Cost = Final pricing of a component Cost Sheet: Part name - 100 ml BottleMaterial Grade HDPENet wt. per piece gsm 10.00Runner wt. per piece gsm 10.00Shot wt. of piece gsm 20.00Insert wt. gsm 0.00No. of cavity nos. 1Total wt. of shot gsm 20.00Reconciliation wt. of piece gsm 10.40Raw material cost Rs./kg 110.00Machine used ltrs. 1lMachine tarrif Rs./Shift 1600.00Cycle time Sec. 25No. of shots/shift Nos. 1152No. of pieces/shift Nos. 1152Prod. quality efficiency@95% Nos. 1094Raw material cost Rs./piece 1.14Moulding cost Rs./piece 1.46Rejection@2% Rs./piece 0.06Deflashing/inspection Rs./piece 0.05Tool cost Rs./piece 1.67Total direct cost Rs./piece 4.38


Profit@10% Rs./piece 0.44Packing cost Rs./piece 0.05Fright charges Rs./piece 0.05Total Cost Rs./piece 4.92Tool cost 40000Quantity.month 2000

Human Resource ManagementEmployment recruitment rules New recruitment are made based on

the qualities such as experience in the plastic industry leadership qualities good communication skills manpower management skills etc.


Machine Operator Training & general ma-chine instructions along with already employed person

Timely support & motivation for the further knowledge.

Supervisor Manpower management shift supervision

Training to understand better aspects of the firm

Manager In house firm manage-ment

Developing & Training for growth of the firm

Helper/Cleaning Staff

General cleaning instruc-tions

General instruction

leave Policies:Staff Leave PolicyMachine Operator 1 month in a yearSupervisor 1 month in a yearManager National Holidays and leave allowanceHelper/Cleaning Staff Not Applicable


Insurance/Medi-claim PolicyStaff Leave PolicyMachine Operator ESICSupervisor ESICManager life InsuranceHelper/Cleaning Staff ESIC

Wage Rate Policy:Staff Wage Rate PolicyMachine Operator Daily Basis Salary PaymentSupervisor Fixed Monthly salary paymentManager Fixed Monthly salary paymentHelper/Cleaning Staff Daily Basis Salary Payment

Salary Structure:Staff For

Fresher (in Rs.)

With expe-rience of 3 years (in Rupees)

Training required, if yes then please mention the train-ing


Machine Operator

270 290 Machine operating & safety

Injection Mould-ing Machine

Supervisor 7000 8500 Shift supervision _Manager 10000 12000 Firm Management _Helper/Clean-ing Staff

250 260 Cleaning Instruc-tion

_


of staffProfile (Ma-chine Operator / Supervisor / Manager / Helper / Clean-ing Staff)





Male 14 Includes all Aurangabad/Out-side Aurangabad but within Maharashtra/Outside Maharashtra

Depend on person to person

Mould-ing m/c (60,80,100, 150,200,500 tons)

Female 4 Includes all Aurangabad/Out-side Aurangabad but within Maharashtra/Outside Maharashtra

Depend on person to person

Mould-ing m/c (60,80,100, 150,200,500 tons)



Compensation Plan for workers in case of injury or accidents: Covered in Insurance for all workers

Career Graph Plan for Employees: Growth & continues development under motivation & guidance

Retention Policies and Welfare Schemes: Insurance Policies

Assistance required from Government in the following areas:• Subsidy approvals and grant

Assistance by CIPET, Aurangabad:• Testing of Raw Material

Assistance by IGTR, Aurangabad:• Manufacturing of Moulds

Assistance by ITI, Aurangabad:• Helping in recruitment of New Employees (Technical)

Assistance by MCED, Aurangabad:

• Help in development and design in association with NID




design & components by other competitors.






6 months Purchasing of new land for factory premises and new product development

Finance & Design Assistance Growth of sales & promotion

1 year Purchasing of new machinery & other development






Product Design Brief


Design Brief 1

The company has planned to develop an automatic dog food dis-penser. The actual sample has been imported from Canada. The samples is under research by the R&D team.

Design Brief 2

It contains a hopper of 4kg containing dog food. The dispenser works on an automatic timer system once the hopper is filled with dog food and the timer is set on the food is automatically dispensed in the tray. The main advantage of this dispenser is that it does not require time to time manual feeding. It will be very useful in day to days life and is an effective time saving idea. We will be the first on to develop this product in India.


Automatic Dog food Dispenser. (six days food storage Timer based automatic dispensing sys-tem)


Timeline 3 monthsBudget Rs. 28 lacsTeam members & Skills Required

Team includes 3 Members• Designer• Technical Engineer• Marketing

Benefits for the Company It will create brand value inhale confidence and more profitability


The gap between the wall and the rotomoulding machines is very less to walk through.

The product samples manufactured at the unit are displayed very well for reference and presenting to the clients.


White board for discussion and project planning in the mid-dle of the work area.


Need better arrangement for the moulds and the exposed wires.


The mould is lying in the middle of the walk way. Need to be placed in a safe area.

The walk way between the machines is blocked. Need proper place for the workers for finishing of the parts.


The pores of the Inline Dripper are being cleared by the tip of a pen. It needs a better process for finishing the blockages.

De-flashing processes to remove the flash which occurs because to excessive injection pressure.

The moulds needs to be arranged properly to avoid damage to the mould and avoid accidents with the working area.


The moulds are hidden under the stairs. Moulds needs to be arranged in its specified area to keep it damage-proof.

The wrong posture of the workers will make them suffer from work-related diseases, which are further complicated by social, psychological and physiological issues. Overall this will further affect the productivity of the unit

The wrong posture of the workers will make them suffer from work-related diseases, which are further complicated by social, psychological and physiological issues. Overall this will further affect the productivity of the unit


The floor is temporarily covered with plywood sheets. Need to be fixed to avoid any accident.

The machines layout as seen from the top.


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Workplace need to be properly managedPlant layout Improvement • Space arrangement is a concern as there is

lot of congestion of machine.• No use of Natural light

New Product Development Yes, R & D in process Packaging Yes, goodMarketing Yes , need to upgradeHuman Resource 1 year training

Business DesignMarketing Needs to improvelogo Design GoodVisiting Card GoodBrochures & leaflets GoodWebsite Needs up-gradation

Recommendations• Company has only injection moulding. For product diversification, ma-

chinery expansion is needed. • No design development initiative, completely depend on other companies

for development.• Company needs to focus on becoming a Tier I supplier to increase the

profit margin which is just 2 % in Tier II supplier.

• Depend on the agent for importing moulds from China, and other compa-nies

• Financial planning need to be done for the new product development• Brand communication strategy need to be formalised, no visibility in mar-

ket as the company is tier II. As the company has plan for huge expansion, company logo has to more creative and need to be protected. it has good visibility in market, need to capitalise on that.

• Very less safety precautions are taken by workers, this need to be improved by providing gloves and other safety gears to workers.


2

31

21Sw

agat

Polym

ers


Name of the Unit: Swagat PolymersAddress of the Company: Plot no. K-195-196, MIDC, Waluj, Aurangabad, Pin: 431136, Maharashtra, IndiaLandline number: 0240 - 2552347Mobile Number: 9822037318Company e-mail id: [email protected]: www.swagatpolymers.com Company started in: 2002




Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Ashok Joshi 35 Owner M. Com. 15 yrs - 9822037318

Company’s Initial Investment: 3 lacs and the total internal investment is 1 cr.

Company’s Specialization/Product/Services:• Polythene Polybags• Stretch wrap film

Swagat PolymersMIDC, Waluj, Aurangabad

• UCI Bags, Rolls films• Air Bubble Bags & Rolls• Self Protective film



Closed)1 HDFC 2010 Cash Credit 130 lacs -2 SBI 2012 Housing 40 lacs -3 HDFC 2013 Car loan 12 lacs -


Customer Issued in Products Supplied Last Audit by Customer

1 Bajaj Auto 2005 Packaging Items -2 Varroc Group 2002 Packaging Items -3 Endurance 2002 Packaging Items -

Production capacity of the Unit:Year Production capacity2013-2014 1200 tons2013-2012 1200 tons2012-2011 1000 tons2011-2010 1000 tons2010-2009 800 tons

Types of Customer:


Type Total number of Customers

Names/List of Customers Products Manufactured

Automotive 40 • Varroc Group • Endurance

Auto Parts

Pharmaceutical 3 • Savera Pharma • Atra Pharmaceutics

Medicine

Household Products 10 • Ultima Plastc • Aquara Moulders

Carrots & otherAppliances

Consumer Products 5 • B.G. Appliances • Videocon

Electronic Consumer Products

Food & Beverage 10 All Hotels

Total number of Employees at the company: 25 (15 workers, 2 supervisors, 2 dispatch, 1 accountant, 2 marketing, 1 security and head of departments)

Organization Chart:

Plant Head

Sales

Production

Dispatch

Purchase Dept. Marketing Dept. Accounts Dept.

CEO


Area of the Unit: 12000 sq. ft

Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2009-2010 115000000 N. A. N. A.2010-2011 125000000 N. A. N. A.

2011-2012 135000000 N. A. N. A.

2012-2013 155000000 N. A. N. A.

2013-2014 (expected) 170000000 N. A. N. A.

Certifications: ISO and CRISIl

Business Competitors:• Multistar Polythene• SRK Polythene• Trimurti Polymers

Company Plant layout

Garden

Office

Cutting machine area

Finished Goods

Raw material

Securityroom

Tubing machine 1

Tubing machine 2

Tubing machine 3


Types of MachinesSr

. No.

Nam

e of

M

achi

ne

Qua

ntity

Mak

e of

m

achi

ne

Spec

ifica

tion

Pric

e of

the

Mac

hine

(R

s.)

Year

of

Purc

hase

Loan

/ by

Self

1. Extrusion Machine

1 Vipul Engineer-ing, India

Tubing 500000 2000 loan

2. Extrusion Machine

3 Maitree Engi-neering

Tubing 2000000 2005 loan

3. Cutting & Sealing

4 Ashok Engineer-ing

Cutting & Sealing

1000000 2005 loan

4. Slitting Machine

1 Thakkar Engi-neering

Slitting Ma-chine

300000 2005 loan

Sr. N

o.

Raw

Mat

e-ri

al

Cur

rent

R

ate

(Rs.

Per K

g)

Spec

ifica

-tio

n

Supp

lier’s

N

ame

Min

imum

qu

antit

y m

aint

aine

d in

the

com

-pa

ny p

er

mon

th

1 llDPE 125 Granules Arihant Polymers 70 Ton

2 UPDE 126 Granules Arihant Polymers 10 Ton

3 lDPE 128 Granules Arihant Polymers 10 Ton

4 PP 128 Granules Arihant Polymers 10 Ton

Warehouse/Storage of Raw material (Inventory Control Techniques)Order Quantity: As per customer requirementOrder Process: As per customer requirementQuality Control: In house testing lab


Shift Timings: 7 AM to 7 PM


Sr. N

o.

Nam

e of

w

orke

r

Age

(yrs

)

Gen

der

(M/F

)

Ope

ratio

n / F

unct

ion

Year

s of

expe

rien

ce

in In

dust

ry

Wor

king

ho

urs /

day

1 Operator (5) M Machine Oper-ator

8 years 8 hrs

2 Helper (5) M Cutting Packing 6 years 8 hrs3 Office Staff (7) M Staff 9 years 8 hrs

Business Process FlowMarketing In various Industries

Sample confirmation & price quoting

Production as per samples approved by

Samples collection Approval

Order Collection

Dispatch





Wastage %

1 Tubing Machine 3 24 hrs 8 hrs 1 %2 Cutting Machine 4 24 hrs 8 hrs 1 %


3 Slitting Machine 1 24 hrs 8 hrs 1 %



Price to Customers

Repeat Order

Supplied to

1 Polythene Bags 140 150 Yes N. A.2 Stretch Film 145 160 Yes N. A.3 Air Bubble 130 145 Yes N. A.

Quality Control PlanProject Documentation

Quality Control Procedure: In-house testing facility available


Material verified as per our requirement


• Micrometer• Gauze Meter




ingYes


Design & DevelopmentWhat is Design? “Design is a concept to create a plan

of new theme before it is made”


5 lacs


Sr. N

o.

Exhi

bitio

n / S

how

Part

ic-

ipan

t /

Vis

itor

Last

at

tend

ed

(Yea

r)

Fees

(in

case

the

com

pany

pa

rtic

ipat

-ed

)

Bene

fits

1 Maha Expo Organisation

100 2010 15000 New customer added





Tubing - - -Cutting Machine Scratches First Aid Box



Effectiveness of the company logo

Medium. No need to focus on Branding and Market-ing as it is a B2B business and Brand awareness of the company is high in its target market.

Online services Yes


High

Online services Yes


Packaging type Packaging specifications

Material used



1 Non woven snack bang

Woven Bag Orchid foam -

2 Corrugated Box Boxes Paper Box Safe Pack -


Salary Structure:Staff For

Fresher (in Rs.)

With experi-ence of 3 years (in Rupees)

Training required, if yes then please men-tion the training


Machine Operator

10000 to 12000

290 Machine operating & safety

Injection Moulding Machine

Supervisor 10000 to 14000

8500 Shift supervision _

Manager 14000 to 16000

12000 Firm Management _


250 260 Cleaning Instruction _

Number of Employees: 30


Assistance by CIPET, Aurangabad: Certifications of finished Goods

SWOT Analysis of the CompanySTRENGTHS• Positive Attitude towards New

Development

WEAKNESSES• Unable to capture Market

THREATS• New Competitors

OPPORTUNITIES• Target New customer


Time-lines Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)


6 months Development of Manufacturing capacity

Finance Financial position strong to increase in Manufacturing capacity

Product Design BriefProduct Design Brief specifications

PVC Plain wrap food grade film, PE food wrap firm (10 to 12 micron)

Budget Rs. 25 to 30 lacsTeam members & Skills Required

Team includes 3 Members• Designer• Technical Engineer• Marketing


It will create brand value inhale confidence and more profitability


The work area is not clean as a result the finished good may get spoiled. The area needs regular cleaning.

The worker’s clothes is seen hanging in the work area.

The filing cabinet is arranged properly.


Worker is not equipped with hand gloves/safety equipments.

The wires and pipes are not arranged properly.


The machine is temporarily adjusted with hand tools to function properly.

The floor is not maintained properly.

The packaging tape is kept on the level which disturbs the worker while operating the machine.

The machine is under maintenance.


Slitting machine

The plastic sheet scrap is lying in the working area close to motor which can be hazardous. The area needs to be cleaned.


Needs proper disposal of used belts and machine parts.

Sealing machine


The raw materials needs to be segregated according to the specification and stacked properly.

Tools are seen lying around after use and the wiring needs to be fixed. The working area not maintained properly.


The pipes are not arranged properly.

The roller is damaged.


The water filter for the workers.


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations SatisfactoryWorkplace & Ergonomics Need to improvePlant layout Improvement Space arrangement is a concern New Product Development In-house product development process not

strictly followedPackaging Need to improveMarketing Need to improveHuman Resource Training initiatives for the workers need to

improve

Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Need to developWebsite Need to improve


Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and

emergency situations.


Product: Company is producing very basic product in which there is lot of competition, so new product development should be looked into.

Human Resource: To reduce employee attrition rate, the salary levels need to be revised to attract better skilled manpower as well as a proper career growth plan should be for-mulised.


can be extended.• Marketing is not so effective; it requires more publicity on retail level. A

proper branding strategy should be formulised to get maximum visibility in the market.





2

31

22Ti

rum

alaIn

dustr

ies


Name of the Unit: Tirumala IndustriesAddress of the Company: Plot no. H-5/41, MIDC, Chikalthana, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9850963136, 7588534243Company e-mail id: [email protected], [email protected] No.: N. A.Website: N. A. Company started in: 2011


Company’s Specialization/Product/Services• Plastic Water Tank



Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Ajay Annasaheb Pathrikar

48 Owner M. A., I. T. I.

2 years [email protected]

9850963136, 7588534243

Tirumala IndustriesMIDC, Chikalthana, Aurangabad


Sr. N

o.Fa

mily

Mem

ber

Rel

atio

n to

the

Ow

ner o

f th

e C

ompa

ny

Age

(in

Year

s)

Educ

atio

nal Q

ualifi

catio

n

Wor

k Ex

peri

ence

pri

or to

jo

inin

g th

e C

ompa

ny

Invo

lved

in C

ompa

ny’s

busi

ness

act

iviti

es (Y

es/N

o)

Rol

e in

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Ajinkya Ajay Pathrikar

Son 22 B.E. Me-chanical (appear)

No Yes Manager [email protected]

9850194545




Year Purpose Amount (Rs.) Status

1 State bank of Hyderabad 2011 Term loan 10 lacs 2 State bank of Hyderabad 2011 Cash credit 5 lacs

Production capacity of the Unit:Year Production capacity2013-2014 3600 (Proj. Sales Rs. 60.00 lacs)2013-2012 3000 (Sales Rs. 48.75 lacs)


2012-2011 1300 (Sales Rs. 25.40 lacs)2011-2010 N. A.2010-2009 N. A.

Types of Customer:

Type Total number of Customers

Names/List of Customers Products Manufactured

Household Appliances

150 Plastic Water Tank

Building Contractors, Traders and Hardware shops

200 • Building Construction contractor

• Abhimanyu traders• Govind traders• Arihant traders• Shrikrishna Hardware• Santosh traders• Padmavati

Plastic Water Tank

Total number and List of Vendors or Suppliers: All types of customers like contractor, traders, home user, etc.


Ajay Pathrikar (Proprietor)

Manager: 01

Shift in charge: 01

Operator: 03

Helper: 02


Area of the Unit:

Plot Area 5500 Sq. mtr.Total Built-up Area 3000 Sq. mtr.

Turnover of the Unit (in Rupees):

Year Annual Turnover Gross Profit Net Profit2011-2012 25.40 6.74 2.102012-2013 48.75 9.87 4.60 2013-2014 (expected) 60.00 12.80 5.50

Certifications: N. A.


Business Competitors:

Sr. No.

Competitor’s name

Competitor’s Product Speciali-zation


1 Sintex water tank Plastic Water tank Exporter2 Sarita water tank Plastic Water tank OEM3 laxmi water tank Plastic Water tank OEM4 Ganga Water tank Plastic Water tank OEM5 Vasundara Water

tankPlastic Water tank OEM



Manufacturing area

Finishedmaterialstorage

OpenSpace

Rawmaterial storage

Worker room

Toilet

StaffCabin

Stairs for 1st floor

Garden Space

M. I. D. C. Road

Temple Security


Sr. N

o.

Nam

e of

wor

ker

Age

(yrs

)

Gen

der (

M/F

)

Wor

kers

/ Su

perv

isor

/M

anag

er /

Staff

for

clea

ning

Qua

lifica

tion

Ope

ratio

n / F

unct

ion

Year

s of e

xper

ienc

e in

In

dust

ry

Wor

king

hou

rs /

day

1 Ajinkya Pathrikar

22 M Manager B.E. Mech.

Mgt. 2 yrs 4 hrs

2 Sagar Patil 26 M Accountant (Staff) M.com Accounting 6 yrs 4 hrs3 Balasaheb

Dhepale45 M Supervisor BA Shift incharge

/ supervisory 8 yrs 8 hrs

4 Parmeshwar Dehade

42 M Worker 9th Machine operator

5 yrs 8 hrs

5 Kashinath Tejankar

47 M Worker HSC Machine operator

5 yrs 8 hrs

6 Machindra Mhaske

40 M Helper SSC Helper 3 yrs 8 hrs

7 Tukaram Shinde

37 M Worker HSC Machine operator

4 yrs 8 hrs







Design & devel-opment of plastic products

DMEBE

03 03 8 hrs 1


Business Process FlowPurchase raw material

Weighting of raw material required for mfg. process

Cooling process done, after completion of total mfg. process

Quality control / inspection done by supplier

Required raw material load in machinery (mould)

Screen printing on logo name

Dispatch material

Manufacturing Process FlowThe rotational moulding process for manufacturing water storage tank consists of the following major process steps.

loading of raw material in Dies / Mould

Cooling or curing

Unloading of finished part

Moulding of the part as per layer

Screen printing on logo name





Wastage %

1 Roto molding machine

4 55-60 min



Price to Customers

Repeat Order

Supplied to

1 300 ltr Plastic water tank 900 1100 Yes All types of custom-ers in Aurangabad, Jalna, Jalgaon

2 500 ltr Plastic water tank 1300 1600 Yes3 750 ltr Plastic water tank 2100 2400 Yes4 1000 ltr Plastic water tank 2900 3200 Yes

Quality Control PlanProject Documentation: N. A.


N. A.



Name of Testing Labs for Raw Mate-rials (tie-ups for Raw Materials)

N. A.


N. A.

Testing of Finished Products It is done in house

Design & DevelopmentDesign Process: Presently not done. Design process will be done in house by using technical & qualified employee.


10 lacs


IT/CAD/Softwares/CAM used in the Com-pany

N. A.


Sr. N

o.

Exhi

bitio

n / S

how

Part

icip

ant /

V

isito

r

Last

atte

nded

(Y

ear)

Fees

(in

case

the

com

pany

par

tici-

pate

d)

Bene

fits

1 Advantage Maharash-tra Expo-2014

Ajay Pathrikar

2013 N. A. New design & development





Moulding (Heating process)

Fire fire extinguisher First Aid Kit



Describe the Company’s Target Market: Export the product and develop new products in plastic industries. Special marketing not required for the products. Its easily sales in local market.


Medium


N. A.

Online services Yes

Company Label: N. A.

Company Packaging: N. A.

Finance & AccountsCostingCost Sheet: Part name - 1000 Ltr Plastic water tankCost of raw material Rs. 2160Processing cost Rs. 375labour cost (wages) Rs. 300Transport cost Rs. 65Total cost to company Rs. 2900Margin Rs. 300Selling cost Rs. 3200

Human Resource ManagementEmployment recruitment rules No any specific recruitment rules. Employee’s

selection on their skilled and work efficiency.


Training Policy for the new recruits and already employed with the company:

For New Recruits For Already Employed

Machine Operator Work experience / trail run Work experience Supervisor Work experience Work experience Manager Work experience Work experience Helper/Cleaning Staff N. A. Work experience

leave Policies:Staff Leave PolicyMachine Operator 4 days in months and public holiday Supervisor 4 days in months and public holiday Manager 4 days in months and public holiday Helper/Cleaning Staff 4 days in months and public holiday


Insurance/Medi-claim Policy: N. A. (proposed to start)

Wage Rate Policy:Staff Wage Rate PolicyMachine Operator On work experience or fixed on Rs.6000 - 7000 p.mSupervisor On work experience or fixed on Rs.9000 - 10000 p.mManager On work experience or fixed on Rs.10000 - 12000 p.mHelper/Cleaning Staff Helper / cleaning fixed Rs.3000 – 4000 p.m


(in Rs.)With experi-ence of 3 years (in Rupees)



Machine Operator

6000-7000 p.m.

7000- 8000 p.m

Practical work done -

Supervisor 9000-10000 p.m.

10000-12000 p.m.

HRM -

Manager 10000-12000 p.m.

11000-13000 p.m.

Business Management training

-


4000-6000 p.m

6000-8000 p.m For staff - as per post training

-

Male & Female Employees:

Staff Number of staff

Profile (Ma-chine Operator / Supervisor / Manager / Helper / Clean-ing Staff)




Male 02 Manager / staff Aurangabad 2 yrs – 3 yrs N. A.Female 01 Receptionist Aurangabad 1 yr N. A.

Covered under ESI/EPF/Gratuity: N. A. (Proposed to cover)


Compensation Plan for workers in case of injury or accidents: (Proposed to cover)


Retention Policies and Welfare Schemes: N. A. Assistance by CIPET, Aurangabad: N. A.

Assistance by IGTR, Aurangabad: : N. A.

Assistance by ITI, Aurangabad: : N. A.

Assistance by MCED, Aurangabad: : N. A.


SWOT Analysis of the CompanySTRENGTHS• Good reputation among custom-

ers• Huge works orders in-hand• Use of pure raw material for pro-

duction

WEAKNESSES• Unskilled labour• Insufficient capital

THREATS• Competitor sale produce in lesser

amount• Recovery of credit sales

OPPORTUNITIES• Export the product• Design & develop new products




6 months Acquired certification from ISO

N. A. Develop material quality

1 year Design & development new products

Finance/Training/Design Assis-tance


3 years Export sales Finance Export order 5 years N. A. N. A. N. A.


design & development of new plastic products and estimated cost for the same up to 10 lacs to 15 lacs


Various types of Plastic products

Proposed Design Process N. A.Timeline 2 to 3 yearsBudget Rs. 10 lacsTeam members & Skills Required


Benefits for the Company It will create brand value and build business con-fidence and more profitability


The owner of the unit is showcasing his innovating water tank with offset opening. This helps the uses to look into the tank easily.


The gear box is seen damaged. Needs proper maintenance.

The inner wall of the remoulding machine chamber is covered with thick layer of burnt plastic. The inner wall needs proper maintenance to maintain the heat transfer efficiency of the machine.

The lid of the tank is sourced from vendors as a result there is mismatch between the tank and lid w.r.t. the colour. The lid is also seen fitted very loosely.


The defect in the tank is very common because of the frequent disruption in the electricity supply.





The nuts used in locking the tank is prone to wear and tear very easily. Need frequent change leading increase in operational cost.

The company’s logo needs to be printed more accurately.


The stock of lids received from vendors generally does not match with the tank of the colour.


The oil supply system is not proper. Needs urgent up-gradation.

The fire extinguisher is kept out of reach in case of accident and emergency. It is kept in the store room.


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations SatisfactoryWorkplace & Ergonomics Need to improvePlant layout Improvement Space arrangement is a concern as the plant area

remains un-utilised for most of the period.New Product Development No In-house product development process fol-

lowedPackaging Need to improveMarketing Market awareness is a problem. No effective

marketing for business growthHuman Resource Training initiatives for the workers need to im-

prove

Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Need to developWebsite Need to improve




There is lot of space remain un-utilised in the work place can be used more efficiently. For example granule grinding machine can be purchased to reduce the cost of raw material.


Product: Company is dependent on only one type of product, it should think about venturing into other products to reduce the business risk. The colour cap of the tank is always mismatch with the tank colour, effort should be put up to manu-facture the cap in-house.

Human Resource: Employee attrition rate is high so the salary levels need to be revised to attract better skilled manpower.


can be extended.• It requires more publicity on retail level. A proper branding strategy should

be formalised to get maximum visibility in the market.• A logo needs to be more creative, to make a place in the customers percep-

tion.• Emphasis should be given on the putting the stall in the exhibitions to cre-

ate awareness among probable customers.• A company can tie-up with the trade bodies, which give funding for the

new product development, this will be very beneficial to speed up the de-velopment process.


31

2

23Tr

imur

tiPo

lymer

s


Name of the Unit: Trimurty PolythenesAddress of the Company: Gut. No.48, Plot no.12, Opp. Siemens ltd., Near MIDC, Waluj, Aurangabad, Pin: 431 136, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9372005542, 9922245562Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2005


Company’s Specialization/Product/Services• Manufacturer of poly sheet and bags•Affiliated units/sister concern/subsidiary: N. A.


Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Misal Bhaskar Harinathr

52 Owner M. Com. DME ap-peared

Purchased of-ficer with Bajaj Auto, Waluj, from 1986 to 2002

[email protected]

9372005542

Trimurti PolymersMIDC, Waluj, Aurangabad


loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name /

Govt. AssistanceYear Purpose Amount (Rs.) Status (Active/

Closed)1 HDFC Bank 2007 Purchase of

machine11.40 lacs Still continue with

regular repayment

Production capacity of the Unit:Year Production capacity2013-2014 150 M Tones 2013-2012 125 MT2012-2011 113 MT2011-2010 102MT2010-2009 99 MT

Customer: (Automotive and Pharmaceutical) For Packing materials• Fiat India Automoboils ltd., Ranjangaon, Pune• Acey Engg P ltd., Bilimora Gujrat• Videocon Industries ltd., Aurangabad • lombardini India P ltd., Chikalthana, Aurangabad• Mac Engg Inds, Bilimora, Gujrat • Baxtor India lTd., Waluj, Auranbagad• J K Ansell ltd., Waluj, Aurangabad• Minda Industries ltd., Aurangabad• Shree Chemicals, Beed• Durga Polytherm p ltd., A’nagar


• Akar Tools ltd., Waluj, Aurangabad• Addon Engg P ltd., Faridabad• Jolly Board India ltd., Aurangabad• Varsa Plastic p ltd., Waluj, Aurangabad• Precision PlasticPltd.,Waluj, Aurangabad


Organization Chart:• Proprietor• Main Supervisor• Main Operator• Sub Supervisor• labour

Area of the Unit: 2000 sq feet rented

Types of Machines

Sr. N

o.

Nam

e of

M

achi

ne

Qua

ntity

Mak

e of

m

achi

ne

Pric

e of

the

Mac

hine

(R

s.)

Year

of

Purc

hase

Loan

/ by

Self

1. Extruder 3 Intec, India 19 lacs 2005, 2007 and 2013

HDFC bank loan

2. Cutting & Sealing 3 Vijay Platomech, India 4 lacs 2005, 2008 and 2012

Self

Types of ToolsSr. No. Name of Machine Quantity

1 Spanners 502 Hammers 53 Plier 54 Dial gauge 25 Scale 3

6 Measuring tape 37 Punches 28 Alley keys 25

Raw materialsSr. No.

Raw Material

Current Rate (Rs. Per Kg)

Specifi-cation

Supplier’s Name

Minimum quantity maintained in the company per month

1 HMDPE 112 basic Reliance Reliance 500kg2 lDPE 115 basic Reliance Reliance 1000 kg

3 llDPE 112 basic Reliance Reliance 1500kg

4 RE-cycle 90 basic local local 1000 kg5 Master

batches160 basic alok alok 200kg







Store Keeping & Accounting


Quality Inspection Graduate 1 0 12 hrs/day 1Production Incharge Graduate 1 0 12 hrs/day 1Factory Inhouse Manager


Quality Control PlanProject Documentation

Does the company maintain Documents for every Project? NoQuality Control Procedure: (In house/ External agency) In-house

Testing of Raw Materials (Incoming - Quality Control Techniques) In-houseName of Testing Labs for Raw Materials (tie-ups for Raw Materials) In-house


Name of Testing Labs (tie-ups for Finished Products) NoTesting of Finished Products No



2 612 Holders Free from defect and flash Yes3 Automotive

castingFree from silver marks flash Yes

4 Dripper Free from flash Yes5 Bottles Free from damage and over

deflashingYes

6 Protective Sleeves

Free from flash Yes

Design & DevelopmentWhat is Design? “As per customer requirement”


No


Not required

Exhibition/trade shows visits:Sr. No. Exhibition / Show Participant / Visitor Last attended (Year)

1 Plastic exhibition visitor Mumbai, 20132 Plastic exhibition visitor New Delhi 2012




low

Finance & AccountsPrice break upHM DHPE 56GF004 112.00Plus Excise duty 12.36% 13.40Plus power 9.00Plus labour 4.00plus wastage 1.00plus transport 1.00Plus profit 3.00Total rate 143.40Salex tax 5% 7.17

Grant total 150.57SAY 151

Human Resource ManagementShift Timings: 8 AM to 8 PM

Number of Shifts per day: 1 shift of 12 hours



Assistance required from Government in the following areas:• Burden of Excise duty and other taxes should be less• Procedure of various return to be cut down or to be simplify• Excise audit to be simplified to be as audit and not policing

Assistance by CIPET, Aurangabad: For making sample test report prompt in time and at low cost

Assistance by MCED, Aurangabad: Assistance required for new project and for recommendation for financial institutions.




design & components by other competitors.



Product Design Brief: N. A


The granules is being readied for putting into the hopper. The method is completely manual.

Extrusion blow moulding process for making sheets



Tools are left unattended near the machine which may damage the sheet being manufactured

The space around the machine is not maintained which congests the work area.


Complete process for making sheet using the extrusion blow moulding machine.

A lot of temporary arrangement using wood is seen while controlling diameter of the plastic sheet.


The sheet rolling process

The sheet slitting process

The sheet sealing process



A lot of clutter is seen around the machine


Wires are seen hanging loosely around the main switch board leading to a risk of accident and fire.

Tool box is not maintained properly. All tools are mixed up in a small crate.



A lot of temporary arrangement using wood is seen while controlling diameter of the plastic sheet.

A lot of clutter is seen around the machine

Improper posture while packing the finished goods. Needs better packaging methods.


lot of clutter is seen around the working area. No space management is practised

Proper maintenance of the machine and the support systems is required

The entrance to the unit is very not welcoming

The entrance to the unit is very not welcoming


2

31

24Ulk

a Plas

ticIn

dustr

ies


Name of the Unit: Ulka Plastic IndustriesAddress of the Company: Plot no. B-10, Add. MIDC, Jalna, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 98232984905, 9975656193Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: September, 1995


Company’s Specialization/Product/Services: • Manufacturing Of Krushi Pipes• Manufacturing Of Polythylene Sheets Upto 12’wide• Manufacturing Of Jerry Cans,1lit, 2lit & 5 lit Capacity• Polythylene Bags• Reprocessed Granules



Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

Ulka Plastic IndustriesMIDC, Jalna, Aurangabad

1 Mr. Subhash Wamanrao Thete

63 Owner DME, BE-CIVIl

Exp. In Marathwada Sheti Sahayya Mandal

9823984905


Sr. N

o.

Fam

ily M

embe

r

Rel

atio

n to

the

Ow

ner o

f th

e C

ompa

ny

Age

(in

Year

s)

Educ

atio

nal Q

ualifi

catio

n

Wor

k Ex

peri

ence

pri

or to

jo

inin

g th

e C

ompa

ny

Invo

lved

in C

ompa

ny’s

busi

ness

act

iviti

es (Y

es/N

o)

Rol

e in

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Ulka s thete

Wife 62 Bachlor of Arts

EDP Train-ing BY MCED

Yes Management

2 Sachin S. Thete

Son 36 DCE, Civil Enggineer

Civil Enggi-neering

Yes Production & Marketing

3 Pallavi S. Thete

Daughter in law

29 M. com Ac-countant

Yes Accounting / Finance

4 Dr. Swati S. Thete

Daughter 38 BHMS Consult-ant

Yes Medical Assis-tance

5 Swapnil S. Thete

Son 33 B-Arch Consult-ing

Yes Production & Supervision


Loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name /


tive/Closed)1 Maharashtra State

Finance Corpo-ration

1995 For land and Building

178750 Closed

2 State Bank of India

1996 C. C. 150000 Closed

Affiliated units/sister concern/subsidiary:Sr. No. Unit name Product / Service Address Contacts

1 Ulka Associates Architectural Consultancy B-Add. MIDC. Jalna 99756561932 U A D P P Architectural Consultancy B-Add. MIDC. Jalna 9823984905


Customer Issued in

Products Supplied Last Audit by Customer

1 Gujarat Oil Depot. Sillod - Krushi Pipe -2 Bhansali M/C Rahata - Krushi Pipe -

3 Ambika General Stores, Jalna

- Jerry Cans -

Production capacity of the Unit:Year Production capacity2013-2014 5 Mt / year2013-2012 50 Mt / year2012-2011 200 Mt / year2011-2010 5000 Mt / year2010-2009 600 Mt / year



ManufacturedAgricultural / Irrigation

154 - -

Consumer Products

58 - -

Total number and List of Vendors or Suppliers: 25


Organization Chart:

Administrative Officer

Office Staff Skilled worker Unskilled worker

Manager Accountant Supervisor Marketing Officer

Proprietor


Area of the Unit:Plot Area 1000 Sq. mtr.Total Built-up Area 310 Sq. mtr.

Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2009-2010 8 lacs 8 lacs 0.8 lacs2010-2011 9 lacs 2.5 lacs 1 lacs2011-2012 9 lacs 2.5 lacs 1 lacs2012-2013 7 lacs 1 lacs 0.5 lacs2013-2014 (expected) 2 lacs 0.5 lacs 0.25 lacs



Manufacturing Unit

Store

Office Waiting

area Office

Toilet

Block Store

FoodCourt

Garden

Parking

M. I. D. C. Road

Types of Machines

Sr. N

o.

Nam

e of

M

achi

ne

Qua

ntity

Mak

e of

m

achi

ne

Pric

e of

the

Mac

hine

(R

s.)

Year

of

Purc

hase

Loan

/ by

Self

1 Extruder 90 mm 01 Raj Machinery, India 2 lacs 2011 30% selfand 70% loan

2 Extruder 60 mm 01 Raj Machinery, India 1.5 lacs 2011

3 Extruder 40 mm 01 Raj Machinery, India 1 lacs 20114 Mixer 01 Raj Machinery, India 1 lacs 20115 Grinder 01 Raj Machinery, India 0.5 lacs6 Cutter 01 0.15 lacs7 Sealing & Cutting 01 Raj Machinery, India 0.80 lacs8 Air Compressor 01 0.15 lacs9 Generator 01 0.80 lacs10 Take up/Mould 01 1 lacs

Types of Hand Tools: Set of spanners, Set of Hammers and Chisels

Raw materials

Sr. N

o.

Raw

Mat

eria

l

Cur

rent

Rat

e (R

s. Pe

r K

g)

Spec

ifica

tion

Supp

lier’s

Nam

e

Min

imum

qua

ntity

m

aint

aine

d in

the

com

pany

per

mon

th

Prod

uct M

anu-

fact

ured

with

the

mat

eria

l

Prod

uct S

uppl

ied

to

(OEM

/Tie

r 1 su

pplie

r/Ti

er2

Supp

lier/

Tier

3

Supp

lier)

1 lDPE 126.23 20FS040 Distributors 50 MT 49 MT

2 llDPE 118.57 FIlM 71601D

Distributors 30 MT 25 MT

3 HDPE 117.25 HDBM B6401

Distributors 1 MT 0.80 MT

4 Master Batches

400.00 - Distributors 50 KG --

5 lDPE 90.00 - local Manu-facturers

5 MT 4.7 MT


Warehouse/Storage of Raw material (Inventory Control Techniques)Order Quantity: As per Stock RegisterOrder Process: As per Stock RegisterQuality Control: As per Stock Register


Shift Timings: N. A.

Number of Shifts per day: N. A.

Sr. N

o.N

ame

of w

orke

r

Age

(yrs

)

Gen

der (

M/F

)

Wor

kers

/ Su

perv

isor

/M

anag

er /

Staff

fo

r cle

anin

g

Qua

lifica

tion

Ope

ratio

n /

Func

tion

Year

s of e

xper

i-en

ce in

Indu

stry

Wor

king

hou

rs

/ day

1 B. S. KHODKE 50 M Manager SSC Quality & Production

22 12

2 Vijay Reddy 47 M Operator M.com Operator 20 123 K. S. KHODKE 44 M Operator HSC Operator 18 124 KASIM SHAIKH 52 M Operator 9th Operator 12 125 ANKUSH SHINDE 35 M Helper HSC Helper 9 126 MANOJ GAIKE 25 M Helper SSC Helper 6 127 ANSHIRAM

KACHRE30 M Helper HSC Helper 4 12







OPERATOR TECH.QUAlI-FIED

03 03 12 2

HElPER MIN. S.S.C 03 -- 12 2ClEANING S.S.C 15 -- 12 2

Business Process FlowRaw Material

Purchase Production Transport Supply to Distributors

Manufacturing Process FlowThe rotational moulding process for manufacturing water storage tank consists of the following major process steps.

Heating the Extruder by

Heaters

De-moisturisa-tion of Granules

in Mixer

Feeding Gran-ules in Feeder Zone of Ex-

truder

Extrusion Process

Pass product through

Conveyor’s/Take-ups

Machine operations:

Sr. N

o.

Mac

hine

na

me

No.

of

labo

rs

requ

ired

pe

r ma-

chin

e

Tim

e re

quir

ed

for

proc

ess

Idle

tim

e pe

r shi

ft of

8 h

rs

Was

tage

%

1 EXTRUDER 90MM 3 2 HRS 1 HR 3

2 !EXTRUDER 60MM 3 1.5 HRS 1 HR 2 3 EXTRUDER 40MM 3 1.25 HRS 1 HR 2 4 MIXER 1 15 MIN -- 0 5 GRINDER 1 5 MIN -- 0 6 CUTTER 1 2 MIN -- 0 7 SEAlING & CUTTING 2 2 MIN -- 0 8 AIR COMPRESSOR 1 2 MIN - 0 9 GENERATOR 1 5 MIN --10 TAKE UPS 3NOS 3 5 MIN -- 0



Price to Customers

Repeat Order

Supplied to


1 KRUSHI PIPES 139.23 RS/KG 144.23 RS/KG Yes All over Maharashtra2 JERRY CANS 1lIT,

2lIT, 5lIT95.8, 112.56, 211.0PER DOZEN

50.8, 80.56, 175.0PER DOZEN

Yes

3 POlYTHElENE SHEETS

142.75 RS/KG 150.23 RS/KG Yes

4 POlYTHElENE BAGS

125.23 RS/KG 134.23, RS/KG Yes

Quality Control PlanProject Documentation: No Document


AS PER REQUIREMENT OF CUSTOMER


ONlY BY IDENTIFICATION, NO TECHNICAl TESTING


No

IT/CAD/Softwares/CAM used in the Com-pany

Auto CAD 2012 USED


Sr. N

o.

Exhi

bitio

n / S

how

Part

icip

ant /

V

isito

r

Last

atte

nded

(Y

ear)

Fees

(in

case

the

com

pany

par

tici-

pate

d)

Bene

fits

1 Maha Expo 97 Participant 1997 Rs.7000/- Increase in sales





EXTRUSION BlOW MOUlD OPERA-TION

BURNING FIRE EXTINGUISH-ER,SAND BUCK-ETS,WATER TAPS

FIRST AID BOXES/MEDICAl CONSUlTANT

Marketing and Branding:Describe the Company’s Target Market

Brand Awareness in respective markets SCREEN PRINTING - 5000 RS/-


N. A.

Online services No

Company Label: Sr. No. Labelling

typeLabel speci-fication

Material used



1 STICKERS UlKA KRUSHI PIPES

PAPER! -- --

Company Packaging: Sr. No.

Packaging type

Packaging specifica-tions

Material used

Vendor name/Inhouse

Machine details if produced Inhouse


1 BAGS -- POlY PROPE-lENE

-- --




low

Finance & AccountsProcess of Pricing:

KRUSHI PIPES - 1. COST OF RAW MATERIAl- 126.23 RS/KG.2. ENERGY CONSUMPTION - 5.0 RS/KG.3. lABOUR CHARGES - 1.50 RS/KG.4. TRANSPORTATION - 1.00 RS/KG.5. COlOUR’S & ADDITIVES - 2.00 RS/KG.6 PACKAGES - 1.00 RS/KG.7. WASTAGES - 2.50 RS/KG.8. PROFIT - 5.00 RS/KG. ----------------- 144.23 RS/KG.

Human Resource Management

Training Policy for the new recruits and already employed with the compa-ny: No

Leave Policies: Depends upon need of employee

Overtime Policy: As per hour policy

Insurance/Medi-claim Policy: Medi-claim Policy

Wage Rate Policy: As per Govt. rules

Salary Structure: Rs. 12000 for machine operators, Rs. 15000 to 18000 for Supervisors and Rs. 18000-20000 for Manager.Male & Female Employees:

Staff Number of staff

Profile (Machine Operator / Supervisor / Manager / Helper / Cleaning Staff)



Male 22 Operator / Supervisor / Manager / Helper

5 to 20 No

Female 08 Cleaning raw material N. A. No

Assistance required from Government in the following areas: Yes

Assistance by CIPET, Aurangabad: Designing of Moulds etc.

Assistance by IGTR, Aurangabad: No

Assistance by ITI, Aurangabad: : Trained Worker’s

Assistance by MCED, Aurangabad: : Training

SWOT Analysis of the Company


STRENGTHS• Good market for Krushi pipe• Water supply availability• Supply of electricity for 24 hrs• No pollution.• Enough work space.• Availability of transportation.

WEAKNESSES• Energy consumption is more• low production by machines• labour problems• Mostly manual work• Rate fluctuations by raw material

supplier’s (reliance changes rates for every 15 days.

• low finance, no bank credits• No automation

THREATS• No threats

OPPORTUNITIES• Working for farmers




6 months Designing of new products

Design assistance & Training for modification of ma-chines & moulds

Modification & Expansion of unit

1 year Modification & installa-tion of automated ma-chine and start for new product production

Finance min. 90 lacks Modification & Expansion of unit

3 years Production & marketing Cash credit for working Capital

Modification & Expansion of unit

5 years Adoption of latest tech-nology & research for innovation

Assistance for research Modification & Expansion of unit

Product Design Brief

Design Brief

To design, modify & converting old machinery to new latest tech-nology with Atomisation of following products-1. Drip irrigation pipe2.hdpe pipes3.pvc pipes4. Krushi pipes5. Poly sheets for Agriculture farm tank


As per machine manufacturer and designer

Proposed Design Process Design of moulds, electric/ electronic panels, heaters, conveyors, take-ups & modify old m/c or purchase of new machine, etc.

Time-line Within 6 monthsBudget 90 lacksTeam members & Skills Required

10

Benefits for the Company Modification and expansion of Unit


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations SatisfactoryWorkplace & Ergonomics Need to improvePlant layout Improvement Space management is a concernNew Product Development No in-house product development process

followedPackaging Need to improveMarketing Market awareness is a problem. No effective

marketing for business growthHuman Resource Training initiatives for the workers need to

improve


RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear and thus the productivity of machines can be im-proved. Some research and development work to be done so that the depend-ence on the manual work can be reduced. Some part of profit has to be kept for such activities. Processes need to be streamlined to reduce the electricity

wastage.

Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations. Forward contracts can be done with the raw material supplier to reduce the variation in the price of raw material.


Product: Product testing should be done at various levels and report can be prepared to increase customer confidence.

Human Resource: To reduce Employee attrition rate, the salary levels need to be revised to attract better skilled manpower.


can be extended.• It requires more publicity on retail level. It urgently requires a logo so that

customers identity the product with the company. A proper branding strat-egy should be formalised to get maximum visibility in the market.




2

31

25V.

P. P

etPo

lymer


Name of the Unit: V. P. Pet PolymerAddress of the Company: Plot no. E-97, MIDC, Waluj, Aurangabad Maharashtra, Indialandline number: 0240 - 3264000Mobile Number: 9595699555, 9370146402Company e-mail id: [email protected]: www.vppetpolymers.com Company started in: 2007


Company’s Specialization/Product/Services:• Pet Jar• Pet Bottle• HDPE Bottle and Jar• PP Bottle and Jar


Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Mrs. Jayshree Navnath Somase

38 Owner 12th No [email protected]

9370146402

V. P. Pet PolymerMIDC, Waluj, Aurangabad


Sr. N

o.Fa

mily

Mem

ber

Rel

atio

n to

the

Ow

ner o

f the

Com

-pa

ny

Age

(in

Year

s)

Educ

atio

nal Q

ualifi

-ca

tion

Wor

k Ex

peri

ence

pr

ior t

o jo

inin

g th

e C

ompa

ny

Invo

lved

in C

ompa

-ny

’s bu

sine

ss a

ctiv

i-tie

s (Ye

s/N

o)

Rol

e in

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Navnath K. Somase

Husband 46 10th 15 Yes Pro-duction Man-ager

9325108445

2 Vaibhav N. Somase

Son 22 12th 0 Yes Plant Head

9595699555

3 Pranjali N. Somase

Daughter 17 12th 0 No - - -


Loan/Financial Assistance taken since the start of the company:Sr. No.


Year Purpose Amount (Rs.) Status (Active/Closed)

1 Dena Bank 2007 Machineries 25 lacs (20 lacs term loan and 5 lacs C/C)

Closed

Loan/Financial Assistance taken since the start of the company:Sr. No. Unit Name Product/services Address Contacts

1 lelashree Plastics PET Preform MIDC, Waluj Aurangabad 9595699555


Production capacity of the Unit:Year Production capacity2013-2014 40 lac Bottles2013-2012 30 lac Bottles2012-2011 25 lac Bottles2011-2010 15 lac Bottles2010-2009 10 lac Bottles



ManufacturedPharmaceutical N. A. Sydler Remedies Pvt., ltd. at M-190,

MIDC, AurangabadPet jar

FMCG N. A. Ravi Masale, MIDC, Chikalthana, Aurangabad

Pet jar

Total number and List of Vendors or Suppliers: 38 (Thirty Eight)

Total number of Employees at the company: 10 (permanent) and rest on contract as per the work load

Types of Business: OEM and Business Type Products Products supplied toAs a Tier 1 Supplier to OEMAs an OEM

Area of the Unit: Plot Area 10000 sqTotal Built-up Area 3200 sq

The factory plot is taken on rent for and amount of Rs. 21000.

Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2009-2010 10658739 1711752 6192502010-2011 12674833 2064135 769046

2011-2012 16053226 3789195 752246

2012-2013 17900435 6105194 1032640

2013-2014 (expected) 43590230 10897557 3000000

Certifications:Certification Description of the Certification Year taken inISO 9001-2008 2012

Types of Machines

Sr. N

o.

Nam

e of

M

achi

ne

Qua

ntity

Mak

e of

m

achi

ne

Pric

e of

the

Mac

hine

(R

s.)

Year

of

Purc

hase

Loan

/ by

Self

1 Hot filling machine 1 Technopet 717806 2011-12 Nil

2 Blowing machine 1 Technopet 1035437 2011-12 Nil

3 Stretch Blowing machine 1 Technopet 978468 2011-12 Nil4 Injection moulding ma-

chine 1 Electronics plas-

tic machine1716130 2011-12 loan

5 Printing machine 1 Techno print 270000 2011-12 Nil6 5 ltr Double station Blow

moulding machine1 Jagmohan 2691525 2012-13 loan

Raw materials

Sr. N

o.

Raw

Mat

eria

l

Cur

rent

Rat

e (R

s. Pe

r Kg)

Supp

lier’s

N

ame

Prod

uct M

an-

ufac

ture

d w

ith

the

mat

eria

l

Prod

uct S

up-

plie

d to

(OEM

/Ti

er 1

supp

lier/

Tier

2 Su

pplie

r/Ti

er 3

Sup

plie

r)

1 Pet Preform 126 Novel Plast Jar, Bottle OEM

2 Granules 112 Polygram Industries

Preform OEM


Company’s Plant layout

Injection Moulding machine

Grinder

Stretch blow Moulding



Finished Goods area

Office

Office

Stretch Moulding machine

labelling Glue ma-chine

Blow Moulding machine

Com

pres

sor 5

Com

pres

sor 4

Com

pres

sor 3

Com

pres

sor 2

Com

pres

sor 1

Store room

Parking area

Entrance

Main road

Cooling tower

Mould Area Assembly Table


Sr. N

o.

Nam

e of

wor

ker

Age

(yrs

)

Gen

der (

M/F

)

Wor

kers

/ Su

perv

isor

/M

anag

er /

Staff

for

clea

ning

Qua

lifica

tion

Ope

ratio

n / F

unct

ion

Year

s of e

xper

ienc

e in

In

dust

ry

Wor

king

hou

rs /

day

1. Vaibhav M. Somase

22 Male Plant Head 12th, Diploma

5 12

2. Krishna H. Mheisane

32 Male Manager B. Com 5 8

3. Navnath K. Somase

46 Male Production Manager

12th 15 12

4. Gopal Solanki 24 Male Supervisor 12th 5 125. Krishna

Solanki22 Male Worker 12th 3 12

6. Uday Divede 27 Male Operator 12th 5 127. Sandir 27 Male Operator 12th 5 128. Vikas Hevele 25 Male Operator 12th 5 129. Ravi

Bhalkhanch 25 Male Driver 12th 5 12







Production 12th 9 2 12 2

Manufacturing Process Flow

Raw material Heating Blowing Cooling Finished Goods


Machine operations:Sr. No. Machine name No. of labors required per machine

1. Hot filling machine 22. Blowing machine 23. Stretch Blowing 24. Injection moulding Machine 15. Blow Moulding 3


Sr. N

o.

Exhi

bitio

n /

Show

Part

icip

ant /

V

isito

r

Last

atte

nded

(Y

ear)

Fees

(in

case

th

e co

mpa

ny

part

icip

ated

)

Bene

fits

1. Maharashtra Advantage Expo-2014

Participant 2014 37000 New business




High


• Online marketing• Most Important satisfactory customer• Person to person marketing

Online services Yes

Company Packaging: Polypack and cardboard boxes

What is Design ‘‘Unique products for everyday problems. It should also be aesthetically appealing and market friendly’’

Process of PricingCost break up for Food Rite, IndiaPreform Cost 129Neck Size 96 mmPreform weight (+/- 2 gms) 70Preform rate 9.03Cap rate/piece 1.85Packing rate 0.08Transport rate 0.15Blowing rate 1.15Total 12.26Profit 13% [email protected]% 1.64Total 14.89VAT@5% 0.74FINAL RATE 15.63


New recruitment are made based on the qualities such as experience in the plastic industry leadership qualities good communication skills manpower management skills, etc.



Machine Operator 2 2Supervisor 2 2Manager 1 1Helper/Cleaning Staff 1 1

leave Policies:Staff Leave PolicyMachine Operator Weekly OffSupervisor Weekly OffManager Weekly OffHelper/Cleaning Staff Weekly Off

Insurance/Medi-claim Policy: N. A.


(in Rs.)With experience of 3 years (in Rupees)


Machine Operator 6000 9000 N. A.Supervisor 8000 10000 N. A.Manager 10000 12000 N. A.Helper/Cleaning Staff 4000 6000 N. A.


of staffProfile (Ma-chine Operator / Supervisor / Manager / Helper / Clean-ing Staff)




Male 4 2 4 3 -Female - - - - -

SWOT Analysis of the CompanySTRENGTHS• Quality manufacturer of PET

bottles in Aurangabad

WEAKNESSES• The company is running on a rent-

ed factory space

THREATS• Too much dependency on big

companies• Increasing price constraints

leading to low profits

OPPORTUNITIES• Supply of PET and Blow-moulding

bottles to Pharmaceutical companies and liquor companies

Future Plan of the CompanyTime-lines Plan Assistance required by the Government

(Finance/Training/Design Assistance, etc.) Benefits for the Company

1 year Own factory space

Subsidies for machineries and land Benefits for the Company

Product Design BriefDesign Brief 1 Innovative Pet jars, Pet bottles, HDPE & P. P. Jars & Bottle.Design Brief 2 Innovative PET bottles for Fridge


Various types of Plastic products

Proposed Design Process N. A.Timeline 1 yearBudget Rs. 10 lacsTeam members & Skills Required

• Industrial Designer• Technical Engineer

Benefits for the Company It will create brand value and build business con-fidence and more profitability


The previous company’s name is still seen on the wall.

Special mention of the sponsoring bank.

The injection moulding machine. The area is clean and has sufficient space around it.

The box of PET Preform as received from the vendor.


The stack of finished goods is well maintained.

The cartons are too close to the machine.


Needs proper arrangement for moulds maintenance and should be ergonomically fit for the workers.

The packaging plastic quality is inferior.


The blow moulding process.

The product inspection is in progress

The blow moulding process.

The PET jars are thrown which may damage the finished products.


The machine needs proper arrangement w.r.t. it’s pipes

The flooring needs to be cleaned and maintained

The work area needs to be cleaned and maintained


The entrance needs to be cleaned and maintained

The chiller area needs to be cleaned and maintained

The moulds needs to be arranged properly

The compressor area needs to be cleaned and maintained.


The pipes are not arranged properly.

Improper approach for machine maintenance

The cartons are too close to the machine. The machine is hidden


Blow moulding machines. The area is maintained clean

The samples of jars produced by the unit

Company’s branding on office vehicle.

Company’s branding on transport vehicle.


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergonomics Need to improvePlant layout Improvement Space management is a concernNew Product Development no in-house product development process



improve

Business DesignMarketing Needs to improvelogo Design Needs to developVisiting Card Needs to developBrochures & leaflets Need to developWebsite Need to improve

RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear and thus the productivity of machines can be im-proved.

R&D budget to be planned to develop new products.


Product: Company currently producing only one type of product (pet jars), it should venture into other categories to reduce the business risk. Product testing should be done at various levels and report can be prepared to increase customer confidence.

Human Resource: To reduce Employee attrition rate, the salary levels need to be revised to attract better skilled manpower. Proper training should be formulised to improve the skill of the workers.

Marketing:• A website need to be up graded on urgent basis so that the customer reach


tion in a logo so that customers identity the product with the company. A proper branding strategy should be formulised to get maximum visibility in the market.

• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers. A company should participate in trade fairs related to plastics to attract new customers



2

31

26Va

rroc P

olym

er(T

ech.

R&D)


Name of the Unit: Varroc Polymers Pvt. ltd. (Technical Center: R & D)Address of the Company: M – 138/139, MIDC, Waluj, Aurangabad, Pin: 431136, Maharashtra, IndiaLandline number: 0240-6676196Mobile Number: 9673001490Company e-mail id: [email protected] No.: N. A.Website: www.varrocgroup.com Company started in: 2010

Type of Company: Private limited

Company’s Specialization/Product/Services• Body Parts: 2W/3W/4W• Mirror: 2W/3W• Seat: 2W/3W• Af: 2W


Sr. N

o.N

ame

of

Ow

ner /

Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wn-

er /

Part

ner)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail I

d.

Phon

e nu

mbe

r

1 Tarang Jain 48 Owner MBA 10 -- --

Varroc Polymer Pvt. Ltd. Tech. CentreMIDC, Waluj, Aurangabad

Company’s Initial Investment: 16 Crores

Loan/Financial Assistance taken since the start of the company: NA

Vendor Code Details: NA

Production capacity of the Unit: NA (No Production Plant)



ManufacturedAutomotive - • Bajaj Auto

• Mahindra & Mahindra• Volkswagen & Skoda• General Motors• Honda• Yamaha• Harley Davidson• Volvo

Moulding, Painting, Assembly, PU Foam Moulding, etc.

Total number and List of Vendors or Suppliers: 10


Types of Business: Tier 1 supplier to OEMs

Area of the Unit:Plot Area 40000 Sq. feetTotal Built-up Area 32528 Sq. feet


Organization Chart & Resources


Certifications: Department of Scientific and Industrial Research (DSIR)


Competitor’s name Competitor’s Product Specialization

Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Sup-plier / Tier 3 Supplier

1 Motherson Automotive Product Tier 12 Mahalle Automotive Product Tier 13 Field Guard Automotive Product Tier 1

Company Plant and Process FlowTypes of Machines:Tool Room • 5 Axis Double column computer numerical control

M/c• High Speed Graphite Milling M/c• Deep Hole Drilling M/c• Drilling M/c• Injection Molding M/c• Die Spotting Press M/c• Double Column Electrical Discharge M/c• Continuous 5 Axis Horizontal M/c• Crane

Prototyping • Hot Melt Pleating Machine• Polyurethane Dispensing Machine• Air Filter Mould – Pneumatic Press

Testing • Air Filter Test Rig• Pore Size Meter• Particle Counter• Burst Strength tester• Vibration Meter• Weighing Balance• Crock Meter• Digital Torque Wrench• Shore Hardness Tester• Modular Fixture• Portable portable coordinate measuring M/c

Reverse Engineering • White light Scanner

Raw materials

Sr. N

o.

Raw

Mat

eria

l

Cur

rent

Rat

e (R

s. Pe

r Kg)

Spec

ifica

tion

Supp

lier’s

N

ame

Min

imum

qu

antit

y m

ain-

tain

ed in

the

com

pany

per

m

onth

Prod

uct M

an-

ufac

ture

d w

ith

the

mat

eria

l

Prod

uct

Supp

lied

to

(OEM

/Tie

r 1

supp

lier/

Tier

2 Su

pplie

r/Ti

er

3 Su

pplie

r)

1 Polypropylene (PP)

- - - - Seat, Af -

2 Polyethylene (PE)

- - - - - -

3 Polyurethane (PU)

- - - - Seat foam -

4 Nylon (NY) also known as Polyamide)

- - - - Radiator Tanks

-

5 Acrylonitrile Butadiene Sty-rene (ABS)

- - - - Body Parts -

Number of Shifts per day: One general shift

Products manufactured at the Company: NA


Yes


In house / ARAI


In-house: C Q A lab



In-house: C Q A


CQA

Testing of Finished Products In house as applicable

Quality Standard for Product: As per customer requirements

Design & DevelopmentDesign & Engineering Capabilities:• Bench Marking • Styling proposals• 3D Cad data Feasibility and drawing conversion• Reverse Engineering• Product Re-engineering• Styling (‘A’) surface to product Design• New product design• Rapid Proto typing• VA / VE / Poka Yoke• Design Optimization through CAE• Plastic flow simulation through mold flow• Structural analysis• CFD analysis• Jigs / Fixtures / SPM design

Project Organization:

Business Head

Project Manager

lead Engineer

Quality EngineerPlant NPD Team

Plant Head

MFG EngineerMFG Team

Sales

Supplier & VD

FeasibilityStudies Kick off

Production Part Approval Process

Execution &Validation Ramp Up


1 crore


Catia, Unigraphics

Safety standards in the Company:Possible accidents / hazards Safety measures in the company Remedies / MedicationZero Fire Extinguisher, Safety alarm,

Smoke detectors and Fire Hy-drant System

First Aid BoxAmbulance


Marketing and Branding:logo of company: ogo of company:



Medium

Online services No

Finance & AccountsComponent_ Cost Break UPItem name Unit Bracket

RHD_MTC

Bracket RHD-Disel

Lever Clutch RHD

Pedal Pad MTC_RHD

Hous-ing

Drawing No. - 102P-J3084

102P-J3033 102P-J3086

102P-J3098

Item no. 1 2 3 4Mould Cost Assumption

RS 0 2000000 785000 415000 0

Delivery Period Weeks 10~12 weeks

10~12 weeks 10~12 weeks

8~10 weeks

Material As-sumption

- PP CP GF 20% BlACK SEB 200

PP CP GF 20% BlACK SEB 200



PP

Colour - Black Black Black Black BlackNet. Wt. gms 1337 1060 365 31.4 100Runner gms 100 80 12 7 6Shot wt. gms 1437 1140 377 69.8 106Cavity nos 1 1 1 2 1Recon. Wt. gms 1483.9 1177.0 392.9 35.8 109.8Raw matl. Cost Rs/kg 140.00 140.00 120.00 120.00 120.00Raw matl. Cost/piece

Rs/piece

207.7 164.8 47.1 4.3 13.2

Cycle time secs 90 90 80 60 60Prod. Per shift nos/

shift293 293 330 880 440

Production @ 90 % effeciency

nos/shift

264 264 297 793 396

M/c used Tonns 1800 1800 300 180 250M/c tariff Rs/shift 18000 18000 3000 1800 3000Moulding cost Rs/

piece68.2 68.2 10.1 2.3 7.6

Inspection and packing cost

Rs/piece

0.8 0.8 0.3 0.2 0.3

Subtotal Rs/piece

276.8 233.8 57.5 6.8 21.1

Rejections @ 5 %

Rs/piece

13.84 11.69 2.88 0.34 1.05

Profit +over-head @ 10 %

Rs/piece

27.68 23.38 5.75 0.68 2.11

Poly bag cost Rs/piece

0 0 0 0 0

Packing box cost

Rs/piece

1.0 1.5 0.9 0.6 0.2

Plating Cost Rs/piece

- - - - -


Total Com-ponent Price

Rs/piece

319.26 270.36 67.08 8.38 24.41

Terms & Conditions:• Above price is basic price. Other taxes will be as applicable.• For making of moulds 60 % advance along with PO balance against first

trial.• For supply of components payment within 30 days after despatch from

our end.• Above rates are ex our works K-151, MIDC, Waluj.• Cost is subject to change if there will be any change in material ,product

design or raw material rate.• Packing cost of polybag is extra if needed.• Component wt. considered as per given by you.

Human Resource ManagementEmployment recruitment rules As per policy given by corporate. Recruitment is

done only through references.


Supervisor Technical Induction As per new IdentifiedManager Technical Induction As per new Identified

leave Policies:Staff Leave PoliciesMachine Operator NASupervisor As per policy (24 - Pl, 6 – Cl, 6 – Sl)Manager As per policy (30 - Pl, 6 – Cl, 6 – Sl)Helper/Cleaning Staff NA

Mediclaim Policy: Mediclaim Policy from Bajaj Alliance for managers.

Salary Structure: N. A.

Covered under ESI/EPF/Gratuity: EPF

Compensation Plan for workers in case of injury or accidents: Medical Policy

Career Graph Plan for Employees: Career plan as per policy

Retention Policies and Welfare Schemes: As per Policy

Assistance required from Government in the following areas:

Assistance by CIPET, Aurangabad: One year Trainee

SWOT Analysis of the CompanySTRENGTHS• Innovative• The Value Methodology: Value

Engineering (VE) & Value Anal-ysis (VA)

• Reverse Engineering• Benchmarking• Computer-Aided Designing &

Computer-Aided Engineering

WEAKNESSES• Workaholic employees• Work life balance• late staying

THREATS• Competition

OPPORTUNITIES• New business of AF / Seat & Body

parts• Tapping market for Four-wheeler

Dash board





1 year Build In-house Design capability of seats

Design Assistance New Opportu-nity


300 seat Assembly to be Designed for auto Rickshaw segment. Help needed in market Survey, Market Potential competition analysis, feedback from OEMs.

Design Brief 2

Design calculation of concepts.

Design Brief 3

Product Design with simulation result.

Plan of the Design ProjectProduct Design Brief specifications To be discussed laterProposed Design Process To be decided laterTime-line To be decided laterBudget To be decided laterTeam members & Skills Required To be decided later

Benefits for the Company New Business opportunities


Company’s product range on display

Company’s product range on display

Good management practices



Mould’s finishing process Mould’s finishing process



The worker’s wrong posture while working on the mould. The mould is kept on temporary arrangement.

The grinding process needs to be in a separate area.

The hanging crane bring used to shift heavy loads.


The grinding process The grinding process

The worker’s wrong posture while working on the mould.



The wrong posture of the workers will make them suffer from work-related diseases.


2

31

27Yo

gesh

Plas

ticIn

dustr

ies


Name of the Unit: Yogesh Plastic IndustriesAddress of the Company: Plot no. A-114/3, Five Shendra, MIDC, Aurangabad, Maharashtra, Indialandline number: 0240-2622422Mobile Number: 9403759542, 8087428329Company e-mail id: [email protected] Company started in: 2011


Company’s Specialization/Product/Services: Agro Shade Net



Sr. N

o.

Nam

e of

Ow

n-er

/ Pr

opri

etor

/ P

artn

ers /

D

irec

tor

Age

(yea

rs)

Stat

us (O

wne

r / P

artn

er)

Educ

atio

nal

Qua

lifica

tion

Wor

k Ex

pe-

rien

ce p

rior

to

star

ting/

join

ing

the

Com

pany

Pers

onal

Em

ail

Id.

Phon

e nu

mbe

r

1 Yogesh Vrajlal Parmar

38 Partner SSC 10 Yrs [email protected]

9403759542 8087428329

2 Pradeep Vrajlal Parmar

45 Partner B. Com

10 Yrs 9421306083

3 Rajesh Vrajlal 40 Partner SSC 10 Yrs 9422712005



AssistanceYear Purpose Amount (Rs.) Status (Ac-

tive/Closed)1 State bank of Hyderabad 2011 Term loan 37 lacs N. A.2 State bank of Hyderabad 2011 Cash Credit 25 lacs N. A.


Production capacity of the Unit:Year Production capacity2013-2014 80000 kgs p.a. (Proj. Sales Rs. 120.00 lacs)2013-2012 34691 kgs p.a. (Sales Rs. 50.30 lacs)2012-2011 11428 kgs p.a. (Sales Rs. 16.46 lacs)2011-2010 N. A.2010-2009 N. A.


CustomersNames/List of Cus-tomers

Products Manufac-tured

Agricultural/Irrigation

20 Farmers Agro shade net

Total number and list of Vendors or Suppliers:• Polygrain – from Pune• Perfect color and plastic – from Daman• Mihir processing – from Rajkot

Yogesh Plastic IndustriesMIDC, Shendra, Aurangabad


• A – top polychem – from Rajkot • Om polybland - from Daman

Total number of Employees at the company:• Partners : 03• Operators : 06• Helper : 04


Area of the Unit:Plot Area 1179 sq. mtr.Total Built-up Area 622 sq. mtr.

Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2011-2012 16.46 l 5.80 l 0.09 l2012-2013 50.29 l 14.59 l 0.28 l2013-2014 (expected) 120.00 l 36.85 l 2.17 l

Certification/s (If any): N. A.

Audit Report/s (If any): N. A.


Competitor’s name



1 Rushi Packers Agro shad net N. A.2 Krushi Net Agro shad net N. A.3 Mayura Agro Agro shad net N. A.4 Balaji Agro Agro shad net N. A.

Types of Machines:

Sr. N

o.

Nam

e of

M

achi

ne

Qua

ntity

Mak

e of

m

achi

ne

Spec

ifica

-tio

n

Pric

e of

the

Mac

hine

Year

of

Purc

hase

Loan

/ by

Self

1 Extruder 01 Renuka, India

75mm 8.00 2011 30% Self & 70% loan

2 Sletting machine

02 Rose Ind., India

58 inch 11.50 2011 2013

3 Net wraping machine

02 Rose Ind., India

3 mtr 31.00 2011 2013

4 Grinder Mixer 01 Rose Ind., India

30 kg 0.70 2011

5 Bale press ma-chine

01 Rose Ind., India

1.50 ton 1.00 2011 Self

6 Weight lifting 01 Rose Ind., India

1 ton 0.80 2011 Self

Types of Hand Tools:

Sr. N

o.

Nam

e of

To

ol

Qua

ntity

Mak

e of

m

achi

ne

Spec

ifica

-tio

n

Pric

e of

th

e To

olYe

ar o

f Pu

rcha

seLo

an/ b

y Se

lf

1 Hand grinder

01 Max India India

4 inch grinder 0.02 2011 Self

2 Hand drill 01 Max India India

5 mm drilling 0.02 2011 Self

3 Air blow 01 Prakash India

0.02 2011 Self

4 Weighing scale

04 Excel India

500 kgs, 300 kgs, 150 kgs, 30 kgs, 600 gram

1.20 2011 Self


5 Tools kit 01 Tapadiya India

8-24 Instruments 0.02 2011 Self

Raw materials

Sr. N

o.

Raw

Mat

eria

l

Curr

ent R

ate

(Rs.

Per K

g)

Spec

ifica

tion

Supp

lier’s

Nam

e

Min

imum

qua

ntity

mai

n-ta

ined

in th

e co

mpa

ny p

er

mon

th

Prod

uct M

anuf

actu

red

with

the

mat

eria

l

Prod

uct S

uppl

ied

to

(OEM

/Tie

r 1 su

pplie

r/Ti

er2

Supp

lier/

Tier

3

Supp

lier)

1 H. D. P. E. 127 per kgs

Natural, Virgin

Pol-ygrain, A-Top poly and Mihir process-ing

10 ton (12.70 lacs)

Agro Sheet net

Warehouse/Storage of Raw material (Inventory Control Techniques)

Order Quantity: N. A.Order Process: N. A.Quality Control: N. A.

Sr. N

o.

Nam

e of

wor

ker

Age

(yrs

)

Gen

der (

M/F

)

Wor

kers

/Sup

ervi

-so

r/M

anag

er/S

taff

for c

lean

ing

Qua

lifica

tion

Ope

ratio

n/

Func

tion

Year

s of e

xper

i-en

ce in

Indu

stry

Wor

king

hou

rs/

day

1 Munari Manji 28 M Supervisor SSC Supervi-sor

6 yrs 8hrs

2 Ramchandra Manji

20 M Operator SSC Machine Operator

3 yrs 8 hrs

3 Shikant Pawar 21 M Operator HSC Machine Operator

2yrs 8 hrs

4 Anil Rathod 19 M Operator 9th Machine Operator

3 yrs 8 hrs

5 Vijay Manji 23 M Operator 8th Machine Operator

3 yrs 8 hrs

6 Chotelal Prajapati

30 M Operator SSC Machine Operator

4 yrs 8 hrs

7 Rakesh Paswan

22 M Helper 9th Helper 2 yrs 8 hrs

8 Pankaj Singh 25 M Helper 11th Helper 2 yrs 8 hrs9 latabai 35 F Helper 5th Helper 2 yrs 8 hrs10 Rukhmanibai 35 F Helper 6th Helper 2 yrs 8 hrs

Functions/Operations in the company:Function / Operation Required

Qualifi-cation of workers





Design & Development of household & other plastic products

DME, BE 03 03 8 hrs 1

Flow chart of Business Process:

Purchase Raw Material > Raw Material With Master Batches & Extra life Chemicals > Heating Process > load in Extruder Ma-chine and Prepare Films > Films Roll loading in Sliting Machine > Weaving in Neting Machine > Folding and Prepare Bales on Press


Machine > Weighing as per Customer Requirement

Flow chart of Manufacturing Process:• RM Mixing with master batch• Heating process• load in extruder• Film roll from extruder machine load in slitting machine• Weaving with neting machine• Folding and prepare bale for dispatch• Weighing





Wastage %

1 Extruder 01 1 hrs – 45 kgs production

350 kgs 2%

2 Slitting Machine 01 2 hrs – 15 kgs production

120 kgs 10%

3 Weaving Machine 01 2 hrs – 15 kgs production

120 kgs 0%


Product name

Cost to Company

Price to Customers

Repeat Order

Supplied to

1 Agro shade net

Yes Farmers, Building construction, Schools, Sport ground, etc. in and around the state of Maharashtra

Quality Control PlanProject Documentation:


No


In house



Name of Testing labs for Raw Mate-rials (tie-ups for Raw Materials)

N. A.


N. A.

Testing of Finished Products It is done in house by manually

Quality Standard for Product: N. A.

Design & DevelopmentWhat is Design? “Design is new Customers and New

Money earned”

Design Process of existing products (choose any top one product that is being manufactured at the company for a OEM or a Customer): N. A.

Design Process/Plan fora new Product innovation: Design process will be done in house by using technical & qualified employee, and we will developed new design in plastic Agricultural products, household & other products.


Rs. 15,00,000/- (proposed plan for development)


Tally


Exhibition/trade shows visits:Sr

. No.

Exhi

bitio

n /

Show

Part

icip

ant /

V

isito

r

last

atte

nded

(Y

ear)

Fees

(in

case

th

e co

mpa

ny

part

icip

ated

)

Bene

fits

1 Advantage Mahar-ashtra Expo-2014

Yogesh Parmar

2014 N. A. New Design & Development

2 Plast Vision, Mumbai

Yogesh Parmar

2013 N. A. Information about New Agri-cultural products

Safety standards in the Company:Manufacturing Operations

Possible acci-dents / hazards


Remedies / Med-ication

Slitting Machin-ing

Hand Injuries Sensor attached with machinery

N. A.




Medium

Describe the Company’s Target Market: Export the product and develop new products in Agricultural & plastic Indus-tries.


Medium


N. A.

Online services No

Company label: N. A.

Company Product Samples: Yes. Swatch of the Agricultual Sheet net is presented with all the relevant information

Finance & AccountsWhat is the process of Pricing? Also attach a Cost Sheet of one of the product manufactured at your company.

Cost sheet for 1000 kgs Agro Shade netCost of raw material Rs. 1.00 lacsProcessing cost Rs. 0.40 lacslabour cost (wages) Rs. 0.05 lacs


Total cost to company Rs. 1.45 lacsMargin Rs. 0.05 lacsSelling cost Rs. 1.50 lacs

Explain the Distribution Process. Backward linkages and Forward linkages (Supply Chain): Finished material dispatched to customer by transport or cus-tomers directly purchased from our factory premises.

Human Resource ManagementEmployment recruitment rules No any specific recruitment rules.

Employee’s selection on their skilled and work efficiency.


N. A.

Training Policy for the new recruits and already employed with the company:Staff For New Recruits For Already Employed

Machine Operator Work Experience / trail run Work ExperienceSupervisor Work Experience Work ExperienceManager Work Experience Work ExperienceHelper/Cleaning Staff N. A. N. A.

leave Policies:Staff Leave PolicyMachine Operator 4 days in months and public holidaySupervisor 4 days in months and public holidayManager 4 days in months and public holidayHelper/Cleaning Staff 4 days in months and public holiday

Overtime Policy:Staff Overtime PolicyMachine Operator Wages per hourSupervisor Wages per hourStaffManager Salary per hourHelper/Cleaning Staff N. A.

Insurance/Medi-claim Policy: N. A. (Proposed to begin for all staff)

Wage Rate Policy:Staff Wage Rate PolicyMachine Operator On work experience or fixed on Rs.6000 – 7000 p.m.Supervisor On work experience or fixed on Rs.9000 – 10000 p.m.Manager On work experience or fixed on Rs. 10000 – 12000 p.m.Helper/Cleaning Staff Helper / Cleaning fixed Rs. 3000 – 4000 p.m.

Salary Structure:Staff For Fresher (in

Rupees)With experience of 3 years (in Rupees)



Machine Operator

6000 – 7000 p.m. 7000 – 8000 p.m. Practical work done N. A.

Supervisor 9000 – 10000 p.m. 10000 – 12000 p.m. HRM N. A.Manager 10000 – 12000 p.m. 11000 – 13000 p.m. Business Management

TrainingN. A.


4000 – 6000 p.m. 6000 – 8000 p.m. For staff – as per post training

N. A.


of staffProfile (Machine Operator / Supervisor / Manager / Helper / Cleaning Staff)

Hometown (Aurangabad / Outside Aurangabad but within Maharashtra / Outside Maharashtra)




Male 03 Supervisor / Manager / Staff

Aurangabad 2 yrs – 3 yrs

Female 01 Receptionist Aurangabad 1 yrs

Covered under ESI/EPF/Gratuity: N. A. (Proposed to begin for all staff)


Compensation Plan for workers in case of injury or accidents: N. A.


Retention Policies and Welfare Schemes: N. A.


Timelines Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)


6 months Acquired certification from ISO

N. A. Develop material quality

1 year Design & development new products

Finance / Training / Design Assistance


3 years Export sales Finance Export order5 years N. A. N. A. N. A.

Product Design Project BriefDesign Brief

Design & development of new plastic products and estimated cost for the same up to 10 lacs to 15 lacs

Plan of the Design Project

Product Design Brief specifications Various types of plastic productsProposed Design ProcessTimeline 2-3 yearsBudget Rs. 15,00,000Team members & Skills Required 05 (Ind. Designer, Engineer,

Researched, etc.)Benefits for the Company Develop new products and develop

new markets for the company


Used blades are seen lying casually at the entrance. This needs to be properly disposed after its use.

The stock of Rolls and the tools need to be arranged properly and labelled.


Need urgent attention for the proper wiring to avoid fire, electric shock or any kind of accident.

The raw material bags are seen lying in the aisle. These bags need to placed at proper distance from machine.

The scrap to be collected properly for the properly functioning of the machines.

The tools are lying unattended. The tools need to be removed after its use.


Need urgent attention for the proper wiring to avoid fire, electric shock or any kind of accident.

The tools are lying unattended. The tools need to be removed and placed at its specified shelves after its use.

The scrap to be collected properly for the properly functioning of the machines.



The gap to move around the working area is too less. The stocks around seen around needs to be arranged properly.



The gears and the chain is seen open and exposed to material scrap. Need to keep the machine covered to avoid damage.

The machine parts is seen open which prone to accident. The wiring and the oil spillage needs to be maintained.


The machine switches needs to be maintained and needs proper marking as per its function.

The production area is chaotic. The raw material is kept in haphazard manner and not enough space to seen to walk around the area.

The incomplete rolls are not stocked properly. Needs to be arranged neatly.


FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergonomics Need to improvePlant layout Improvement Space management is a concernNew Product Development No in-house product development process



improve


RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear and thus the productivity of machines can be im-proved.

Some research and development work to be done so that the dependence on

the manual work can be reduced. Some part of profit has to be kept for such activities.


Wastage and spoilage of the material can be reduced to improve the through-put of material, thus reducing the cost of manufacturing.

Product: Company currently producing only one type of product, it should venture into other categories to reduce the business risk. Product testing should be done at various levels and report can be prepared to increase customer confidence.

Human Resource: To reduce Employee attrition rate, the salary levels need to be revised to attract better skilled manpower. Proper training should be formalised to improve the skill of the workers.



tion in a logo so that customers identity the product with the company. A proper branding strategy should be formalised to get maximum visibility in the market.


• A company should participate in trade fairs and exhibition related to plas-tics to attract new customers



FInishing the woven plastic mat’s rough edge at Siddhi Polyweave, MIDC, Waluj, Aurangabad

SWOT - Plastic Clusterstrengthsweaknessesopportunities & threats


STRENGTHS:

• First Generation Entrepreneurs• Eagerness to take challenges and risks• Predisposition to scaling up the scope of business and modify prod-

uct offerings as per changing market demands• Efficient production capabilities for Product Designs & Specifications

provided by customers Easy availability of Raw Materials in desired quality & quantity

• A good dealer network• low Real Estate prices and easy availability of land / Industrial Plots• Government policies supporting the access to by entrepreneurs• Government Incentives for investment and credit availability

WEAKNESS:

• Increased competition in same type of manufacturing• The cluster operates on very low margins with some companies oper-

ating on margins as low as 3%• Dependence on single / two companiesw• No own Products. No investment in IPR• lack of funds for R&D • lack of trained manpower and no structured plan for skill up-grada-

tion• No standard practice of visiting Trade Fairs which results in lack of

Market Awareness• First Generation Entrepreneurs hence limited risk absorbing capacity• No structured growth plan in place• low awareness levels for Government schemes and policies

SWOT - Plastic cluster• Inadequate water and power supply• Infrastructure is not upgraded to meet the changing industry require-

ments• Focus only on making basic products• Reliance on customer to provide all design inputs• Absence of product benchmarking as basic Quality control process is

followed• Moderate to high wastage• Slow Technology Up gradation and basic to minimum use of software

which lengthens lead time• Ergonomics and Medical facilities

OPPORTUNITIES:

• MIDC has planned to develop Additional MIDC’s in the region which creates good opportunities for industries.

• Cluster development programme of Central Govt. boost for creation of jobs /skilled & unskilled man power.

• Expansion project of CIPET is playing vital role for plastics manufac-turing in the region.

• Government initiatives like DMIC Project, Shendra-Bidkin Industri-al Park, Revised Seed Money Scheme, Prime Minister Employment Generation Programme etc.

• Development of retail sector.• Growth possibilities through mutual cooperation.• Government incentives for Infrastructure and Technology Up-grada-

tion.• Awareness regarding importance of training. • Positive attitude towards product diversification.


• With the growth in the size of the cluster, there will be greater availability of cheaper raw materials due to industry forces.

THREATS

• Skill up-gradation is crucial for keeping pace with changing technological needs.• Increasing pace of competition while the customers remain limited.• limited product innovation might make the companies redundant in future.• No safeguards for reducing environmental waste which might result in problems in future.• Slow pace of market expansion by targeting new customers.• The export market has not been tapped.• No testing labs which might lead to issues while dealing with international companies with stringent quality norms.• No plans for making the business self-sustaining.


Findings

Survey work in progress at Mould Technology, MIDC, Waluj, Aurangabad


The survey presents the findings focussing on the lack of MSMEs’ exposure to new markets as most of the units is catering to OEM based job work wherein each and every detail is specified by the client not leaving any scope of design intervention in terms of product design and development.

Si. No. Current Status Impact on Business1 Most of the units in the

cluster are focussed on making component parts for the OEM market.

The job work kind of business identity prohibits any kind of product development as the product designs are provided by the customers and the units are just supposed to execute the same.

2 No substantial efforts at attending Trade Shows.

The units lack market awareness about the cur-rent product requirements of the industry.

3 No substantial marketing or branding efforts.

It increases dependence on a smaller customer base which increases the business risk.

4 lack of commitment for Research & Develop-ment.

The units continue to make similar products which prohibits innovation and product diver-sification which might result in weakness in the face of increasing competition.

5 Extremely small margins in the product because of the units making basic products and competing of rates.

Generation of moderate to minimum profits which cannot be ploughed back in business. Hence, the units cannot become self-sufficient.

Some of the Unit owners have ideas about the products they want to diversi-fy with, but the problem is the market awareness. There is an urgent need to create an awareness about the opportunities at common business platform for the entire cluster where people can share there strength and weakness, come up with a cumulative solution wherein everybody gets benefited w.r.t. the focussed design research, processes, emerging technologies, new target market, etc.

The cluster may contribute towards developing a common market place in their area where all the manufacturers can individually showcase and market

Findings - Highlight observations at cluster leveltheir products and processes continuously.

Technology:Most of the units uses conventional machines such as semi-automatic ma-chines. Also, due to the high cost of new machines the units generally uses the second hand machines which leads to high energy consumption and decreased productivity. Investment in technical up-gradation is low. The units hardly use IT technology. There is no any tie up with technical and R&D institutions.

Infrastructure: limited growth scope in basic infrastructure. The units are not able to main-tain delivery schedules due to logistics bottlenecks in region due to bad roads and connectivity. The social infrastructures are also inadequate at Aurangabad region. There is an alarming gap between supply & potential demand for the infrastructure required for high growth.

Raw Material:The frequent increase in raw material prices is adding up to the input costs of the production. The easily procurement is also a big problem faced by the small units in the cluster.

Design Process and Product Development:Most of the companies depends on the design and specifications which are provided by their clients. The production is done as per the job work. As a result the units do not get opportunity to implement design processes required to come up with better designs and increasing the intellectual capability of the units. Barely any units have product innovation facility and most of the cluster units do not have their own products as they are manufacturing on job work for bigger units.

Target Market:Most of the target market is local clients except a few units who manufacture products sold directly in retail markets through dealers. Due to increasing


competition the units and are always under pressure to keep prices low in spite of rising input costs. The units have enough critical mass to promote their common brand subject to form the marketing consortia.

Production Capacity:Due to fewer and low capacity machines the units have low productivity. Most of the units uses second hand machines which requires frequent maintenance and effects the productivity. Also, the production is tightly defined by the cli-ents and their requirements.

Logistic, Packaging & Transportation:Most of the production being manufactured for the local clients the products are packed in polythene bags and corrugated boxes.

Plant Layout:In most of the units the layout is not according to the process flow of raw ma-terials and the manufactured items. When a item moves haphazardly during processes it leads to increased time periods and overall efficiency of the work-ers and the unit itself. The travel distance increases and also its material han-dling or transportation cost increases. layout shall be reviewed in the light of process flow to reduce the travel-distance of the items in the unit.

Ergonomics:In most of the units finishing, assembly and packing and final packaging op-erations are being done by persons sitting on floor or against a wall. This puts more strain on work , thereby reducing the productivity. The wrong posture of the workers will make them suffer from work-related diseases, which are further complicated by social, psychological and physiological issues. Overall this will further affect the productivity of the unit. Arrangements should be made to make work stations in such a way that workers work while standing. For workers working on machines gravity chutes etc. may be used.

Material Handling:Most of the units the raw material and finished goods are moved by manually. Only in a bigger units material handling trolleys are being used which are used manually. Use of Fork lifters, Pallet lifters and hoists or cranes is used by a

very few units. There is a need to identify and start using mechanized material handing system.

Skills & Training:The skill of the workers in most of the units have deficit in the area of Produc-tion techniques, Machine know-how, 5S, Information technology, Machining & Programming, design & testing of financial Management. Workers are most-ly focusses on one type of skill and are not multi talented. Higher attrition rate of the skilled employees due to lack of career planning and promotion avenues.

Entrepreneurs & Enterprise:Majority of the units are family owned. Barely any fresh talents are recruited from outside which restricts the sense of innovative w.r.t. to products or busi-ness. There is very low level exposure and awaress among the workers and staff about the technological development around the world. There is also very little awareness about the training programmes and promotional schemes of the state and central government. The risk taking capacity is least seen among the smaller units. There is also a poor co-ordination and trust level between cluster units. Majority of the entrepreneurs in the cluster are with artisan background and have attitudinal constraints and not open to the changes in new technolo-gy and modern management practices.

Finance and Credits:The financial planning, control & accounting system is not properly main-tained by most of units get these important work done by external agents such as local Chartered Accountants due to lack of adequate resources and exposureDue to lack of financial management skills the return on investment in low as planned by them. The relationship between the cluster units and borrower & financial institutions seems to be weak.


Recommendations

Turning Process at Mould Technology, MIDC, Waluj, Aurangabad


WAY FORWARD

Business Processes:Currently the manufactures in the plastic cluster are working on the various types of products catering to automobile to the household industry. While interacting with the participants under this survey, they opened up with their problems of supply chain, managing the capital, labour issues and majorly the marketing aspects. Here we will try to focus on the some of them:

Profit Margin:It is clear from the information given by the respondents of this survey that profit margin is very tight in this sector. This is because competitors from man-ufacturers of other industrial area are producing the goods with same specifica-tion at very reasonable rate. Major reasons that the respondents said are: • Higherelectricitycharges• Highertransportationcosts• Fluctuationsintherawmaterialprices• NosubsidyfromGovernmentinanyform• Noinitiativeontheexpansionofthemarket

Higher raw material costs:The major component of the total cost is raw material; which is around 85%. The raw material required for most of the units in the cluster is of similar nature and as per respondents the issue that the prices are changing every 15 days. This issue can be sorted out by placing a combined order from all manu-facturers. This will reduce the raw material cost by economies of scale and buyer can also negotiate with the supplier for trade discount.Alternate source of raw material can be found out to reduce dependency on one supplier.

Research and development:Very few companies are engaged in the new product development process, either because of they don’t have skilled manpower to do that or they lack the

funds required for it. Also no company is taking benefit of the synergy and developing the new product. A platform should be provided to the manufactures so that they can share the ideas, resolve the issues or problems and come up with the strategy to solve the major concerns of the cluster. Cash rich big companies can also fund the development activities of the small units facing financial problems.

Transportation:The overall infrastructure specially the condition of roads is not in such a good condition. This hampers the growth of the business by increasing the lead-time. A better and efficient logistics means faster movement of the raw materi-al and finished goods, thus reduces the business cycle for a company.It is also evident that the market for most of the manufacturers is common and very nearby. To reduce the overall cost of transportation, the products from all the supplier going to the same market place can be combined together thus reducing the transportation cost per unit. A delivery schedule can be planned as per the market place and variety of goods produced by different manufactures are transported in the same vehicle on a particular date. As per the demand the transportation frequency can be increased.

Power:Currently a plastic cluster at Aurangabad is facing problems in supply of electricity. The fluctuations in the power supply hamper the efficiency of the machines as well as the defects in the products. A smooth and regular power supply is the need of the hour as it will increase the throughput and reduce the wastage and spoilage.

Starting of Common Facility Center (CFC):A common facility center can be formed to sort out following issues:• Acombinedbulkpurchaseorderofrawmaterialforallthemanufac-turers to get trade discount,• AcommonR&Dunitforalltheparticipants,• Managementofcommontransportationfacility• Stringenttrainingscheduletoconverttheunskilledlabourtoskilledworkers


• Formulationofcareerpathtoattractmoreworkforceinthisindustry• Financialhelpinvisitingandexhibitinginthetradeshow

Porter’s view:There are three approaches to run an organization are referred to as “generic strategies”, because they can be applied to products or services in all industries, and to organizations of all sizes. They were first set out by Michael Porter in 1985 in his book Competitive Advantage: Creating and Sustaining Superior Performance. Porter called them Generic Strategies.

Porter’s generic strategies are ways of gaining competitive advantage – in other words, developing the “edge” that gets the sale and takes it away from the com-petitors.

“Cost leadership” (no frills): it involves being the leader in terms of cost in the industry or market.

“Differentiation” (creating uniquely desirable products and services): making products or services different from and more attractive those of competitors. And

“Focus” (offering a specialized service in a niche market): concentrate on particular niche markets and, by understanding the dynamics of that market

and the unique needs of customers within it, develop uniquely low cost or well-specified products for the market. He then subdivided the Focus strate-gy into two parts: “Cost Focus” and “Differentiation Focus”. The terms “Cost Focus” and “Differentiation Focus” can be a little confusing, as they could be interpreted as meaning “A focus on cost” or “A focus on differentiation”. Cost Focus means emphasizing cost-minimization within a focused market, and Differentiation Focus means pursuing strategic differentiation within a focused market.

How to choose which generic strategy to adopt?STEP 1: The units need to conduct a SWOT analysis of their individual units or discuss with the experts to take an outsider view of their unit.

STEP 2: This should be followed by a Porter’s Five Forces Analysis of the clus-ter.


STEP 3: This will enable the units to identify which Generic Strategy will suit them the best on the basis of their vision for the company.

Collaborations & Exhibitions:

The unit owners in the cluster should collaborate to organize an exhibition every six months to showcase their new product developments to the industry. This exhibition can be promoted with the help of Government agencies.

The unit which exhibits most unique product development or process improve-ment may also be rewarded by signing up deals or contracts with the business houses.


5 Day Workshop

Work in progress at Varroc Polymers, MIDC, Waluj, Aurangabad

About the WorkshopSchedule of the WorkshopDay 1Day 2Day 3Day 4Day 5Design Briefs


Design clinic workshop held for the Plastic Cluster was a combination of pres-entation and interactive sessions on interactive design study and need assess-ment, design seminar and design clinic activity. The design expert/s presented the opportunities identified from need assessment. The design seminar pres-entation from design expert/s and guest design speakers focussed on design topics and case studies relevant to the plastic cluster and participants. During the design clinic, design expert/s diagnosed solutions for existing design prob-lem/opportunity and suggested on the spot remedial steps, during the work-shop. The workshop helped the participants to get quick remedies on identified opportunities for design intervention from existing problems taken up from their respective work areas.

Objective: Objective of Design Clinic Workshop was to create a platform where partic-ipants were able generate the holistic perspective for their scenario with the help of design expert/s guidance. The design expert helped participants in identifying opportunity areas in their respective units and cluster with the help of interactive design study insights. The expert also helped in providing on the spot design solutions to problems taken up by participants from their respec-tive backgrounds of products, process, communication and design strategy.

The major activities of design clinic workshop was as following:

• Discussion of opportunity areas identified from interactive design research • Design presentations by guest design speaker/s • Provide remedies to design problems taken up by the participants

Guest Speakers/Experts: Mr. S G Rajput, GM, DIC AurangabadMr. T R Sharma, Dy Dir. MSME AurangabadMr. S K Thote, Regional Officer, MCED Aurangabad

Mr. Thaware D U, Project officer, MCED AurangabaadMs. Bharti Sose, Project Officer, MCED AurangabadMr. Sanjay Bondekar, Dy General Manager, NSIC AurangabadMr. Anidya Pal, Dy General Manager, SIDBI AurangabadMr. Pravin Bachhav, Sr. Technical Office, CIPET AurangabadMr. Vinayak Garkhedkar, Project Consultant, AurangabadMr. Tanmay Kandekar, andMs. lipi Choudhury

About the Workshop


Date Day Time Session Speakers8th March, 2014 1 10 AM – 10:30 AM Registration Process

Inauguration

Welcome Address

MCED teamMr. S G Rajput, GM, DIC AurangabadMr. T R Sharma, Dy Dir., MSME AurangabadMr. S K Thote, Regional Officer, MCED AurangabadMr. Thaware, D U, Project officer, MCED AurangabaadMs. Bharti Sose, Project Officer, MCED AurangabadMr. Saurabh Kumar, NIFT MumbaiMr. Tanmay KandekarMs. lipi Choudhury

10:30 Am to 12:30PM Introduction to DCS Workshop Mr. Saurabh Kumar12:30 PM to 12 :45 PM Tea Break12:45 PM to 2:00 PM Trends in New Products Innovation Ms. lipi Choudhury2:00 PM – 2:30 PM lunch2:30 PM – 3:30 PM Personal discussion with participants Mr. Saurabh Kumar, NIFT Mumbai

9th March, 2014 2 10:00 AM to 11:00 AM Schemes for MSMEs Mr. T R Sharma , Dy Dir MSME Aurangabad 11:00 AM to 11:30 AM DIC Schemes for MSMEs Mr. S G Rajput , GM, DIC Aurangabad11:30 AM - 12.00 PM Design & Trademark Protection & Issues Mr. Tanmay Kandekar 12:00 Noon – 1:30 PM Design Process & Design Case Studies Mr. Saurabh Kumar1:30 PM to 2:00 PM lunch2:00 PM – 3:30 PM Personal discussion with participants Mr. Saurabh Kumar, NIFT Mumbai

10th March, 2014 3 10 AM – 1:30 PM live Clinic: Personal Interaction with Twelve MSMEs - Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification

Mr. Saurabh Kumar & Mr. Tanmay Kandekar

1.30 PM – 2:00 PM lunch2:00 PM – 5:30 PM live Clinic: Personal Interaction with Six MSMEs

- Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification


Schedule of the WorkshopACTION PlAN - 5 DAY workshop (5DW) for PlASTIC Cluster, AurangabadMarch 8th - March 12th, 2014, Co-ordinator: Saurabh Kumar (NIFT Mumbai) & MCED team


10th March, 2014 4 10 AM – 1:30 PM live Clinic: Personal Interaction with Nine MSMEs - Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification


1.30 PM – 2:00 PM lunch2:00 PM – 5:30 PM live Clinic: Personal Interaction with Six MSMEs



12th March, 2014 5 9:30 AM – 10:00 PM live Clinic: Personal Interaction with One MSMEs - Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification


10:00 AM – 11:00 AM Schemes of NSIC for MSMEs Mr. Sanjay Bondekar, Dy General Manager, NSIC Aurangabad11:00 AM – 11:30 AM Schemes of SIDBI for MSMEs Mr. Anidya Pal, Dy General Manager, SIDBI Aurangabad11:30 AM – 12:30 PM Support Schemes of CIPET for MSMEs Mr. Pravin Bachhav, Sr. Technical Office, CIPET Aurangabad12:30 PM– 1:30 PM Design Process & Design Case Studies Mr. Saurabh Kumar1:30 PM – 1:45 PM Project Proposal for Bankable loan for MSMEs Mr. Vinayak Garkhedkar, Project Consultant, Aurangabad1:45 PM - 2.15 PM lunch 2:15 PM – 2:45 PM live Clinic: Personal Interaction with One MSMEs



2:45 PM – 3:30 PM Closing Ceremony MCED teamMr. S K Thote, Regional Officer, MCED AurangabadMr. Thaware, D U, Project officer, MCED AurangabaadMs. Bharti Sose, Project officer, MCED AurangabadMr. Saurabh Kumar, NIFT MumbaiMr. Tanmay Kandelar, NIFT MumbaiMr. Vinayak Garkhedkar, Project Consultant, Aurangabad


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The workshop was inaugurated by the esteemed guests. Mr. T. R Sharma Dy Dir. MSME Aurangabad congratulated MCED on this initiative to streamline and bring structured design thinking to the Plastic Cluster. The esteemed panel of guests were facilitated by the MCED representatives.

The event was attended by the key stakeholders of the Plastic Cluster at Aurangabad like Electroplast, Yogesh Plastic, Darshan Plastic, Snehal Plas-tic, V. P. Pet Polymers, Mitali Industries, etc.

The inaugural session was followed by a session on developments in the Plastic cluster with Ms. lipi Choudhury. The session was interactive in nature with design ideas being shared and discussed by everyone present.

Presentation by Ms. Lipi Choudhury on ‘New Product Development’

The session concluded with a question and answer session moderated by Mr. Tanmay Kandekar. The Cluster representatives and the entrepreneurs discussed about various bottlenecks in terms of finances, awareness about schemes for MSMEs, teamwork and capacity building.


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The day started with presentation on Policy Initiatives & Schemes of Govt. of India for Development of MSMEs by Mr. T. R. Sharma Dy. Dir. MSME, Aurangabad. He informed the present MSME units about the Schemes & Programmes such as Credit linked Subsidy Scheme (ClCSS) for Technology Upgradation of MSEs, Cluster Development Programme, CFC & its funding pattern, Credit Guarantee Fund Trust for Micro Small Enterprises, ISO Reimbursement Scheme, Schemes for Capacity Building, Credit Rating Scheme of NSIC, National Manufacturing Competitiveness Programme - components. later the presentation by Mr. S G Rajput , GM, DIC Aurangabad further informed the units about the Cluster Develop-ment Programme.

Presentation by Mr. T. R. Sharma on ‘Policy Initiatives & Schemes of Govt. of India for Development of MSMEs’

During the second phase of presentations Mr. Tanmay Kandekar interact-ed with MSME Units about the Design & Trademark Protection & Issues. He emphasised on the importance of Design protection for creating sus-tainability and long-term growth prospects for the business.

As the day progressed Mr. Saurabh Kumar presented design case studies relevant to the plastic cluster and participants. During the workshop he discussed the diagnostic solutions for existing design problem/opportu-nity and suggested on the spot remedial steps, during the workshop to the MSME units.


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Day 3 was dedicated to live Clinic for MSME units. During this session one to one interactions were carried out with twelve MSME units in order to brainstorm for Design Innovation, Product Exploration and Product Diversification. The workshop helped the participants to get quick reme-dies on identified opportunities for design intervention from their Unit’s existing problems taken up from their respective work areas. The list of twelve MSME units is as follows:• APM Plast• AR Polymers• Electroplast• Mitali Enterprises• Moraz Plastic

Live Clinic on Day 3 with Mr. Yogesh Parmar of Yogesh Plastics

• Rupesh Enterprises• Siddhi Polyweave• Snehal Plastic• Tirumala Industries

Trimurty Polythenes• Ulka Plastics• Yogesh Plastics

The expert also helped the MSME units in providing on the spot design solutions to problems taken up by participants from their respective back-grounds of products, process, communication and design strategy.


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live Clinic continued on Day 4 with the next set of nine MSME units for exploring possible product diversification and new product development opportunities. The list of nine MSME units is as follows:• Cool Engineering• Concept Engineering• Darshan Plastic• Jyoti Industries• Mould Tech• Plast Tech• Sunrise Auto Pack• Sushma Industries• Suyog Plastic

Live Clinic on Day 3 with Mr. Ashok Joshi of Swagat Polymers and MSME unit

The expert helped the MSME units in providing on the spot design solu-tions to problems taken up by participants from their respective back-grounds of products, process, communication and design strategy.

The Design expert along with the MSME unit members discussed oppor-tunities for New Product Development. The Design briefs were generated for the MSME Units to go ahead to the third phase of the DCS i.e. the Professional Design Projects .


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On the final day of the workshop representatives from NSIC and SIDBI were invited to give inputs about loan and financial schemes. Mr. Pravin Bachhav, Sr. Technical Office, CIPET Aurangabad was invited for creating awareness about the various technical programmes run by CIPET. He also discussed the various facilities than can be availed by the MSMEs like raw material and product testing, prototyping, pilot production by associating with CIPET.

live Clinic was conducted for V. P. Pet Polymer for exploring possible product diversification and new product development opportunities.

Mr. Vinayak Garkhedkar, Project Consultant, Aurangabad discussed and

Mr. Shaukat Syed of Electro Plast Industry addressing the Closing ceremony and giving the vote of thanks to all the participating members.

presented the process involved in creating Bankable Project Proposals for loans.

Mr. Saurabh Kumar presented Design, Prototyping and Communication case studies to the MSME unit members. The session was made interactive involving the unit members to raise their concerns and together discuss-ing the solutions for the same. The Unit members also took opportunity to express their enthusiasm and willingness to work further with the DCS and the MCED team for Professional Design Projects.


Design Briefs - by MSME Units of Plastic Cluster, Aurangabad

The Design Briefs generated during the 5-Day Workshop is given below:

Design BriefsSr. no. Name of Unit Name of Proprietor/

OwnerProducts Design brief

1 Annu Industries Vishal Panjabi Automotive Parts. N. A.

2 APM Plast Ajinkya Nandkumar Kawathekar

Engineering Plastic Products Design of a new Mobile cover case which can carry cards and documents

3 AR Polymers Rohit S. Deshpande Injection moulded products Design of a new Key case for storing multiple keys4 Blue Star Engineers Rajesh K. Sanghavi Plastics M. V. & Home Appli-

ances Parts.N. A.

5 Concept Auto Pack-aging

Rahul S. Neele Fully Auto on line Care Pack-ers.

N. A.

6 Cool Engineering S. P. Kale Water Chillers, Industrial Re-frigerators

N. A.

7 Darshan Plastic Ashok B. Thorat Plastic Injection moulded Com-ponents.

Design & Development of lighting Solutions for Household, Automobiles and Two wheelers.

8 Electro Plast Industry Syed Shaukat Abdul Rauf

Inter Storage Tank • Design of a new Water Tank for household and industrial use. • Design of new lid for Water Tanks.• Design of new Pet Bottles

9 Jayshree Enterprises Shailendra Prataprao Baviskar

Plastic Injection Products New Plastic Injection Moulded Component

10 Jyoti Industries Atmajyoti Bapu Na-gare

Drip Irrigation. N. A.

11 Mitali Industries Pramila Kanha Kashide

Auto Components. Design of motorcycle accessories such as Helmet case, Mud cover and Wind-shield.

12 Moraz Plastics Vilas More In Process Design of New Safety Shaving Razor (Patent Pending as on December 2014)


13 Mould Technology Bhalchandra Dhond-pant Bhandrao

Plastic Moulds & moulding Products.

Design & Development of Poultry Farm Equipments. The products to be manufactured using Injection molding, blow molding and extrusion molding technology.

14 Plast Tech laxman Irana Man-dkar

Appliances spare parts N. A.

15 Rupesh Enterprises Godavari Dattrao Narwade

Plastic Mould & Dies Design of a new mould for household products/toys

16 Sejal Plastics Santosh Vajantrao Joshi

P. P. Mats N. A.

17 Siddhi Polyweave Shashikant Nagnath-rao Ernale

P. P. Mats Design & development of Plastic Mats using Floral patterns, Geometric pat-terns, Promotional branding, etc.

18 Snehal Plastic Indus-tries.

Bharat Hariba Shindi-kumate

Caster Wheel Design of Plastic Castor Wheels for application in multiple products/Mul-ti-purpose

19 Sunrise Auto Pack Raju Suresh Neele Flyash Bricks. N. A.20 Sushma Industries Parvati Mahadeo

PhundePVC Pipe N. A.

21 Suyog Plastic. Vinay Walandikar Agriculture , Electrical, Auto-mobile.

Design & Development of Drip Irrigation Equipment.

22 Swagat Polymers Ashok R. Joshi Packaging Products Design and Development of Food-grade Food Wrap Film with dispenser and Wall Mounting System. The product may dispense Film, Foil and Paper Nap-kin.

23 Tirumala Industries Ajay Annasaheb Patharikar

Plastic Water Tank Design of new Water Storage Tank for Household, Farming and industrial use

24 Trimurty Polythenes Misal Bhaskar Hariha-ranrao

Poly Bags & Sheets For India. Design & development of a new Garbage Bag for Household, Hospitals, Hotels, etc.

25 Ulka Plastic Industries Sachin S. Thete Krishi Pipe, polymers Sheets Design of a new Drip Irrigation Pipe system26 V. P. Pet polymer Jayshree N. Somase Pet jars , pet bottles N. A.27 Varroc Polymer Pvt.

ltd. Tech. Centre Ritesh Solanke Seat Assembly, Air Filter, Body

Parts & Mirrors.N. A.

28 Yogesh Plastic Indus-tries

Yogesh Vrajlal Parmar Plastic Shed net. • Design a range of Agricultural nets using different patterns, e.g. floral, geometric, branding, etc.

• Marking at Fixed length in the net.


• Database of District Industries Centre regarding MSME, large enterprises• Database of Directorate of Industries regarding Mega Projects, SEZs• MIDC office information regarding existing and proposed MIDC• Infrastructure and DMIC Employment Self Employment data from Assistant Director employment and self employment• Maharashtra Economic survey 2009-10• Sales tax information from Assistant Commissioner Sales tax• Suggestions from committee members, industrialist, experts

References


Notes


Need Assessment Survey ReportPlastic Cluster, AurangabadSurvey byNIFT Mumbai

Supported byMCED Aurangabad, NID Ahmedabad,& Design Clinic Schemeby Ministry of MSMEsGovt. of India

2014 www.designclinicsmsme.org

Need Assessment Survey - Plastic Cluster, Aurangabad

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Transcript of Need Assessment Survey - Plastic Cluster, Aurangabad