Packages BIG

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No quality, No life SECTION 1: INTRODUCTION : History & Background Objectives of Packages Vision Statement/Mission Statement Market Standing

Transcript of Packages BIG

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SECTION 1:

INTRODUCTION:

History & Background

Objectives of Packages

Vision Statement/Mission Statement

Market Standing

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INTRODUCTION TO PACKAGES LTD

HISTORY AND BACKGROUND:

PACKAGES PUBLIC LTD is the number one firm in Asia. It is the market leader at this time.In the beginning 22 Swedish Experts came to Pakistan to run the factory and to train the Pakistani staff. Packages Limited was established in 1957 as a joint venture between the Ali Group of Pakistan and Akerlund & Rausing of Sweden, to convert paper and Paperboard into packaging for consumer industry in 1958 production of packaging cartons for different industries started. Packaging. Cartons include soaps, biscuits, cigarettes, tea, and pharmaceutical products and many others.

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SYED BABAR ALI

Over the years company enhanced its facilities to meet the growing demand of packaging product. Additional capital was raised from sponsors, financial corporations and from public in making the total paid up capital to Rs 3.1 million in 1965.

RUBEN RAUSING

At first Packages commissioned its own paper mill in 1968 with production capacity of 24000 tons paper and paperboard based on waste paper, wheat straw and kahi grass.Since 1982, Packages limited has a joint venture in Tetra Pak Pakistan Limited with Tetra Pak International to manufacture paper for liquid food packaging and to sell Tetra Pak Packaging equipment. The main industries covered by Packages:

Soap IndustryShoe IndustryTissue Industry

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No quality, No life Tea IndustryTobacco IndustryFood IndustrySweets & Confectioneries

In Tetra Pak Pakistan Limited Packages Limited has 45% shares, 6% shares owned by Syed Baber Ali Shah and 49 % owned by Tetra Pak International.

Since 1957, Packages has been producing ink for its own consumption. In 1993, the Company agreed to joint venture with equity participation from Coates Lorilleux, world’s largest ink manufacturer. Packages have transferred its ink manufacturing facilities to another company by the name of “Coates Lorilleux Pakistan Limited”.

In 1963 a joint venture was signed with “Mitsubishi Corporation of Japan” for the manufacturing of polypropylene films at the industrial estate in Hatter, NWFP. This project, Tri-Packs Films Limited commenced production in June 1995.In 1996, a joint venture agreement was signed with Print care (Ceylon) Limited for the production of flexible packaging in Sri Lanka. This project Packages Limited Lanka (private) Limited commenced production in 1998.Packaged owned 62% of this company.In 1999-2000 Packages Limited has successfully completed the expansion of flexible packaging line by installation of new rotogravure printing machine and the expansion of the carton line by a new Leman tic rotogravure inline printing and cutting creasing machine. The machine is in production since December 1999.

The Company is at advanced stage of implementing SAP, an Enterprise Resource Planning System, which through common database allows the company to fully integrated and be live in respect of all at business information. This will enable the Company to serve its customers better.

The Rubber Division working under the Research Development & Control Department is also selling its products in the local market as well as selling to the Defense Authorities apart from providing services to its own department.Another important service department of the Packages Limited is its “Power Plant”. In 1967 they set up 6 MW power plants, but to ensure a continuous and dependable supply of power for its production lines. It has also established its own power plant with 10 MW power in 1991, the cost of which was 180 million rupees..In the field of consumer product, Packages Limited has shown tremendous potential and commendable talent. Consumer Product Division provides 12% share of the Packages total sales. The consumer product of the company is “Rose Petal” Tissues. The production of Rose Petal was the first introduction to tissues paper industry in Pakistan. Through Packages has introduced various brands of tissues. Rose petal is now the market leader in tissue paper industry in Pakistan. Its has more then 75% share of tissue paper industry. Other consumer products includes paper cups, paper plates, paper napkins, paper hot cups, wet tissues of Rose Petal have been introduced in their market in 1992.

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PACKAGES TODAY:

Now Packages Limited is exporting in managerial skills & technical expertise to the third world countries like:

IndonesiaTanzaniaKuwaitSaudi ArabiaNigeriaZambiaSomaliaRussia

It also started export of tissue to countries

IranBangladeshSrilankaIndonesiaUAEMaldives

Packages have a large workshop for repairing and replacing the damaged parts. R& D control department was established to ensure quality and standard of product.Started with only 500 workers now it has more then 2782 employees working in different departments.

Today Packages is considered as one of the leading packaging firm in Asia.

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ISO CERTIFICATE :

WHAT DOES BEING ISO CERTIFIED MEAN?

Enhanced products quality and reliability at a reasonable price.Reduction in the number of models and thus reduction in costGreater compatibility and interoperability of goods and simplification for improved usability.Improved health, safety and environment protection, and reduction waste.Increased distribution efficiency, and of maintenance.

ISO 9001:

In compliance with worldwide standards, the ISO9001 Certificate has been awarded to the Flexible, Carton Division of Packaging and Paper and Board Division.

ISO 14000:

Groundwork for implementing ISO 14000 (Environment Management Standards) has been started and it will be achieved in due course of time.Packages Limited is a quality conscious organization, emphasis always remains on quality. For this reason they have employed quality seeking management. And because of this reason it got the certificate for quality in five departments:

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Flexible DepartmentCarton lineCorrugated divisionConsumer product divisionPaper & board mill

Certificates are shown on the next pages.

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GLOBAL PARTENERS:

Packages Limited has extended its expertise to a number of Third World countries in the 1970s. Management and Technology was exported to Tanzania, Zambia, Indonesia, Kuwait, Saudi Arabia, Somalia and Nigeria where packaging companies required assistance in running and managing their operations. Packages Limited has also provided technical assistance to Tetra Pak for general packaging in Kuban, Russia. Packages looks forward to expanding its horizons for more multi-cultural experiences.

The Packages Group is proud of its long standing network of friends and family, with key business partners as diverse as Print Care, Coca-Cola, Tetra Pak and Mitsubishi Corporation.

  Nestle Milkpak Ltd (NML)

Milkpak was established in 1981. It collects milk from the rural areas, processes it by the UHT method, and sells it in Tetra Pak containers. In 1988, Nestle of Switzerland bought into Milkpak and expanded its scope and activities - Nestle now owns 58% of the enlarged company. NML sales in year 2004 were Rs. 12.8 billion with 1,560 employees.top

   

  Tetra Pak Pakistan Ltd.

Tetra Pak Pakistan Limited is a joint venture between Packages Limited and Tetra Pak International, the world's leading liquid food packaging company. It was established in 1982. top

   

  Tri-pack Films Ltd.

Tri-pack manufactures BOPP film with an annual capacity of 11,000 tonnes. Tri-Pack sales in 2004 were Rs.2.05 billion. The number of employees of the company is 220. Packages Limited has 33.3% ownership while Mitsubishi Corporation of Japan holds 25% shares in the company. The Company has increased its capacity to 26,000 tonnes with a new plant in Port Qasim, Karachi, which started production in 2004.top

   

  DIC Ltd.

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A joint venture between Packages Limited (55%) and Dainippon Ink and Chemicals Singapore Pte. Limited (45%). DIC Limited has an annual capacity of 3,075 tonnes of printing ink. Sales for 2004 were Rs. 640 million. Number of employees: 131. Dainippon Ink and Chemicals is one of the largest printing ink manufacturing groups worldwide.top

   

  Packages Lanka Pvt. Ltd.

A joint venture between Packages Limited and Printcare (Ceylon) Limited of Sri Lanka. This project was set up for the manufacture of flexible packaging material. Packages Limited owns 79% of this company. Packages Lanka Private Limited has an annual capacity of producing 54 million meters flexible packaging. Packages Lanka Private Limited had sales of Pak Rs. 265 million in the year 2004. The number of employees of the company is 122.top

   

  International General Insurance Company of Pakistan Ltd. (IGI)

IGI, the insurance company of the Group, was established in 1953. It had a gross premium of Rs. 423 million in the year 2004. Number of employees: 81. Recently IGI has acquired the insurance business of Pakistan branch of Royal & Sun Alliance Insurance Plc.top

   First International Investment Bank Ltd. (Interbank)

Established in 1990, a joint venture between American Express Bank, International Finance Corporation, and the Packages Group with an issued share capital of Rs. 404 million. In the year 2003-2004 the Bank had an after-tax profit of Rs.42 million. The number of employees is 83.top

 

  Coca-Cola Beverages Pakistan Ltd.

Packages Group is a minor shareholder in Coca-Cola Beverages Pakistan Limited (CCBPL) of which The Coca-Cola Company, Atlanta, U.S.A. holds 92% shares.

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TECHNICAL COLLABORATION:

AMCOR Flexibles, AustraliaStora Enso, Sweden

JOINT VENTURE PARTENERS:

Name of Joint Venture Joint Venture with

Tetra Pak Pakistan Limited Tetra Pak International

Coates Lorilluex Pakistan Limited DIC Asia Pacific Pte Limited

Tri-Pack Films Limited Mitsubishi Corporation of Japan

Packages Lanka (Private) Limited Print Care Group of Sri Lanka

OBJECTIVES OF PACKAGES LIMITED

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Objectives are the ends towards which activity is aimed. They represent not only the end point of planning but also the end towards which organizing, staffing, leading and controlling are aimed. It works with objective of increased sales, profit and expansion programs.

The objectives for which the company is established

1. To carry on business of manufacturing and printing of cartons, packages, special containers for various commodities, utensils, and other articles, printers, lithographers, type founders, stereotype, engravers, die sinkers book binders, designers, paper and ink manufacturer and dealers in or manufacturers of any other articles or things of a character similar or analogous to the foregoing or any or any of them or connected therewith; manufacturer importers, exporters, and dealers in raw material,articles and things required for purpose of manufacture and printing of cartons, packages, specialized containers for various commodities, and to establish and maintain showrooms for this purpose; and of distributors, suppliers and sellers of the said articles and contractors for supplying them.

2. To carry on all or any of the business of the manufacturer of and dealers in paper and board of all kinds and Tetra Paper for making Tetra Pak of any type, description and dimensions, straw board, plain and corrugated duplex board, chip board, card board, box board, veener board, mill board, wall and ceiling paper, and articles made of paper, pulp, paper board specialists and board in all their branches.

3. To carry on business of stationers, printers, publishers, fancy good dealers, bill posters and advertising contractors.

4. To carry on business as producers and processors of and dealers in poultry, dairy produce of all kinds and other liquids of every description.

5. To carry on business of manufacturers and dealers in chemical of all kinds, paints, varnishes, printing inks and all other things which can be conveniently manufactured or dealt in either wholesale or retail and either as principles or agents.

6. To purchase and provide machinery and equipment for the purpose here in before as well as here in after set out and to manufacture or assemble such machinery.

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No quality, No life 7. To establish laboratories R & D center perform such research and development,

as the company may deem advisable.

8. To train workers and personnel both in Pakistan and abroad to obtain technical proficiency various fields.

9. To enter in to an arrangement with any government, state or authority, central or provisional, railway, municipal, local or otherwise, that may seem conductive to the company’s object, or any of them and to obtain from any such government, state or authority any rights, privileges and concessions.

10. To sell and dispose of the undertaking of the company or any part thereof or such consideration as the company think fit, and in particular for shares, debentures, or

Securities of any other company having objects altogether or in part similar to those of this company.

11. To invest and deal with the money of the company not immediately required in such manner as may from time to time be determined.

12. To develop and build local skills and competence in a sophisticated industry order to make the country self sufficient in its need for packaging.

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BUSINESS PHILOSOPHY:

NATURE OF BUSINESS:

Packages Ltd. is an industrial organization manufacturing packaging material which provides services for other industries. Its business is to provide packaging materials for the products of different industries. It also produces all types of tissues available in the local market as well as for export purposes.

BUSINESS VOLUME:

Business volume of Packages Limited is about four million rupees, in the year 1999.

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NUMBER OF EMPLOYEES:

There are twenty seven hundred and seventy employees in Packages Limited.Following are the professionals and experts:

Ph.Ds 3Charted Accountants 3FCMA/ACMA 4 M.B.A/M.P.A/M.B.E./M.A 52 Graduate Engineers 99 Diploma Engineers 300

Skilled Labor 2309 2770

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MISSION STATEMENT

To be leader in the market Packages serves by providing quality products and superior services to their customers while leaning from their feedback to set even higher standards for our products.

To be company that continuously enhances its technological competence to provide innovative solutions to customer needs.

To be a company that attracts and retain outstanding people by creating a culture that fosters openness and innovation promotes individual growth and rewards initiate and performance.

To be a company which combine its people, technology, management system and market opportunities to achieve profitable while providing fair return to its investors.

To be a company that endeavors to set the highest standards in corporate ethics in serving the society.

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QUALITY POLICY

We at Packages Limited are committed to producing quality products, which confirm to our customer’s requirement and strengthen our position as Quality-manage Company. Our pledge is to provide the market with the best quality products at competitive prices through a customer-driven and service-oriented, dynamic management team. To meet this obligation, the Company will continue updating of employee skills by training, acquisition of new technology, and regular re-evaluation of its quality control and assurance system. Appropriate resources of the company will be directed towards achieving the quality goals through employee’s production.

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ENVIRONMENT, HEALTH & SAFETY POLICY STATEMENT

Packages Limited shall:

Minimize its environmental impacts, as its economically and practically possible.Save raw material including energy and water, and avoid waste.Ensure that all its present and future activities are conducted safely, without

endangering the health of its employees, its customers and the public Develop plans and procedures and provide resources to successfully implement

this policy and for dealing effectively with any emergency. Provide environmental health and safety training to all employees and other

relevant persons to enable them to carry out their duties safely without causing harm to themselves, to other individuals and to the environment.

Ensure that all its activities comply with national environmental, health and safety activities.

This policy shall be reviewed as and when required for the betterment of the same.

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ENVIRONMENT, HEALTH AND SAFETY (EH & S) POLICY:

The Management of Packages Limited realizes that we live in a world where resources are finite and the eco-system has a limited capacity to absorb the load mankind is placing on it. That is why it is our belief that we must do everything practically possible to lessen the load we place on the environment and make every effort so that sustainable development becomes a reality. Packages Limited has formulated its environment, health and safety (EH&S) policy to address these issues in a more effective way. It is very clear to us that these objectives can not be realized by the efforts of the Management alone. While the general directions are to be provided by the Management, the help of all the employees will be required to transform these ambitions into reality. It is expected that all the employees will do their best to implement the policy in its true spirit.

CONCLUSION:

To see the quality policy as well mission statement and other information we can concluded that Packages Limited is Customer s oriented which gives importance to its customers and solve problems to the customers at their door step.

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MARKET SHARE OF PACKAGES LIMITED IN PACKAGING INDUSTRY:

Market Share Of Packages Limited In 2000 In

Packaging Industry (Percentage)

Packages Limited 25%

Others 75%

But there is no competitor, who has more than 10% market share. The Packages Limited has an edge over competitors in different factors:

Packages has own Paper & Board MillModern Machines & equipmentPrinting quality of productsProvides help in designing

Packages' Market Share

0%

20%

40%

60%

80%

Packages Limited Others

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No quality, No life Almost 91% of the sales of Packages Limited comprise of Industrial Products. Packages Limited is the marketing leader of the packaging industry of Pakistan. Packages Limited produces the wide range of packaging material in the country. It manufactures materials, which cover paper & board, corrugated board, plastic packing. The major industries whose packaging requirements are being fulfilled by Packages limited are as follows:

Tobacco IndustryTea IndustryShoe IndustryMatch Boxes IndustryToffee and Candy IndustryFood IndustrySoaps & Detergents IndustryBiscuit IndustryPharmaceutical IndustryChemical IndustryTooth Paste IndustryGarments Industry

PRIMARY AND SUPPORT ACTIVITIES:

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PRIMARY ACTIVITIES

Primary activities contribute to the physical creation of the product, its sale and transfer to the buyers and after sales service.

INBOUND ACTIVITIES:

Raw material for the production of paper and board is obtained locally through regular purchasing from the agricultural sector and to maintain the quality the ingredients are mixed with imported wood pulp. About 9000 tons of wood pulp and 1500 tons of chemicals (sulphur and raisin) are imported annually.

OPERATIONS:

Continuous flow is followed in the paper and board mill and assembly in the packaging division as paperboard is cut in the appropriate sizes, printed and then modified to be folded into the desired shape.

OUTBOUND LOGISTICS:

The packaging division uses all the paper produced by the paper and board mill, which are stored from time to time to accumulate in the warehouse and prevent from stock outs. Final products are transported from the production dept and the warehouse via trucks.

MARKETING AND SALES:

Packages provide packaging solutions to major consumer industries in Pakistan through cost effective packaging. They do not have to extensively practice aggressive marketing or sales, as their position is strong being the only one capable of providing high quality paper and board.

SERVICES:

There does not exist any dealer network and they do not operate in the consumer market for the production of paper and board except of providing tissue papers and toilet paper.

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SUPPORT ACTIVITIES

Support activities assist the primary activity and each other.

DEPARTMENTS:

Packages Limited is divided into ten departments. Which are as follows:

A. HR Department & personal Department

B. Pre-press planning Department

C. Research and Development Department

D. Production and Planning Department

E. CPD Marketing

F. Technical Department

G. Quality Control Dept (Covering packaging Div and Consumer product division)

H. Marketing department

I. Finance Department

HUMAN RESOURCE DEPARTMENT

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No quality, No life Regardless of the size or type of the business, any organization’s most important asset is its Human Resources. Human Resources management strives to achieve organizational goals and goals of the employees through effective personnel programs, policies and procedures. Personnel management program varies from organization to organization. If there is good performance of personnel department, then the employees of the company will be motivated and satisfied. The department manages and mobilized the human resources. There are several personnel functions, such as:

Job Analysis & DesignRecruitment & SelectionPerformance AppraisalTraining & DevelopmentCompensation & HealthEmployee RelationsNegotiation With UnionMaintaining DisciplineWelfare Programs For EmployeesGrievance Handling

Packages Limited possesses a well-organized and systematically operated Personnel Department. The success and effectiveness of this department’s policy and programs can be judged from the fact that no major problem has come to surface in the recent years.

There are 2782 workers at Packages Limited at present. In 1957, when it came into production there were no more than 500 workers employed. The retirement age is 58 years for employees. Personnel (Industrial Relations) Manager heads the Personnel

Department. Under his supervision five sections or wings of the Personnel Department work:

Legal WingPersonnel Staff WingPersonnel WingWelfare WingEstablishment Wing

LEGAL WING:

In every organization, personnel function includes the legal aspect of human resource management. As long as organizations exist, the disciplinary problems tend to occur. The Legal Wing looks after all the legal aspects and issues concerned with labor and personnel. This wing handles all legal issues of labor. Senior personnel officer heads it. Its main concerns are:

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No quality, No life MisconductCivil and Criminal CasesRevenue Cases

The Legal Wing, internally as well as externally, and with all other industries deals all legal problems of Packages Limited. It can also hire the services of outside lawyers. It also handles disputes between the labor and management and settles controversial issues. This wing also conducts the case of organization related to Income Tax. Two types of ordinances find their application here:

Industrial Relations OrdinanceStandard Order Ordinance

The Industrial Relations Ordinance gives power to employee against the employer. Usually it helps in solving the disputes, strikes, slow production, elections and other problems of labor unions. The Standard Order Ordinance gives power to employer against the employee and it enables to conduct inquiry according to civil law about leaves, disobey, misconduct, dishonesty, negligence, theft etc. Packages Limited has a computerized system. When a complaint is received from any department a "Show Cause Notice" is given and the worker is required to submit his reply within 2 days. If the reply is not received then a letter of inquiry is issued. If the worker fails to plead his case effectively, then, in accordance with the advice of the inquiry committee, the Personnel Manager has the right to terminate the worker's services or take some other action against him.

PERSONNEL STAFF WING:

This wing includes the personal staff of the Personnel Manager. The job of the clerk is to carry out all the orders and information given out by the Personnel Manager.

RECRUITMENT POLICY:

Packages Limited prefers fresh graduates than experienced once, except for high managerial posts where experience is must. The management believes in developing the employees according to the requirements of the organization.

EMPLOYEE GRADES:

There are different grades for workers. These are:

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No quality, No life Grade-1 G-1Grade-2 G-2Grade-3 G-3Grade-4 G-4Grade-5 G-5

Grade G-5 is for supervisors and G-1 is lowest grade in the organization. Packages Limited has four different executives grades. These are: Executive-1 E-1Executive-2 E-2Executive-3 E-3Junior Executive J.E

E-1 is the most senior in executive group and J.E is the most junior in this group. There are three Managers grade in Packages. These are:

Manager-1 M-1Manager-2 M-2Manager-3 M-3

In this group M-3 is most senior and M-1 is joiner. The retirement age is 58 years and extension is not granted. If the employee is needed he or she is hired on contract basis.

PERSONNEL WING:

The personnel wing performs two main functions:

1) It looks after all the sports activities at Packages Limited.2) It looks after the disputes between the management and the workers if they arise.

There is a sports hall, cricket ground, a football ground, a hockey ground and a volleyball court at Packages Limited. The Sports Complex comprises of two courts for Squash and Two Badminton courts. In sports complex there are two table tennis tables, Carom Board and Chess. Annual sports are held every year and prizes are distributed to the winners. The Personnel Wing holds all these activities.

WELFARE WING:

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No quality, No life The function of Welfare Wing is to look after all the welfare activities and facilities on the factory premises. This wing controls the Fair price shop, the Canteen and all the Messes. The evolution of this wing was the result of the management’s thought that it is a big deal to feed and clean a big factory. It is directly under the Personnel Manager.

MESS:

In Packages Limited, they believe that, the primary conditions for good health is nutritious food which is prepared under the most hygienic conditions in the company and served at highly subsidized rates. There are four types of mess in Packages Limited Lahore:

VIP’s Mess

Officer’s Mess

Supervisor’s Mess

Worker’s Mess

The food is provided at very less cost to employees in these messes. Charges of different messes in Packages Limited from each employee are:

Officer’s Mess 180 rupees/month Supervisor’s Mess 60 rupees/month Worker’s Mess 60 rupees/month

Officer’s Mess is for executive grade employees, supervisor’s Mess is for supervisors, worker’s Mess is for labor class and VIP Mess is for guests and VIPs.

FAIR PRICE SHOP:

This wing supervises the Fair Price Shop, from where employees can get all the things of daily use at lower rates than market. All consumers’ products manufactured by Packages Limited are sold over here at 20% discount.

SANITATION WING :

The job of this wing is to clean the factory area. There are two supervisors and 35 sweepers.

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ESTABLISHMENT WING:

The Establishment Wing performs the following functions:

1) Maintaining Personnel Records

2) Recruitment

3) Maintaining Personnel Strength

4) Maintaining Leave Record of All Workers

5) Keep Check on all the Staff

This wing consists of one senior personnel officer, two assistant personnel officers and, section in charge and 13 timekeepers.

TIME OFFICE:

The most important section of the Establishment Wing is the “Time Office”. All employees and workers of the Packages Limited are enrolled here. In the Time Office, employees’ records from appointments till retirement are kept, like transfer, promotion,

leaves etc. All appointments are made only when there is a new vacancy or need for replacement. There is an “Appointment Register” in which details like name, father’s name, and appointment date, address, department etc. are entered. This register also tells about the appointments made in a year and strength of all the departments.

Along with the Appointment Register, there is another register known as “Strength Register”. It shows the number of workers employed. All entries regarding the wages, allowances etc. are kept in it. All new workers are appointed on probation for one year. Three probation reports are given during this period.

This wing also maintains the personnel records. The record is being used to, calculate wages and salaries, make work plans for employees and evaluate their performance. There are two types of employees in the organization:

Employees who are paid on monthly basis.Employees who are paid on hourly basis.

Now in Packages Limited computers make all the records of employees. A card exists, for noting the time spent on job by workers, which are paid on hourly basis.

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No quality, No life The card notes time of starting and finishing by punching machines. These cards are collected by Production Department, and then they come to Time Office, where they are kept in record. Then the Time Office calculates the wages of hourly workers. In Packages there are three shifts

First Shift 06.30 a.m. To 03.00 p.m.Second Shift 02.55 p.m. To 11.25 p.m.Third Shift 11.20 p.m. To 06.25 a.m.

This Wing also supervises the activities of Gate. For making their employees punctual, the employees who come late are stopped at the gate and they are allowed to enter after the approval of the related divisional manager. There is a gate pass system in Packages Limited. People who want to go out-side the organization in duty hours; they have to submit a "Gate Pass" signed by their head of department. The time of leaving the organization and coming back to the organization is written at gate pass. The record goes to Time Office. There is a casual leave of 10 days and medical leave of 16 days on the basis of medical certificate issued by the company's medical officer. The hourly staff is allowed 14 days of

annual leave. However, for one-day medical leave no medical certificate is required. Strict disciplinary action is taken if an employee remains absent without prior notification.

An advisory note is issued for more than three absents. Packages Limited also gives bonuses for extra work. For each hour of overtime, the hourly wage is doubled. For monthly paid workers there is an attendance register. They can get leaves also. If an employee is absent for more than ten days without leave then he is issued a "Charge Sheet".

RECRUITMENT AND SELECTION CRITERIA:

Packages Limited has designed a sound but easy method of recruitment. When any department needs an employee, it sends its requirement to the Human Resource Department, which in turn advertises the vacancy in the leading newspapers and asks for the qualified people. In case of the posts requiring some years of experience, only interview method is used to select the best candidate.

RECRUITMENT OF WORKERS:

Minimum qualification for the post of the workers is Matriculation 2nd Division with science subjects. The workers should not be more than 21 years old and must be medically fit. These are employed as "Apprentice Trainee". If the performance of the worker is satisfactory during the probation period, he is hired. Normally workers get

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No quality, No life promotion after two years on the recommendation of their supervisors. This post is not advertised.

RECRUITMENT OF DIPLOMA HOLDERS:

Diploma holders in Electrical, Mechanical and Instrument Engineering are also employed. They are given a training of six months. They are employed for supervisory jobs.

RECRUITMENT OF EXECUTIVES :

1) Job Identification : When any department needs an employee, it sends its requirement to the Human Resource Department.

2) Recruiting & Hiring : For recruiting and hiring some factors are taken into consideration. These factors are as follow:

Nature of the job.Time required filling the vacancy.

If there is time to fill the vacancy, advertisements are given in the newspapers.If the vacancy has to fill immediately, the Human Resource Department contacts the authorized institutions, universities etc.

BUDGET CONSTRAINTS:

PROCESS:

The recruiting and hiring process starts from the applications submitted by the degree holders. They provide their CVs along with the applications. These applications and CVs are screened out on the basis of:

Merit InstituteExperience etc.

After this, approximately 50% of the applicants are selected for the further process. Then the H.R Department lists out the salient features of the CVs (only the accepted CVs).

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No quality, No life Then the H.R. Manager takes a test. This test is based on:

English comprehensionBasic mathematicsData sufficiencyIQ

Some questions about the particular job, for which the applicants have applied.After taking the test, the top 10, 20 or 30 applicants (according to the job requirement) are chosen for the first interview. At this stage the selection of applicants also depends on the H.R. Manager and the departmental head. Normally 30% of the applicants, who have given the test, are selected for interview.Through telephone calls or letters, the selected applicants are informed about the date and time of the interview. Normally two interviews are takenH.R. Manager and the departmental head take first interview. In this interview they observe,

AlertnessConfidenceLeadership skillsRelevant knowledge

Social acceptanceInterestsCommunication skillsFirst impressionMaturity

According to these observational factors rating or grading is made. Normally 5% rating in each factor is acceptable. Then successful candidates are called for final interview.Final interview is taken by:

General ManagerDeputy General ManagerHuman Resource ManagerDepartmental Head (sometimes)

Previous traits or factors are once again examined. After the final interview, the selected applicants are sent for medical test and then the Industrial Relations Manager issues them the appointment letters.

TRAINING & DEVELOPMENT:

Appointed persons are trained for one year, the are given the title “Management Trainee” In the Industrial Marketing, the trainees are called “Sales Executives” and after one they are given the designation of “Assistant Manager Sales”.

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No quality, No life The trainee is given a brief view (orientation) of the company, various processes, rules & regulations etc. this orientation may be from two weeks to two months.After the orientation program, the participants may ask to submit short report or presentation.After the 6 months training, the trainee goes to H.R. Manager and tells him what he has learnt in this program.Some external courses may be offered not only to the existing employees but also to the new trainees. These courses are held in,

LUMSPIM

Recently Packages has jointly entered into a diploma program with LUMS. It is 18 weeks program called Diploma in Business Administration. Two sessions of this program has passed out till now.

PERFORMANCE & APPRAISAL:

Performance & appraisal are two sides of a coin. Immediate officer appraises performance.

For the appraisal of the performance, there is a Performa, which is filled by immediate officer. This Performa is named as (PPE) Performance Planning & Evaluation.There are seven sections in this form. The particulars of the candidates are written on the top of the form.

PERFORMANCE PLAN:

In this section, some standards and targets along with time frame are given. The target given in Packages Limited is known as “SMART”.

PERFORMANCE EVALUATION:

In this section, the net results of the standards & targets given in section # 1 is evaluated or checked. Whether the person can achieve the targets in the required time frame or not.

COMPETENCY DIMENSION:

In this section, different behavioral indicators, in accordance with the performance are checked. These indicators are as follows:

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No quality, No life Communication SkillsWork OrganizationResult OrientationTeam PlayerCustomer ConsciousnessSelf-ConfidenceLeadership QualitiesDevelopment OrientationStrategic VisioningBusiness KnowledgeCritical ReasoningHuman resource Development

PERFORMANCE EVALUATION RESULTS:

In this section, there are two parts.

Part A Section # 2 score (%) Part B Section # 3 score (%)

Total score of Part A and Part B are calculated here.

STRENGTHS & LIMITATIONS:

In this section, the strengths and limitations of the trainee or subordinate are written. This is all up to the immediate officer.

PERFORMANCE IMPROVEMENT PLAN:

In this section, the immediate manager gives some suggestions and recommendations.

OTHER FACILITIES:

1) HEALTH & SAFETY:

To safeguard the health and safety of the employees Welfare Wing takes care to the medical facilities provided to employees. In this regard, periodic check ups, inoculations, and family planning programs are arranged. A dispensary with qualified doctors is working for this purpose in the factory premises.

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No quality, No life The health of the employee at the time of recruitment has to be sound and fit persons are employed who are medically examined at the time of appointment.

2) BONUS:

All the employees get handsome bonus every year, which varies from grade to grade.Employees Old Age Benefit:

Packages Limited has two different types of pension schemes. One is for management staff and other is for workers. In management staff pension scheme, Packages contributes 13% and the employee contributes 4.5% of wages. Investment is made in Government securities by this amount. Retirement age is 58 years. The employee gets 100% pension up to his life. In workers pension scheme the Packages contributes 5% of the wages, which ensures a reasonable pension on retirement. After employee’s death, his widow gets 50% of pension amount. After wife death the children can take 20% of pension until they are less than 21 years.

3) HOUSE RENT:

Employees can get house rent at the rate of 30% of their basic salary. More than 50% of the employees own their own house.

4) ADULT EDUCATION:

All illiterate workers have the facility of adult education. Qualified teachers teach adult education classes. Workers are paid for the time they spent in the classes as these studies are during the working hours. Books and other educational materials are provided free.Ali Industrial Technical Institute:For solving the problems of technical staff for Packages Limited, there is an independent training institute established by the “Ali Group” with the cost of Rs. 5 million. The institution's annual output is 230 students in different fields. In this school preference is given to the children of employees of Packages at the time of admission. Scholarship of Rs. 150 per month is given to all students.

5) HAJJ SCHEME:

The Packages Limited sends every year three employees from Grade V and one person from J.E and the above categories for Haj Pilgrimage on its own expenses. Draws are taken out for this purpose. Any worker who wants to go on Haj on his own expanses is given one month paid leave.

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6) PERSONAL CLEANLINESS:

Every worker is provided with a cake of soap each month for personal hygiene. All the workers are given uniforms. The factory provides the washing facilities and maintenance. Lockers, change rooms and showers are available to all the employees. Each worker gets two free uniforms and one pair of shoes annually and also has the locker facility.

7) OVERTIME:

Over time facility is available for all the workers.

8) SERVICE AWARDS:

The Company gives a wall clock to an employee who completes his 20 years of service in Packages Limited. Company also gives a valuable wristwatch to employee who completes 25 years service.

9) RECREATIONAL FACILITY:

The management also encourages recreational activities. Employees in groups are encouraged to go on excursion trips and the Company pays the transportation and other miscellaneous expenses. Employees can also use the rest house owned by Packages Limited in Murree.

10) GROUP INSURANCE:

Company’s policy is to have its employees safe and sound financially. So Group Insurance facility is available to all employees. The amount paid to employees on account of group insurance differs as follows:

WORKERS Rs. 30,000J.E Rs. 45,000E-3 Rs. 55,000E-2 Rs. 65,000E-1 Rs. 75,000Above E – 1 Rs. 85,000

11) ATTENDANCE AWARD:

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Among the workers up to Grade V, who shows a good record of attendance throughout the year, is provided monetary rewards and certificates.

12) CONVEYANCE ALLOWANCE:

Conveyance facility is given to the workers in the form of the Conveyance Allowance. Employees are provided adequate allowance for the maintenance of their vehicles. Some employees are enjoying the company's transport facilities. For the outdoor activities employees are provided enough fund to bear their expenses. A beautiful parking facility is also available.

13) MOSQUE:

One beautiful mosque is in the factory premises so that everybody can offer his prayers, and I observed that, considerably large number of employees uses this facility.

14) ON JOB TRAINING:

Packages Limited attached a great deal of importance to the training programs of the employees to help them to increase their skills and expertise. This helps to increase the efficiency of the employees.

15) LIBRARY:

There is a library of moderate size in Packages Limited. This library works under the Research, Development & Control Department. Many employees during the lunch break spent their time in it. All Newspapers are available here.

16) SOCIAL SECURITY:

Social Security Scheme is applicable to all the workers of the company who are drawing up to Rs. 1800. In case of injured employees, the company ensures full payment to the worker by paying the balance, in advance in addition to benefits given by the social security

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RESEARCH, DEVELOPMENT & CONTROL DEPARTMENT:

To keep up with new demands Packages Limited has a Research, Development and Control Department. This Department is considered as one of the most important department. The Research, Development & Control Department works in close collaboration with the Production Department. It helps the Production Department to maintain a standard of the products being produced. All the new materials are tested according to the certain specifications. It also has a lot of interaction with the Marketing Department. Research, Development and Control Department has well equipped

laboratories and pilot machines, which are used to test various chemicals, raw materials and machines. It enables Packages Limited to provide better quality and latest packaging to the consumer industry enabling it to introduce new product lines and develop new materials.

FUNCTIONS:

testing and suggestion of sample product development suggestion of tentative parameter for pre bulk to productionoptimizationquality and productivity of improvement cost reducing projects

LABS:

Pulp lab – wheat to paper.Chemical lab – quality control research.Physical lab – strength surface. Optical propertiesMicro labs – flexible.

Response time = 48 hrs Max

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No quality, No life The Research development and Control Department has three major areas for his research:

RESEARCH DEVELOPMENT CONTROL

1. RESEARCH:

This section is directly answerable to the Production Manager. In Research, work is done with the new ideas, the experiment is divided into parts and on each part attention is focused and conclusions or suggestions are given. Packages Limited, tries to get as many information and technology which is possible and beneficial to the organization. All such information is collected for research.

2. DEVELOPMENT:

Development is a continuous process in any organization. A lot of development is the result of feasibility studies, study of new production methods and new products. Packages Limited has a paper & Board Mill, so it uses largest number of chemicals. The "Environment Protection Agency" has set some standards for reducing pollution. The Research Development & Control Department developed new way of reducing pollution and always tries to meet EPA standards.

3. CONTROL:

Packages Limited Research, Development and Control Department ensure the quality standards off all the products produced in the factory.

Quality is synonymous with Packages Limited. Every package made by Packages Limited guarantees the use of quality materials and processing. This is all due to the strict Quality Control standards, observed at every stage of the production, from raw materials to dispatch Department. The Research Development and Control Department makes

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No quality, No life stringent requirements on quality control, which help in working consistently towards attaining better results for customers. The incoming raw materials and end products leaving the factory are constantly checked to make sure the items produced meet the expected standards. To ensure constant quality and improvement this department managed by qualified scientists.

PRE PRESS PLANNING DEPARTMENT

All efficiency of Production Department depends on the working of Planning Department. The Planning Department has the following functions:

COORDINATION BETWEEN MARKETING AND PRODUCTION DEPT:

First of all, it coordinates between Marketing Department and Production Department. It means they calculate the capacity and the availability of machines and give this

information to Marketing Department so that they can accept orders from customers. Similarly it informs the Production Department about the requirements of the Marketing Department. The availability of the machines is notified through “ Loading Charts”.For the maximum utilization of the machines and the time, the Planning Department prepares Loading Charts. The Marketing Department is informed about the time when the job will be completed and the goods will be delivered. The time to be spent on printing, cutting, folding, gluing and packing is summed up.

MAKING A BALANCE BETWEEN PRODUCTION & SALES:

Planning Department makes a balance between sales & production. It gives targets to both the departments to achieve neither more nor less. If production is more and sales are less then Marketing Department is pressurized to increase the sales.

CREATING LINK WITH PAPER & BOARD MILL:

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No quality, No life Planning Department has also a link with the Paper & Board Mill. What kind of paper the customer requires, is known by the Marketing Department and what type of paper they can use in printing, only Planning Department knows both the things. So it orders the required things and if it is not possible to produce such type of paper in their own mill then Planning Department has two options. They can import such type of paper, as the customer needs. Second option is that they can propose to the Marketing Department to use any alternative. In this way, Planning Department works as a nervous system from order placement to sales.

LOADING SHEET:

Planning Department also prepare Loading Sheets. Loading Sheets are prepared for each job and are sent to the computer. The computer gives all necessary data about the quality of paper to be used, the weight-age, other materials required etc., so that the Production Department may make all necessary arrangements in advance.

MAKING SHORT-TERM & LONG-TERM PLANS:

Planning Department makes short-term as well as long-term Plans. They project the state of the company in local and international market after five years. They also plan for the “Diversification” and “Close Down” stages. Planning Department plans for the future development.

OPTIMUM UTILIZATION OF AVAILABLE RESOURCES:

This department makes the optimum utilization of available resources, i.e. (5 Ms)

Material MachinesMeasurementMethodsManpower

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PRODUCTION DEPARTMENT

Planning and Production are the most important departments in Packages Limited. Production department controls all the operations under the factory. Planning department is responsible to plan and organize the allocation of jobs to various lines or divisions in a way that their maximum capacity is utilized and that the delivery is given to the customer by the given date.Production Manager is the head of Production department and is responsible for the production function. There is also one Planning Manager, which is under the Production manager. The Production Manager looks after the production while the Planning Manager supervises the Planning Section. The heads of the following departments are directly answerable to Production Manager and they have to present their special problems to him for advice and help:

Carton LineCorrugated Division.Flexible Packaging DivisionPoly & Paper Conversion Department.

Art Department.Camera Department.Coating Department.Cutting & Creasing Department.Lamination Department.Folding and Gluing Department.Dispatch Department.Quality Control Department.Coates Lorilleux (Ink Factory).

The Production Planning and Control unit is also directly under the Production Manager and acts as the brain cell for him. Production Department prepares internal planning of the whole Paper & Board division. It takes into account the total capacity of the machinery, and the manpower. It also arranges the resources to attain maximum utilization. The other goal is to reduce the wastage of resources. The Planning Department acts as a coordinator between the Marketing and Production Departments. This is very important in the sense that if there is no communication between the Marketing and Production Departments, a lot of confusion will be created.

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PRODUCTION PROCEDURE:

The sales staff is in direct touch with the customers. After the business has been finalized, an Internal Sales Order (ISO) is sent direct to the Production, Planning and Control Department for checking and planning out the production schedule. The Planning Officer and his staff communicate and correspond directly with sales staff. Sales staff also deals with Art Department in the initial stages of the business negotiations. Art Department prepares comprehensive, color schemes and alternate suggestions for the approval for the customer. The direct link of the Art Department ceases after the customer has approved the comprehensive. First of all the sales executive gives the customer design and made job reference to the Planning Department where Planning Assistant for Art & Camera sends the job to Art Department for finalizing the ultimate shape of the product’s design. They also prepare mechanical for the Offset and Flexographic jobs. The job then moves to Camera department, where the staff prepares the printing negatives followed by Production Department who prepare the printing plates. The plates will either go to proof press or for mass production to Offset presses. The order received by the customer to Marketing Department may be:

New jobAmended old jobRepeating job

In order to develop a new job, to create a new product or to give special suggestions to the customer, sales staff takes help from Development Manager. Development Manger is in touch with all the facilities available at the factory and develops the projects until it is fit for mass production. The new job is first sent to Art and Camera Department for the Art & design to be printed. In case of repeat order, the Production Department will receive the ISO with the sample and the job will be sent to the Planning Department.

Planning Department issues a Job Card, as soon as the Job Card is made out, Paper & Board stores arrange material. The immediate requirement is indicated in the Job Card, which has to be available in stocks, while the long-range requirements are stocked up. Production Manager has to foresee the future requirements. In case of new development, special materials are to be ordered. When substantial orders are expected in a particular line then raw materials will have to be ordered. For example, if there is trend of packing polyethylene bags then polyethylene Granules will have to be bought ahead of time.

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No quality, No life After Offset Department and Poly & Paper Conversion Department (PC) the job runs through Cutting and Creasing, Folding and Gluing and is sent out through Dispatch Department. The jobs emanating from Paper Converting & Offset Department go directly to the Dispatch Department. One important function of the Dispatch Department is to prepare Dispatch Notes for the goods sent out whether by trucks or by railway.

ART DEPARTMENT

When the blank development deptt. Develops the design according to demands of the Customers then it is sent to art deptt. In the digital form. The blank samples are designed Different soft wares are used in this department e.g. Adobe Photoshop, Adobe illustration, Freehand etc. in the digital form as well as the printouts are sent to customers to customize it. So the preparation of design is the basic purpose of this deptt.

MARKETING DEPARTMENT

“Customers forget what they have bought or good what they bought was. But they never forget how they were treated”.

(Lynda R. Paulson)

We are living in an age of Marketing. It’s a famous adage; “You don't sell what you make rather you make what you can sell”. Today in any organization, Marketing Department is of paramount importance. Because it plays a link between the consumer and the manufacturer. The function of the Marketing Department is to ensure that consumers receive what they need. If marketing department works effectively and efficiently, the whole organization is on a smooth run. The Marketing Department plays a

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No quality, No life key role in the operations of the organization. The Marketing Department of the Packages Limited is headed by the Marketing Manager who is responsible for all the marketing operations in all three offices in Lahore, Karachi & Islamabad. Packages Limited has a very effective Marketing Department, which is acting a vital role in the working of the company. This department is responsible for the sale of industrial & consumer products. Planning Division of the Production Department works closely with the Marketing Department to ensure the meeting of established targets. Packages Limited has divided into the four regions i.e. Lahore, Karachi, Multan and Islamabad. Area Marketing Managers, who are third in the line of authority, direct under the Deputy Marketing Manager, are the heads of these regions. Marketing Manager also looks after the Consumer Products Division. Each region is responsible for the sales of its area. A team assists all Area Marketing Managers, consisting of Regional Sales Managers, Assistant Sales Manger and Sales executives. There are two Regional Sales Managers under the Area Marketing Manager. One for industrial sales and one for the consumer products. Then there are Regional Sales Managers and Sales Executives. The Deputy General Manager who is also among the Board of Directors of Packages Limited is often consulted by the Marketing Manager for important managerial decisions concerning Marketing Department. The job of Area Marketing Manager is just like a Supervisor. He checks the performance of each officer. He, some times, visits the customers and asks them whether they are satisfied with the services of the officer concerned. The Regional Sales Manager acts as a coordinator between the Sales Executives and the Area Manager. Each Sales Executive is allocated a certain number of customers. The respective Executive will deal with these customers and solve their problems. In case of some trouble, the Area Manager does involve and tries to settle things. His advice is especially taken while developing, launching and pricing of new products or amending the prices of existing products and so on.

SRUCTURE OF MARKETING DEPARTMENT:

NUMBER OF EMPLOYEES:

Packages Limited has almost 40 employees in their Marketing Department. Out of these some are performing sales activities and others are in different direct marketing activities.

MARKETING OPERATIONS: Packages Ltd. has been departmentalized on functional basis. The major functions of Marketing department is discussed as below.

Marketing department is responsible for carrying out all the activities necessary to market the company products, this includes sales promotion coordination and evaluation of the

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No quality, No life performance of its sales force and formulating marketing policies and strategies. They also carry out market surveys for new as well as existing products.

The Marketing Department is becoming more and more powerful in modern organizations. Because it acts as a link between the consumer and the producer. The function of the Marketing Department is to ensure that consumers receive what they need. The Marketing Department is also responsible for the promotion of the products. Packages Limited has a very effective Marketing Department which is playing a vital role in the over all working of the company. The Marketing Department of Packages Limited, also known as the Sales Department is believed to be the bread earner of the company. This department is responsible for the sale of industrial as well as consumer products. The Marketing Department of Packages limited is headed by the Marketing Manager, Mr. Sulat Said. Packages Limited has divided the country into three regions that is Lahore, Karachi and Rawalpindi. Lahore region is responsible for the sale in Lahore and its civility. Rawalpindi region covers Rawalpindi, Islamabad, NWFP, and Azad Kashmir. While the Karachi Region covers Karachi, Sind and Baluchistan. Every regional office is headed by a Area Marketing Manager. There are two Regional Sales Managers in Lahore under the Area Marketing Manager. One for industrial sales and one is for the consumer products. Then there are Senior Sales Officers and Sales Officers. Every year, fresh graduates are hired as management trainees. After the selection they have to under take extensive training. After one year of probationary period they are confirmed as Sales Officers.

MARKETING PHILOSOPHY:

The marketing philosophy of Packages Limited in general and Industrial products in particular, moves around the policy to provide strength in:

ServiceQualityDependability

In simple words, providing good services to the customers. Also along with good quality and services. The dependability means, the customers should have trust in Packages. By making strength in quality, goods and services and being trustworthy, gaining the market share is the philosophy of Packages Limited.Another marketing philosophy is not only to satisfy the existing customers but also by doing this to attract new customers.

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No quality, No life METHODS OF MARKETING:

Face-to-face meetingsTelemarketingThrough E-mailThrough FaxGroup meetings

PROSPECTING FOR NEW CUSTOMER:

According to my discussion with the Senior Sales Manager, Ms. Humaira Shazia, that how they do prospecting for new customers. She told that first we see our production lines i.e.

Carton LineFlexible LineCorrugated division

In which division or line we need new customers and the existing customers are not fulfilling our requirements of that particular line. Then we select our target market. The selection of target market may be through market surveys. From that target market we select the potential customers, means the customers with which we can do business. Then these prospected customers are sent free counter samples. The customers use these samples and if the samples are matched with their standards. They contact with the Industrial Marketing Department for further negotiations. For their standards and satisfaction, the strength in quality, services and trustworthy are the base.

FUNCTIONS OF SALES EXECUTIVE:

Customers’ identificationCustomers’ servicesCustomers’ satisfactionDevelopment of new jobsHaving an eye on competitors’ activitiesMarket knowledgeCollection of paymentsMaintenance of timeTraining development of trainees and internees.

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TOP THREE CUSTOMERS OF INDUSTRIAL MARKETING DIVISION:

Pakistan Tobacco company PTCLever Brothers (Pvt) LimitedNestle Milkpak Limited

There are two divisions of marketing department in Packages Limited:

The Industrial Marketing DivisionThe Consumer Product Division

The performance of marketing activities of the Company has increased due to this segmentation of division. Following are the important factors that differ between these two divisions:

Distribution channels are different.Target market is different.They both have their own competitors.Marketing policies are different for each division.

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INDUSTRIAL PRODUCTS DIVISION:

WORKING OF INDUSTRIAL MARKETING DEPARTMENT:

The basic job of Marketing Department is to make sales and to satisfy the customer's needs.

ALLOCATION OF CUSTOMERS:

At Packages Limited every sales Executive and Sales Managers are allocated customers and they are held responsible for dealing with them. Every Sales Executive has a complete record of his customers and pays regular visits thus remaining in regular contact with them. On average a Sales Executive has to deal with more than 10 customers.

DAILY MEETING:

In the Marketing Department, a meeting of all the Sales Managers and Executives is held every morning. The Area Marketing Manager heads this meeting. Each Sales Officer explains the current situation of his customers and the development in the new prospects, if any. The Sales Officers also inform the Area Marketing Manager about what they did the previous day. They are then guided as to what should do, and are assigned certain duties regarding the mode of action they are to adopt. Sales people also provide current information about market. The sales people are also responsible for getting the payment from the customers. In the daily morning meeting, they have to show that how much payment they have got from their customers and how much amount is still outstanding with their customers. The Area Marketing Manager sees that which sales person is lagging behind in receiving the payments and then guides him to speed up his efforts for getting the payments from the customers.

In this morning meeting, the daily dispatch report is also discussed. The Area Marketing Manager discusses with each Sales person, the status of the order delivery of his customers. If the orders are not executing according to the schedule given by the planning department, then the Area Marketing Manager, himself contacts with the planning department and asks them to speed up the delivery process of the late orders.

DEVELOPING NEW CUSTOMERS:

Every organization aims to satisfy its present customer and at the same time tries to increase the number of its current customers. But with Packages Limited the task is

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slightly easier, since it is the largest packaging concern in Pakistan and off course the most reputed one. In order to find out the potential customers, it is the duty of every Sales person to remain well informed about the market and grab every opportunity as and when it arises if it seems profitable. Hence, the sales persons are required to carry out an active search for potential customers and have to make sure that they miss no opportunity to strike a deal that can be profitable to the organization. As a matter of fact, it is the job of sales force to track new opportunities for the organization. Although it is not an easy task, but the good repute of Packages Limited about its quality oriented production serves as a promotional tool and helps the Sales staff. Sometimes, some prospective customers directly contact the organization. The reason is the highly strong market position of Packages Limited.

PROCEDURE FOR GETTING A NEW ORDER FROM THE CUSTOMER:

Like any marketing department, the marketing people here too are supposed to attract the new customers and get the business from them. Fortunately, the Packages Limited has very loyal customers, who have been purchasing from them for a long time. So we can say that, more or less, the Packages Limited has fixed number of customers. That’s why, except Area Marketing Manager, every sales person has assigned certain number of customers. The sales Executive has to make all the dealings with his allotted customers. But this does not mean that in Packages Limited, attention is not given to the new customers. The point is that the old and loyal customers have become the permanent customers of the company. The other thing is that the company is operating at full capacity in case of carton and corrugated divisions. Only in flexible line they are below their capacity. So, mostly, they focus their attention to attract the customers in the flexible line. If a new customer comes, then he may be assigned to any sales Executive.Now there is a certain procedure through which the new order from either a new customer or the old customer is executed and final product is dispatched to the customer. The flow chart of this process is given below:

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PROCESS FLOW:

DESCRIPTION:

Process flow in Industrial Marketing Department is as follows:First of all there is contact between the customer and the sales department. The contact may be in two ways:

Customer contacts the marketing department

Industrial Marketing dept.

Art Department

Black & white mechanicalPlanning dept. for

confirmation

Confirmation of ISO

Order Confirmation

Customer

ISO IssuanceApproval

Color Print

Approval

Sample Proof

Approval

Customer’s order

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No quality, No life Sales executive contacts the customer.Now if the customer has any idea, he gives “specification” about the required product i.e. size, material, design etc. and also tells about the approximate order.The marketing department sends the specification to the Art Department to convert the idea into a shape. If the customer has no idea then it is the work of Art Department to make a design.The Art Department makes blank sample to the concerned sales executive. The sales executive also gets pre-costing report and then sends the blank sample along with quotation to the customer. The blank sample is sent to the customer to get approval of four things:

SizeMaterial usedStructure of packagingConstruction

At the same time, the quotation is also given to the customer. On quotation, the following information is given:

The price of the product according to the size and quantity Terms of paymentThe expected lead timeThe material to be used to manufacture the product The printing modeThen the customer approves the blank sample and also agrees to the quotation.Then the marketing department sends a color print to the customer for approval of:Text on the packaging Space coverage Color combinationsColor usage

After the approval of color print, a sample proof is sent to the customer. This sample proof is an original product according to the requirement of customer. Till now the main work was done by Art Department. After the approval of sample proof, the marketing department issues Internal Sale Order (ISO), one copy of ISO is sent to Planning Department for the confirmation of:

ISO numberProduct qualityProduct quantityDate of issuanceTime durationPrinting mode Dispatch date

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No quality, No life The planning department confirms the ISO, and bulk Production starts. After getting the confirmation from planning department, the marketing department sends order confirmation to the customer and by the process between the customer and the marketing department completes.

DOCUMENTATION FLOW IN INDUSTRIAL PRODUCTS DIVISION:

From Document to

Pre costing

Sales

Customer

Sales

Planning

Sales

Dispatch

Sales

Production

Sales executive

Sales

Customer

Planning

Sales

Sales & production

Planning

Production

Planning

Sales

Customer

Accounts

Accounts

Dispatch

Sales

Customer

Customer

Information

Pre costing report

Quotation

Purchase Order

Order confirmation

ISO

ISO Confirmation

Job Card

ISO amendment

Transfer note

Dispatch note

Credit note

Debit note

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DESCRIPTION:

Before the documentation flow, the customer has made the contact with the Industrial Marketing Department.

The sales manager/executive gets information from the customer and decides whether the order can be done or not.If it can be done, then the pre-costing department prepares the pre-costing report and sends to executive.From this pre-costing report the sales executive fills a quotation form and sends to the customers.From this quotation, the customer gives, the purchase order, if he is agreed with the quotation.Now if the purchase order is according to the standards and requirements of Packages, the sales executive sends the order confirmation to the customer.Now the sales/industrial marketing department issues an Internal Sale Order (ISO). One copy is sent to the planning department.The planning department issues the ISO confirmation slip to the Industrial Marketing Department.Then the planning department issues Job Card. One copy is sent to the production department and the other one is sent to marketing department.Now if there is any amendment in the purchase order, required by the customer, the IM.Department makes an amendment form and sends to the planning department so as before production this amendment can be made.After the completion of job, a transfer note is made by the production, which is sent to Dispatch section.The Dispatch Section issues the dispatch note to the marketing department to confirm the completion of job.The Account Department issues invoices, means debit and credit notes to the customer.The receipt of payments from the customer is the duty of marketing department.

Packages Limited produces good quality packaging material. Packages Limited has 25% market share in packaging industry; as a result they are the single largest packaging unit of Pakistan. There are lots of small manufacturers, which are much cheaper, but their quality is not of that par but due to low prices they are there. Major competitors are:

Almas (Pvt.) Limited Karachi Pak Paper ProductsPap Board Printers Rawalpindi Metatax Press KarachiSecurity PaperIndustrial Packaging Karachi

National Packages KarachiFriends Packages Karachi

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No quality, No life Uni Flex Printing Services KarachiRainbow Packages Limited LahoreOrient Board (Pvt.) LimitedToufique printers Lahore

SHORTFALLS AND WEAKNESSES OF MARKETING DEPARTMENT:

PACKAGES, at present is functioning without any Marketing Manager, because Marketing Manager. For the last three months Deputy General Manager is looking after the affairs of marketing department.

Marketing department is over conscious about the exercise of rules. It accepts only big orders and don’t entertain small orders. This behavior creates an environment of dis-satisfaction among small or medium size customers and the feeling of, as if Packages Limited look down upon low income people.The products of Packages Limited are perceived as highly expensive which motivate small clients to buy the products from the companies with less prices.Marketing personnel of Packages Limited very rightly claim that they have implemented the marketing plans very effectively resulting in getting 80% market share for the consumer products. However to maintain their market share they especially to advertise the paper products using the services of media.

Another important factor which can be considered as a shortfall is, that in Consumer Products Division (CPD) only one Product Manager and two Asst. Product Managers have been appointed. Generally organization which produces consumer products requires a big supporting marketing team. That is why, being market leaders in tissue and other consumer products they should have more marketing personnel. Despite achieving the predetermined targets, Packages Limited rarely offer incentives to the employees, which may adversely effect their commitment and motivation.

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PACKAGES MAIN CUSTOMERS:

Unilever Pakistan

Nestle Pakistan

Pakistan Tobacco Company.

Lakson Tobacco Company

Reckit & Benkesier

Procter and Gamble

Colgate Palmolive

Tapal

National Foods

Rupali Group

Murree Brewery

Coca Cola

KFC

FFC

PIA

CAA

Pizza Hut

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TARGET MARKET:

Packages Limited focuses its selling efforts mainly on large customers. Due to high over head costs company prefer big orders and usually pays less attention on the small customers. The whole Pakistan is included in the target of the company. In short we can say quality conscious instead of Price.

Packages Limited has defined and identified its target market for its consumer products. Target market for facial tissues includes all classes. market for napkins, and tissues includes all the restaurants, hotels and some industrial markets. Paper cups and plates are aimed for the people who are either at picnics or engaged in some sort of recreational activities. Feminex is aimed at the women belonging to middle and upper

middle class. Cottenelle is aimed at the people with monthly income of 10000 plus and also who are status and quality conscious. Infact, apart from COTTENELLE, the whole range of consumer products is aimed for middle and upper middle class.

MAJOR COMPETITORS:

Few major competitors of Packages are:

Flying PaperCentury Paper and Board Mill LimitedSaima Printer Matatex

FLYING PAPER;

Flying Paper is situated in Sheikhupura Road and its plant and machinery has originated from Korea and Japan, the plant uses wheat straw for the production of writing paper, tissues/toilet paper. Flying focused on its paper and Kraft paper for industrial use and tissue for consumer selling.

CENTURY PAPER AND BOARD MILL LIMITED:

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Century Paper and Board Mill is situated at Bhaipheru, Multan Road, its machinery and plant has originated from Germany, France, Scandinaria and Italy. The plant use wheat straw, grass waste paper and wood pulp for the production of duplex board, white paper and fine paper and poster paper.Century specializes in the production of writing paper and paperboard for industrial selling. Its capacity is much greater than any other to include any threat from the small is strategic groups, strategic groups is based on capacity of production versus variety of production has been formed.Century is the only one which has the most variety of production and produces the most quantity supplied to market and having more than 40% market share, though Packaging capacity is comparably less since it converts its production of paper and board into Packaging for all sort of purposes. Century is the second largest supplier of Paper and Board in Pakistani market. Century paper and board mill emphasizes in Industrial paper and board and supplies its products to various local companies for the use of packaging and used as printing material

MATATEX:

In flexible packaging, metatax, also Karachi based has good technology and quality.

SAIMA PRINTER:

Saima printer is Karachi based and has good quality product and competitor in offset printing. They have good technology.

THE INTENSITY OF RIVALRY AMONG EXISTING COMPETITORS:

Packages have got the market leadership in Pakistan. So there is no such threat of this kind.

THREAT OF SUBSTITUTE PRODUCT OR SERVICE:

Packages have a minor threat from Thermopole drinking cups to its paper cups. Except this there is no such currently known threat from any other substitute. Usually Packages tries to innovate the alternative to any known substitute found in packaging industry.

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THREAT FROM BARGAINING POWER OF BUYER :

This threat is prevailing as other small companies are marketing their products on comparatively low rates then Packages. But the big customers will remain with Packages as small companies (apart from their low cost) are not in a position to fulfill so large projects as Packages can do.

THREAT FROM BARGAINING POWER OF SUPPLIER:

As Packages has backward vertical integration, but a small amount of raw material has to be bought from suppliers too. Normally there is no such threat from these suppliers as well but there always is a chance for bargain.

KEY CHALLENGES FOR PACKAGES LTD:

Packages have to fulfill the following challenges in future in order to achieve super efficiencies. Measure the right set of Supply Chain Key Performance Indicators.

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Identify the capabilities in its supply chain that are most suitable to the company's business strategy, (e.g. low-cost producer, short time to market and quality of service).Quantify supply chain investments that can deliver the highest ROI (Return on Investment).Calculate earlier paybacks. Make the required cultural and organizational changes to ensure that everyone in the organization stays focused on supply chain excellence.Importance of a supply chain perspective is no more a question globally, yet it needs attention and curiosity of our people to see radical results.

FUTURE OF PACKAGES LIMITED:

Today Packages Limited is considered among the leading, fully integrated packaging complexes in Asia. It will continue to keep pace with the requirements of its customers

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No quality, No life by using modern packaging techniques and materials to give its customers value for money.

Packages Limited believes in maintaining stringent quality control standards and is continuing its efforts to implement successfully the current investment program and also to plan for further development. Next Packages plan to export to the foreign countries and develop joint ventures with companies in Iran, South Africa and in many other countries.

SECTION 2:

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MANAGEMENT SYSTEM

Organizational Chart Corporate Policies Managerial Hierarchy Policy Formation Process Managerial Policies

ORGANOGRAM OF PACKAGES LIMITED

Board Of Directors

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MANAGERIAL HIERARCHY

Advisor Managing Director Executive Board

General Manager

Deputy G.M

H.R.DManager

Commercial Manager

MarketingManager

Store Manager

I.RManager

M.I.S Manager

R & DManager

Power ManagerMechanical Manager

Mill Manager

Production Manager

AdminManager

E.H & SManager

Cost & Tax Manager

Finance Manager

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MANAGERIAL POLICIES:

Deputy G.M

Marketing Manager

D.M Manager

Industrial MarketingDepartment

A.M.MKarachi

A.M.MLahore

A.M.MIslamabad

Consumer Product

South Zone

Sukkar Zone

Multan Zone

Central Zone

North Zone

Faislabad Zone

Senior SalesManager

Regional SalesManager

AssistantS.M

Assistant S.M

Sales Executive

Sales Executive

Sales Executive

Sales Executive

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The managerial policies as adopted by Packages limited are as follows:

The price of company’s product is same in all areas pf Pakistan.

In case of consumer Product Company pays freight.

Priced can be changed by the company without any prior notice.

The Company accepts only large orders of high monetary value.

An order, which has been once confirmed by the customer, can only be cancelled at the will of company and not the customer.

In case of consumer product, agreement with customer is made once and for all.

No discounts are offered to customers.

Goods are sold against 100% advance payment.

The company doesn’t pay freight when its industrial products are shipped to the customer.

Punctuality is strongly emphasized.

All the designed and original work done inn preparing the packages of any product will remain the property of the company.

Procurement is made directly with producers so that the middleman’s profit is eliminated.

Once the goods are in transit, they become the property of customers.

For routine matters multiple suppliers are maintained to reduce dependency on any one particular supplier.

An alteration in the approved sample shall be charged extra.

Workers are encouraged to produce more through well-organized incentive system.

Selection of executive s is done strictly on merit bases and no approach is entertained in this regard.

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No quality, No life Investment is made in that project which is outside the line of company but is

expected to improve the sales of the company.

In all production processes both quality and quantity are taken emphasized.

Workers are encouraged to reduce waste and costs.

Only those workers are recruited who have some relationship with the current employs of the company.

Smooth relationship between supervisors and the subordinates is emphasized.

Company makes capital investment equal to the depreciation every year.

Swiftness in the performance of duties is encouraged.

KEY ANALYSIS:

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MACRO ENVIRONMENT:

PEST Analysis:

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POLITICAL FORCES:

As packages has lost its case for not being moving outside residential area, Govt has a legal binding on Package so move there factory in the outskirts of Lahore

ECONOMICAL FORCES:

As far as economical analysis is concerned, there is no apparent problem to Packages. As per the current conditions, interest rates are low from financial institution, so Packages are in the better position to have loan and utilize it as per there requirements

In respect of Dollar rate impact , usually Packages is importing raw material ( Mobil film, raw paper , Plastic granules , etc) from abroad. As the dollar rate increases , the Packages has to invest more in imports and vice versa.

SOCIAL FORCES:

Starting from the society expectations, it is the long felt demand of people to shift the factory out side the residential areas which was not a residential area 40 years before. As Packages has provided to 3000 families, Society is happy with this.

TECHNOLOGICAL FORCES:

Packages have the best technology range in Asia. This also gives it a competitive edge. Due to better technology packages has reduced its cost per unit. As packages has its own research and development department it is on the way of continuous improvement and innovation

As packages is the biggest company in the packaging and the market leader so it does not have any big threat of technology from other competitors

PORTER’S ANALYSIS:

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THE THREAT OF NEW COMPETITOR ENTERING THE INDUSTRY:

Packages have very low threat of new competition from local market .After the implementation of WTO, Packages has got the threat of global competitors but Packages had already planned measures for this threat.

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SECTION 3:

MARKETING MIX

Product Price Place Promotion Publicity

PRODUCTS

PRODUCT LINES:

Packages are producing the following industrial and consumer products.

INDUSTRIAL PRODUCTS:

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No quality, No life The main industries where packaging needs are being fulfilled by the company's

products are as follows:

1. Cigarette Industry2. Tea3. Soap and detergent industry4. Tooth paste industry5. Garments industry6. Shoe industry7. Food industry8. Match industry9. Pharmaceutical industry

The following different categories of packaging material are being produced by Packages.

1. Cartons2. Printed wrappers and labels3. Corrugated Board Containers

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The number of industries as a shipping packaging uses them. Detail of the above lines is given in the section 6.

MAJOR CONSUMER PRODUCTS:

The product line of consumer products of Packages Limited consists of:

i) TISSUES:

Multi coloredRose Petal Classic PerfumedRose Petal PerfumedSweet MemoriesAll FreshCool BreezeRose Petal Luxury Size Rose Petal Pocket Size

Tulip Tissues Tulip Viva TissuesRose Petal Paper TowelRose Petal NapkinsRose Petal Toilet RollsPerfumed Wet Tissues

ii) PAPER PLATES:

Full Paper PlatesMedium Paper PlatesSnack PlatesPaper Bowls

iii) PAPER CUPS:

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80cc125cc160cc200cc300cc

iv) MISCELLANEOUS:

Feminex

With loopsStickon

CRITICAL ANALYSIS:

SUCCESS AND FAILURE OF DIFFERENT PRODUCTS:

Packages Limited is actually serving other industries and provide them packaging material. Thus the possibility of failure of any product is out of question. Sometimes it does happen that certain design or material is rejected by the customer, but it is redesigned or corrected according to the demand. Basically they produce according to the orders therefore never met any failure. Packages Limited is such a big organization that it introduces everything new which needs huge investment, and being not introduced by anyone else in the market. For example, Rotogravior printing is only introduced by Packages and no anyother company in Pakistan as well as in Asia using this printing. In tissue and other consumer products also there is no major failure of any product. Every product met success accept a tissue named COTTONELLE which was printed tissue, it could not get required response. The reason for its failure was the tissue was imported and cost was high, so at the higher price people were not willing to buy.

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PRICE

PRICING STRATEGY:

PRICING POLICIES:

Everything has a price. it is very much obvious when you buy something to satisfy your need, you have to pay some price for it. but on occasions prices are decreased in the larger interests of the company. The basic objective is to reap long term gains.

PRICE DETERMINATION:

The basic formula for price determination is:

The first aim is to cover the cost. After this a reasonable amount is charged in the name of profit. Their are certain factors which affect this profit margin. these are:

a) Quantity of the orderb) Number of color to be used in printingc) Time of completiond) Future prospects

AREA PRICING:

The company has the policy to charge ex-factory prices. They are not concerned with the freight charges. All such costs are borne by buyer.

COST + PROFIT = PRICE

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PRICING POLICIES FOR CONSUMER PRODUCTS :

The basic objective behind the price determination of consumer products is to maximize the market share. The company actually wants a higher turnover.Prices are set by the marketing people by considering the following factors.

i) COST OF PRODUCTION:

Every organization strives to sell its goods on maximum profit. But the first objective is that to cover the cost of production or to sell at the break-even. Packages Limited also first seeks to cover the cost of production while the profit margin is set in order to maximize the market share.

ii) CONSUMER PURCHASING FACTOR :

This is also very significant while determining the final price. Marketing manager has to pay attention on the purchasing power of the target customers. Again the objective or philosophy behind the whole pricing concept is the maximization of market share.

iii) PRICING POLICIES OF COMPETITORS:

The price charged by the competitor is very important particular in case of consumer products. Since price is the basic factor, Marketing department always keep an eye on the track and move made by competitors. If the company starts charging high price as compared with the competitors, then definitely it is going to loose its market share.

iv) GOVERNMENT TAXES:

Another factor which affects the pricing policy is the taxes imposed by the government. Packages Limited has a policy to increase the prices with the increase in the taxes.

v) AREA PRICING:

Packages Limited has the policy to charge a homogeneous price for all of its consumers products through out the country. In this regard, enough margins are kept to cover the freight, octroi and other district taxes.

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PLACEMENT

DISTRIBUTION STRATEGIES

We know that channel of distribution means:

"The sequential linkage of the organization and relationship through which a product flows from the producer to consumer"

DISTRIBUTION POLICY FOR INDUSTRIAL PRODUCTS:

In case of industrial goods no middleman is involved. Company's sales force directly goes to the final customer and gets order form them. In this regard, Packages Limited has a direct marketing approach. Packages people believe that direct marketing is quite cheap for industrial goods. The reason which they quote is that we have enough sales force all over the country and which can cover the industry more economically. Mainly it consists of personal selling. Nominally new orders are obtained by the sales force. In case of repeated order or routine job the customer can acknowledge his order through phone, fax etc.

DISTRIBUTION POLICY FOR CONSUMER PRODUCTS :

So far as the consumer products are concerned, Packages Limited uses dealer or distributors. The company believes that the use of middleman is much more economical for the consumer products. Packages Limited has a net work of distributors, which covers the whole country. At present Packages Limited has more that 100 distributors, in more than 100 cities. Only in Lahore, there are two distributors. Company has a policy to sell its products to all those cities having population more than 200000 through its distribution system. Packages Limited supplies its consumer products to the distributors against cash. The distributor then, supplies these products to the whole seller, who in turn supplies the stuff to the retailer. And finally, the retailer sells the product to the final consumer.

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PROMOTION

PROMOTIONAL STRATEGIES:

It is the job of Marketing Department to promote the business of the organization. In Packages Limited, marketing people have different promotion plans for industrial and consumer products.

PROMOTIONAL POLICIES FOR INDUSTRIAL PRODUCTS:

So far as the promotion of the industrial goods are concerned, Packages Limited has not assigned any budget for it. And in a way they don't promote the industrial sales. But no organization can survive without promotion. The only promotion which they under take is that of personal selling. For this company need not to fix any promotional budget because it is the job of sales officers. Moreover, The Industrial Sales Division is successful enough to keep the production process always working, so the management thinks that there is no need for any other promotional activity.

PROMOTIONAL POLICIES FOR CONSUMER PRODUCTS:

Without promotion, no consumer product can be successful. Promotional activities are an integral part for marketing consumer products.The objectives behind the promotional activities are:

Increase the sales Out pace the competitor Increase the market share Higher turnover Informing the consumer Building of good will

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The management fixes the promotional budget. The basic premise is that whether the organization can afford the budget or not. Apart form this fact, there are a lot a of other factors which the marketing people have to consider, these are:

Cost of media The number of products already in the market The number of new products the company is going to launch

ALLOCATION OF THE PROMOTIONAL BUDGET:

There are number of tools that are used to promote a business. These include:

ADVERTISING PERSONAL SELLING SALES PROMOTION PUBLIC RELATIONS

i) ADVERTISING:

Advertising accounts for about 80% of the total promotional budget. This is because of the fact that all the products are of CONVENIENCE TYPE and hence, require frequent advertisement. Infact, advertising is the most popular and effective media to the advertising campaign of Packages Limited and which includes the following

a) Broad cast mediab) Print mediac) Out door media

a) BROADCAST MEDIA:

The largest share of advertising budget is allocated to the media because it is the most interesting media with far reaching effects. Although, it is the most expensive media, but the nature of the products requires its use. It includes:

TV VCR Radio

Packages Limited extensively uses the TV and VCR. While radio is not used very much. The ad about the facial tissues (Rose Petal) consists of 15 seconds and it runs on

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both the TV and VCR (that is in movies). The budget for TV and VCR is about 65% of the advertising budget.

b) PRINT MEDIA:

Print media is also an important part of promotional technique. it includes:

Newspapers Magazines Direct mail etc.

Packages Limited only places its advertisement in the magazines. Normally, newspapers are not used. It accounts for about 20% of the total advertising budget.

c) OUTDOOR MEDIA :

Marketing people normally don't prefer its use because they think that it is not very effective. it has a very nominal share in the budget. it includes billboard, road side signs etc.

ii) PERSONAL SELLING:

Personal selling is also included in the promotional mix of Packages Limited. It basically aims at the distributors. It constitutes about 10%. It includes;

* Sampling* Gifts* Cent off schemes

iv. PUBLIC RELATIONS:

Public relations has become and integral part of any promotional mix. Every company tries to build its image. Packages Limited also under take some activities in the name of public relationing but its share is very nominal.

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SECTION 4:

FINANCIAL STATEMENT ANALYSIS

Trend/Horizontal analysis Vertical analysis Financial ratio analysis

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SECTION 5:

SWOT ANALYSIS

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Strength Weakness Opportunity Threat

SWOT ANALYSIS

STRENGTHS:

One roof Customer service operation

50 year’s of heritage

Equipped with latest Technology.

Strong financial backing

Own power generation plant.

Strong relationship with customers.

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Environment conscious.

Strong HRD function

Fully integrated company.

Recycling plant to minimize the toxic effect from the water waste.

Skilled and professional employees

World most excellent inter company communication Software (SAP) is being used

Implication of Quality Standards i.e.( ISO 9000, EMS 14000, BEST, GMP & GHP, HACCP)

Employee growth opportunities

WEAKNESSES:

Too much Dependence on imported material.

Less facilities to workers.

Communication gap between management and workers.

Flat structure and overlapping of responsibilities.

Favoritism is found.

Delivery Lead time is too high (at least 4 weeks)

Weak Reward system

Red Tapism

Slow decision making

High customer turn over due to high price quotations

High dependence on foreign technical staff for operations.

OPPORTUNITIES:

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Emergence and growth of consumer products.

Trends toward high quality of packaging.

Demand is greater than supply.

Market share is 22%.

Gaining more market shares after WTO implementation

Customer retention through cheaper packaging material

To create economy of scale and decreasing per unit cost

THREATS:

High and ever increasing cost of raw material.

High energy cost in Pakistan

Increased environmental awareness.

Devaluation of Pakistani Rupee.

Global Competition (WTO)

High customer turn over due to high price quotations

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Threat of new entrant

Threat of bargaining power of supplier

Threat of bargaining power of buyer

SECTION 6:

TRAINING PROGRAMME

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Divisional or Departmental detail

Activities of intern

Projects assignment completed

CUSTOMER SERVICES DEPARTMENT

DEPARTMENTAL DETAIL:

CSD is basically concerned with the industrial customers of packages .CSD is the service provider dept to the top ten customers that are:

TOP TEN CUSTOMERS

UNILIVERNESTLEPTC

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COLGATE PALMOLIVEP&GTETRA PACKASIAN FOODSZULFIQAR INDUSTRIESCONTINENTAL BISCUITSNFL

DESCRIPTION:

The customer interacts with the sales and the sales dept make link with the CSD.Other large customers outside the city are also handled by CSD. When new the job is entered it’s the responsibility of the CSD dept to identify whether it’s NEW, CHANGE or REPEAT.CSD took all the information starting from the job order to the dispatch of material. In case of new and change job CSD intact with art pre press reproduction and planning these are different dept which carry out different activities according to the design requirement of the customer. In case of repeat job ISO is being send to the pre press that maintains its record and directs the production house for its quantity and completion date.

Then this complete information is communicated to the sales or CSD dept that ultimately

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deliver the final product to the customers. this is the complete chain of activities starting from the customer order to the dispatch’s is responsible for the accurate and complete fulfillment of the order with out any error and delay to the final destination.

BENEFITS OF CSD

The benefits of this dept to packages is

Increase customersProvide customer satisfactionRegularly link with customers so that any change in order may be possible Retain large customersManage the VMI (vendor management inventory system) of dedicated

customers

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Assistant Manager CS PortfoliosFatima Ihsan

Samreen Saleem

Mohayyud-din-Ahmad

Hamna Salman Fatima Said

Unilever -PW

Unilever -Walls

Pakistan Tobacco Co.

Nestle Pak. Ltd.National Foods

Ltd.

Unilever-LHC

Unilever -RBF

Colgate Palmolive Pak Ltd.

Continental Biscuits Ltd.

Zulfiqar Industries Ltd.

Unilever -PP

Proctor & Gamble

Tetley Tea Tapal Tea Reckitt Benckiser

Unilever -Tea

Dalda Foods

Logistics Management

Qarshi IndustriesGlaxo Smith

Kline

 SAP

Coordinator

    Clover Foods

DESCRIPTION:

The above table shows that there are five assistant managers and a manager which have been assigned to handle the orders of different companies.They are resposible for the accurate fulfillment and dispatch of orders.

DIFFERENCE BETWEEN SALES AND CSD DEPT:

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SALES:

It deals internally external affairs.It gets orders from customers.Do price negotiation with customers. Checks all tasks related to production. LogisticsCollection of checks.

CUSTOMER SERVICES: It deals all affairs internally. Job related to correct execution of material. Dispatching of material on the committed and required date.The detail of main lines of packages limited which constitute the main

functions of CSD or the basic working of CSD is given below. MAIN DIVISIONS/LINES OF PACKAGES PUBLIC LIMITED Packages Public limited is engaged in the following major activities.

Paper and Board Mill (PBD) Packaging Division Carton Line Flexible Line Corrugated Container Line Consumer ProductsBasic

agricultural raw materials such as wheat straw and river grasses are used together with imported wood pulp in the paper mill, which was established in

1968.FLOWCHART: PAPER & BOARD

MILL The paper and board is the basic input of packaging industry. If an industry is producing its own paper and board, it is very convenient for it. One of main features of Packages Limited is that it has its own Paper & Board Mill. At first, the Packages Limited used to buy paper and board from market. Then in 1968 it set up its own Paper & Board Mill with the capacity of 24,000 tones per year to manufacture various kinds of board, flutings, Kraft liners and Poster Papers conversion into different kinds of cartons and wrappers for the Packaging Division. The aim of Paper & Board Mill is to produce enough paper and board for the needs of Packages Limited.Different types of paper produced by Paper & Board Mill are: Off-set Printing Paper

Twist Proof Paper Tissue Paper Calendar Paper Writing & Printing Paper Duplicating Paper Imitation Art Paper M.G. Brown PaperRA PROCESS: Packages Limited is amongst the first companies in the world to use wheat straw for manufacturing paper and board. It has developed test liner and fluting for corrugated boxes from high yield straw pulp. This environment friendly process uses fewer chemicals, which has resulted in improved strength properties, especially with regard to the stacking strength of containersFOOD BOARD: Food Board, a basic raw material in liquid food packaging is being manufactured since 1979 for Tetra Pak Pakistan Limited. This material is used for making aseptic packaging in which milk,

Paper & Board Mill

Packaging Division

Consumers Products

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cream, oil, fruit juices and other food products are packed.CAPACITY OF PAPER & BOARD MILL: Today Packages Limited has four Paper Machines with installed capacity of 70,000 tones per annum. Used capacity of these machines is 66,000 tones per annum. The average production of one day is 180-190 tones. It also has the straw pulp and liquid packaging board facility, which established in 1992. With this, they have continued supply and better control on the inputs, which has improved the quality and customer service from the company.There are 600 employees in Paper & Board Mill. In Packages Limited 94-95% of the total pulp used, is produced in its own Paper & Board Mill. Remaining 5-6% pulp of total requirements is imported.Paper & Board Mill work under the Planning Department. Marketing Department projects it prospective sales for the coming year. These projections are then sent to Planning Department, which plans the production schedule for the Mill. In the Paper & Board Mill, this whole year plan is broken into monthly plans. The Mill staff then, finds out financial needs and these needs are passed to the Finance Department. Following are the three sections of Paper & Board Mill:PAPER & BOARD DIVISION: Machine House

Beater HouseCooking House Bleaching HouseChemical HouseMaintenanceStraw and linter preparationQuality control (Paper & Board Division)

PULP SECTION:

The function of Pulp Section is to prepare Pulp from raw materials:

PBM

Pulp

Section

Paper

Section

Utilities

Section

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WOOD-BASED:

EucalyptusPoplarPine- wood

NON-WOOD:

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JantarDhenjan KenafCotton StalkReedKahi

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Rice StrawWheat Straw

The Pulp Section has four departments, through which the raw materials pass and pulp is produced.

Straw Preparation DepartmentCooking House

Bleaching Department Beater House

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Raw material is purchased by the Commercial Department.

1) STRAW PREPARATION DEPARTMENT:

Wheat straw is available in wheat harvesting season only, therefore, the management of Mill has to buy according to its requirement and store it. From the storage yard, wheat straw and Kahi are transported by means of trolleys to the Cutter Department. Wheat straw is bought in cut from while Kahi needs to be cut. So Kahi is fed to a cutter machine, which cuts it into small parts. The raw materials are then cleaned on two separate lines. Washer and centrifugal machine are also used for clearing the dust and other particles from the raw materials. All the raw material for the production of Pulp is prepared in this department.

2) COOKING HOUSE :

This cut and clean raw material is delivered to the Cooking Department, where It is mixed with water and cooking liquor. The mixture of raw materials, water and cooking liquor is fed to rotary digesters (Huge Tanks) and cooked. In this process the fibers get separated from the binding material. This process is known as Delingnification. Straw and kahi are either cooked together or in separate digesters.

3) BLEACHIND DEPARTMENT:

In this department Pulp comes for Bleaching from the Cooking Department. If required, this Pulp could be bleached. Here this material is washed and screened and the uncooked fiber is separated in order to get refined Pulp.

4) BEATER HOUSE:

Beater House is very important department in Paper & Board Mill. Here the paper is given the final properties that we want to have in the paper some of the additions, made in this department are:

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Addition of imported Wood Pulp.Addition of sizing agents.All other additions regarding any other properties that we want in the Paper.

VISIT TO PULP MILL:

Paper and board mill constitute 50 % of the investment. The other 50 % investment includes carton, corrugated, flexible and tissue line.

TYPE OF PULPS:

Straw pulpWood pulp- importedWaste pulp

TYPE OF BOARDS:

Tetra – 150/200 - gsmDuplex (White) - 200 / 280 gsm White bleach board (Cigarette) - Tea board (WLCB) – 225 – 250 gsmBleach straw board 315 gsm Core Board 450 - KVP gsm

TYPE OF PAPERS:

Offset paperWhite paperPhoto copy paperWhite card paper

PRODUCTION:

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No quality, No life. 25000-60000 Tons.

PAPER SECTION:

In the Paper Section, we deal with the Paper machines used to make paper and board from the pulp produced by the Pulp Section. Paper & Board Mill has four machines:

PM-1 PM-2 PM-3 PM-4

MACHINE DESCRIPTIONS:

PM- 1 board M/C 3 layers 130 tons / day

PM –2 liner fluting 2 layers 75 tons/day

PM- 3 Single layer straw bleach pulp 10 tons/ day

PM –5 Paper M/C single layer 55-60 tons/ day for white jobs

PM-1:

PM-1 is bought in 1966 from “SANO IRON WORKS, JAPAN”. It had a capacity of 50 tones per day. It was rebuilt in 1981 with “GERMAN TECHNOLOGY”. In 1983 item modified for size press coating and in 1981 its steam part was modified with German Technology. This is a multiple board-making machine. It can make 3-ply board. Its width of paper sheet is 2.7 meters, and grammages range is 120-490 grams.

CAPACITY:

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No quality, No life. Its installed capacity is 120 tones per day and maximum capacity achieved by this machine is 147 tones per day.

The types of paper & board produced by PM-1:

White Duplex Board Corrugating Medium Paper Tetra Duplex Board (TDB) White Bleached Board White Card Board Kraft Line Board (KLB) Chip Board

PM-2:

This machine was bought in 1984 “BELL”, Switzerland. It can only make up to two-ply board. Its paper width is 1.83 meters, and grammage range is 120-275 grams.

CAPACITY:

It had a capacity of 50 tonnes per day. Packages Limited modified it to increase its (installed) capacity to 70- 75 tonnes per day in 1992. Maximum capacity achieved here is 90 tones per day.

The types of paper & board produced by PM-2:

Off-Set Printing Paper Wrapping Paper Craft Paper Tetra Duplex Board Brown Craft Paper

 

 

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UTILITIES SECTION:

Utilities Section is the third department of Paper & Board Mill. Under this section two main sub-sections work, they are:

Quality ControlDispatch Section

1) QUALITY CONTROL:

Various tests, e.g. water and oil absorption test, bursting strength test, are done in this section to ensured the desire quality of the paper and board. This section is also responsible for keeping the Mill working. Its major jobs are:

ReplacementMaintenanceNew Installations

2) DISPATCH SECTION:

This section has three main functions:

Storage of PaperFinishing of PaperDispatching Paper & Board

COATING DEPARTMENT

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No quality, No life. The main contents of the coating dept are:

No. Of machines working in the coating department PurposeProduction capacity Raw materialsCustomersSuppliersOutputsEmployees working on each machineMachine handlingProcesses of each machine

In coating department there are three main machines, which are performing different functions.

Coating machineDoctoring & slitting machinePoly laminating machine

The functions of all these machines are described below in details. There is one more machine, which is engaged in the production of coating materials.

COATING MACHINE:

ABOUT MACHINE:

The first & foremost operation of this department is Coating. Therefore for this purpose a coating machine was installed very first time in 1982 in this department & that time the designed production capacity was 150m/min. But with the passage of time the machine was upgraded by changing its drives & motors & now a days the per minute production capacity is 250m.

PURPOSES OF THE MACHINE:

The fundamental purpose of this machine is coating the white duplex board of different grammages, width & length. Coating is done in order to make the board good looking & fascinating. With coating the wait of the board increases. The capillary action on a coated surface does not take place & thus securing the board from water contents.

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No quality, No life. Two types of coating is carried out in coating machine

White coating Gold coating

There is only one customer of gold coating named as Pakistan Tobacco company.

INPUTS OF THE MACHINE:

White duplex board of the following grammages & the coating material are the inputs or the raw materials of the coating machine.170, 200,225,245,260,280,290,340

The unit to define these grammages is grams per square meters, e.g. 170g/meter Square.

The width of the board may vary from 500mm to 1500mm.The length of the board depends on the wait of the board. Usually 4000m to 6000m roll is enrolled in this machine. Sometimes less than 4000m roll is also used. Coating material used for the coating purposes is a mixture of water, calcium carbonate & polysalts. This coating material is being prepared in this department & shifted to the coating machine with the help of pressure. The calcium carbonate& polysalts are purchased from market according to the demand of the department.

OUTPUTS OF THE MACHINE:

The output of the machine is coated white duplex board which is the final product of the coating machine & then send to the customer via careful hands & covers.

SUPPLIERS OF THE INPUTS :

Basically the supplier of the machine is paper & board department in case of board & external market in case of coating materials.

CUSTOMERS OF THE FINAL PRODUCTS :

There are two types of customers:

MAJOR CUSTOMERS:

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No quality, No life. The main customer of the final product of machine is offset department & almost 80 %to 90% of the total production is sold to this department. But the product passes through sheeting department first then to offset department.

MINOR CUSTOMERS:

The external market is included in the minor customers category. A small Proportion of the coated board is also used within the premises of the coating department for doctoring & slitting & poly lamination.

EMPLOYEES ENGAGED IN THIS PROCESS:

Seven workers are engaged all the times in its operations & controlling process in each shift. They are engaged in accomplishing different functions.

NO. OF SHIFTS PER DAY:

The total duration of the shift is 8 hours & thus 3 shifts in a day because the machine is operating for the whole day & contributing towards maximum share out of three machines.

AVERAGE PRODUCTION CAPACITY:

It is extremely very difficult to determine the exact production of the machine per minute or per day or per month because of no. of factors which develop variations in its productions. But on the basis of previous data we can calculate its average production which is almost 250000m/day.The most important variables involved are:

Customer’s jobGrammages of the boardWidth of the board And may be some others like machine problems etc.

The actual unit of production is tons per day, which can be calculated by multiplying length of the board with grammages of the board.

FORMULA:

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MACHINE HANDLING:

The operations of the machine are completely manually handled. This is the most important factor through we can boost the average production of the machine if the operations are controlled automatically via some well-designed computerized system.

HYDRAULIC SYSTEM:

Hydraulic system is used to increase the speed of the machine & control the other functions of the machine.

EXTERNAL AND INTERNAL DECORATION OF MACHINE:

The process of coating machine is mainly consists of ten stages:

Unwinding unit1st stage coatingIR heater2nd stage coatingIR heaterBurner driverSteam cylinder drier Chill rollerBrushing unitMaintenanceWeb linerRewinding unit

UNWINDING UNIT:

In unwinding unit the board’s roll is enrolled on the excel of the machine and then passed through some horizontal steel’s cylinders to continue the coating process.

1 ST STAGE COATING:

Length*grammages

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In this stage the board is coated from one side with the help of coating materials.

IR HEATER:

In this stage the coated side is passed through IR heater for drying the coated side under the adjusted temperature.

2 ND STAGE COATING:

The same process of stage 1st is repeated here. The purpose is to make the coated board more fascinating & hide the corrugation.

IR HEATER:

The same process of drying is repeated here.

BURNER DRIVER:

For more drying the water contents from board, the board is passed through the burner driver in which the drying is done with the help of Sui gas, or in other words we can say

the remaining moisture from board is removed by burner driver. Because the IR heater is unable to remove the complete moisture from board.

STEAM CYLINDER DRIER:

In this stage on the back side of the board the steam is spurted in order to develop a specified level of water contents in board & then dried in the same unit. The purpose is to make the board wrinkle free.

CHILL ROLLER :

Then the hot & dried board is passed through the chill cylinder.

BRUSHING UNIT:

The board is passed through the Brushing unit in order to increase the shinning of the board.

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No quality, No life. WEB LINER :

After brushing unit the board is passed through the web liner in order to maintain the sides of the board means trimming is carried out here.

REWINDING:

In this step the finally completed product is rewinded with the help of some automatically moving excel on a core.

DOCTORING AND SLITTING MACHINE:

Doctoring and slitting machine also comes under the same umbrella of coating department. This is the 2nd operation taking place in this department.

PURPOSES OF THE MACHINE:

The fundamental purpose of the machine is to identifying the defects still existing after coating of the white duplex board & make the board defect free so that the quality can be sustained & to get customer satisfaction which is the ultimate objective of the coating dept.There is another purpose of the machine named as: slitting the board into two halves of any size according to the customer’s job.

INPUTS OF THE MACHINE:

White duplex board of the following grammages is the inputs or the raw materials of the doctoring and slitting machine.170, 200,225,245,260,280,290,340The unit to define these grammages is grams per square meters,e.g 170g/meter square.The width of the board may vary from 500mm to 1500mm.

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OUTPUTS OF THE MACHINE:

The output of the machine is error free & refined WDB in slitted form, which is then, send to the customer via careful hands & covers.

SUPPLIERS OF THE MACHINE:

The coating machine is the only supplier of the inputs of doctoring and slitting machine. Not every roll of board comes for doctoring & slitting but only those, which are the requirement of the customer.

CUSTOMERS OF THE FINAL PRODUCT:

There are two types of customers:

MAJOR CUSTOMERS:

The main customer of the final product of doctoring & slitting machine is Lemanic department & almost 90 %to 95 % of the total production is sold to this department.

MINOR CUSTOMERS:

The Offset department & the external market is included in the minor customers category. Before to the offset department the product goes through the sheeting department & then to the offset.

EMPLOYEES ENGAGED IN ITS OPERATIONS :

Two workers are engaged all the times in its operations & controlling process. One is responsible in its operations control & the other is engaged in supporting the operator & he is given the designation of AO (assistant operator).

NO. OF SHIFTS PER DAY:

The total duration of the shift is 8 hours & thus 3 shifts in a day because the machine is operating for the whole day.

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AVERAGE PRODUCTION CAPACITY:

It is extremely very difficult to determine the exact production of the machine per minute or per day or per month because of no. of factors which develop variations in its productions. But on the basis of previous data we can calculate its average production, which is almost 45000m/shift to 55000m/shiftThe most important variables involved are

No of defects & jointsGrammages of the boardWidth of the board And may be some others like machine problems etc.

The actual unit of production is tons per day which can be calculated by multiplying length of the board with grammages of the board.

FORMULA:

MACHINE HANDLING:

The operations of the machine are completely manually handled. This is the most important factor through we can boost the average production of the machine if the operations are controlled automatically via some well-designed computerized system.

HYDRAULIC SYSTEM:

Since the main purpose of the machine is to remove all the defects and errors and to make some new joints according to the demand of the customers so for this purpose the machine have to stop abruptly at the already existing joints to make new ones therefore to stop immediately the hydraulic system is helpful in its prompt shut down.

Length*grammages

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EXTERNAL AND INTERNAL DECORATION OF THE MACHINE:

The Doctoring and slitting machine is mainly divided into three parts:

Unwinding unitWinding unitWeb liner

UNWINDING UNIT:

In unwinding unit the board’s roll is enrolled on the excel of the machine and then passed through some horizontal steel’s cylinders to continue the Inspection process.

WEB LINER:

In this division the sides i.e. the width of the board is maintained according to customer’s job and the damaged sides are cut down.

WINDING UNIT:

In this unit the board is refold after its inspection into two halves of any size. The instrument, which is used, for slitting is Blade Cutter. During winding the tags are used to mention the new joints made by the operators of this machine.

POLY LAMINATING MACHINE:

Poly laminating machine also comes under the same umbrella of coating department. This is the last & final operation occurring in this department.

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No quality, No life. PURPOSES OF THE MACHINE:

The fundamental purpose of this machine is to protect the paper or board from water contents and thus strengthen the paper or board & so causes to enhance the life of the paper or board by sandwiching the polyethylene with the paper or board. This machine is also used for alfile lamination of the paper or board. The detailed of the process will be discussed in the later part of the machine.

INPUTS OF THE MACHINE:

White duplex board and paper are the inputs or the raw materials of the Poly laminating machine. The details of the paper and board have been described earlier.

OUTPUTS OF THE MACHINE:

The output of the machine is poly laminated paper & board which is the final product of the poly laminating machine & then send to the customer via careful hands & covers.

SUPPLIERS OF THE MACHINE:

Basically the supplier of the machine is paper & board department but sometimes we use the final products of coating machine as well as doctoring & slitting machine. Not every roll of paper & board comes for poly laminating but only those which are the requirement of the customer.

CUSTOMERS OF THE FINAL PRODUCT:

There are two types of customers:

MAJOR CUSTOMERS:

The main customer of the final product of poly laminating machine is CPD (consumer products department).

MINOR CUSTOMERS:

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EMPLOYEES ENGAGED IN ITS OPERATIONS:

Three workers are engaged all the times in its operations & controlling process.

NO. OF SHIFTS PER DAY :

The total duration of the shift is 8 hours & only 2 shifts in a day because the demand of the product is responsible for its two shifts. When there is no demand of poly laminated paper or board then the machine is shut down& the operators are shifted to the other machines working in this department.

AVERAGE PRODUCTION CAPACITY:

It is extremely very difficult to determine the exact production of the machine per minute or per day or per month because of no. of factors which develop variations in its productions. But on the basis of previous data we can calculate its average production which is almost 35000m/shift to 40000m/shift.

The most important variables involved are

The demand of the customerGrammages of the boardWidth of the board And may be some others like machine problems etc.

MACHINE HANDLING :

The operations of the machine are completely manually handled. This is the most important factor through we can boost the average production of the machine if the operations are controlled automatically via some well-designed computerized system.

HYDRAULIC SYSTEM:

Hydraulic system is used to increase the speed of the machine & control the other functions of the machine.

EXTERNAL AND INTERNAL DECORATION OF THE MACHINE:

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The poly-laminating machine is mainly divided into six parts:

Unwinding unitWeb linerExtruderChill cylinderSecondary unwinding unitWinding unit

UNWINDING UNIT:

In unwinding unit the process is similar to the doctoring & slitting machine. The board or the paper’s roll is enrolled on the excel of the machine and then passed through some horizontal steel’s cylinders to continue the process.

WEB LINER:

In this division the sides i.e. the width of the paper or board is maintained according to customer’s job and the damaged sides are automatically being cut down.

EXTRUDER:

In this unit the board or the paper is provided with melted polyethylene & then one layer of paper or board & the other layer of poly go hand in hand under a high temperature.

ABOUT POLYETHYLENE:

We import low-density polyethylene named as “LOTRENO” from Qatar. The material is available in Pakistan’s market but actually the aim of the Packages is to provide the quality product to the ultimate customer. Since the quality available in this market is not up to the mark. That’s why we not purchase the polyethylene from our market.

CHILL CYLINDER: In this unit the poly plus paper or board are chilled with the help of chill cylinder which operate at very low temperature. This is the last process of the machine. Here the final product is completed & the paper or board is poly-laminated.

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No quality, No life. REWINDING:

In this step the finally completed product is rewinded with the help of some automatically moving excel on a core.

SECONDARY UNWINDING UNIT:

In this unit some sort of sandwiching functions take place. That sandwiching includes all filing of the paper or board under some specified temperature.And at the end the same process of rewinding takes place.

IMPACTS OF KASUR PROJECT ON THE PRODUCTION OF COATING DEPARTMENT:

The exact date of the initiation of Kasur project is not obvious. But it is hoped that it would take almost 8 to 10 years to start. Due to this project the production capacity will increase from 50 to 70 % of the existing production. The basic purpose is to capture the external market with a maximum share. All the deficiencies will be removed from the department like bad working conditions, manually handling of machine etc.

CARTON LINE

Carton line planning starts right from the receiving of ISO till the execution of the job. Carton Line division is the largest printing division in Packages. The sales of carton line accumulate to 55% of the total annual sales of the company. It has a vast printing mode as this division has 12 machines, on which the orders are being printed currently. Carton line use the Duplex Board for printing that gives the extra effect, which satisfy the

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No quality, No life. customer greatly. There are two Varnishing machines and one laminator machine. This printing facility is available from two to six colors. These machines use oil-based ink. The customers who demand of carton line printing are the makers of tea, detergents, soaps, shoes, food, cigarettes, biscuits, matches etc.

FLOW CHART :

Paper & Board mill /PBD

Provides board in two forms

CoatedUncoated

Coating Dept

Paper store

Printing

Offset printing

Lemanic printing

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DESCRIPTION:

In Carton Lime the sheets for printing, come from Paper & Board Mill. These sheets are first coated so as printing can be done.In Carton Line, Offset printing is done. As I have earlier discussed there are twelve machines for the purpose of printing. If the requirement of job is six colored, it is sent to the six-colored printing machine.When the sheets have printed, these are sent to another section where cutting & creasing is done. After the cutting and creasing, the flaps or unit cartons are separated from the main sheetAfter this if the customer wants these flaps to be folded & glued. Then these flaps are sent to folding & gluing section. Otherwise bundles are made and sent to the dispatch section.

TYPES OF CARTONS

Straight cartons Crach lock cartons Tapper corners cartons 4 corners cartons 6corner cartonsTop and bottom cartonsShell

TYPES OF PRINTING: There are two major types of printing in carton line.

OFFSET PRINTINGROTOGRAVURE PRINTING

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OFFSET PRINTING METHOD:

It is modified form of Lithographic printing method. The fleet of offset printing machines includes:One single color-printing machine (Heidelberg)Two –Two color press (Planeta)One-Two color press (Heidelberg)Two five- color presses (Man Roland)One six-color press with double coater (Man Roland)

COLORS:

The basic colors used in this deptt are

CyanMagentaYellow Black

ROLLERS:

Two kinds of rollers are used

Inking rollers Dampening rollers

CYLINDERS

Three kinds of cylinders are used in it

Plate cylinderBlanket cylinderImpression cylinder

PRINTING MODE:

In the Carton Line the printing Mode is offset.

Ink Plate Blanket

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Offset printing is the art of printing from a flat surface. In this method, first the Plate (cylinder) takes ink and coats on the Blanket (cylinder) but the reflection is reverse (off) on the Blanket. Further sheet (white duplex board) passes in between two cylinders, Blanket and Impression. Now on the sheet printing is straight (set).Each Offset machine has different cylinders i.e., six-color machine has six cylinders, and five-color machine has five cylinders and so on. Each cylinder is used for the printing of a specific color. The cylinder takes the ink from the ink pan and prints it on the paperboard running on the other cylinder. The paper goes forward and then another cylinder prints another color and so on, until the sheet is printed according to the right format. The Duplex board is used in this form of printing. The weight of board is 240 to 490 grams.

OFFSET PROOF:

In Carton Line there is a section known as Offset Proof. In section, the sample (proof) of the required job is taken before the bulk production. This is done just to verify that after printing and cutting & creasing the flaps or unit cartons are same as required be the customer.

THE LITHOGRAPHIC PROCESS: The lithographic printing process is a combination of a oil and water with the basic printing process:

The image area needs to be “oil –liking “The non-image area must be “water –liking”

LITHOGRAPHY was the first printing process to make its whole plate, graphics and text together, photographically and photo mechanically.

PLATE The printing plates are most commonly made of aluminum coated with a layer of photosensitive coating.

Sheet

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BLANKET In offset lithography, the inked plate does not come in direct contact with the paper .it is transferred to a blanket which in turn makes the impression on the paper. Because of the double reversal of the image in offset, the plate image is direct one.

The invention of Lithography is credited to Alois Senefelder in 1798 in Munich, Germany. He became interested in letterpress printing and worked with different printing plates, inks and surface treatments. Offset printing method is in the sheet form and intermittent operation and cutting and creasing and folding &gluing are subsequent operations.

INPUTS FOR OFFSET PRINTING DEPT:

1 Board from paper store2 plates (printing and flexo) from reproduction3 inks from Coates

4 job card from planning 5 production supplies from market

ROTOGRAVURE PRINTING METHOD:

In rotogravure printing method, special [printing cylinders are used in which the printed area is e4ngraved in the form of small microscopic cup shaped cells. These cells act like a water wheel and picks up the ink from the ink tank. A doctor blade is mounted which wipes off all the extra ink just leaving behind the ink in the cup shaped cells, which ultimately throws the ink on the board forming the required printing. Like offset printing, for each color of the job there is an independent printing unit. The equipment at Packages capable of doing such kind of printing is known as LEMANIC machine. It also has the facility of inline embossing and cutting creasing. This machine can work equal to five departments. This is the latest machine, not only in Packages but also in Pakistan for the finest printing. Printing mode used in LEMANIC is rotogravure. This machine comes under the Carton Line but the difference is this, printing method is rotogravure and instead of sheets, complete reel is used.

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FLOWCHART

DESCRIPTION:

The process starts from the reel stand unit. White duplex board reel is attached to the reel stand. From the reel stand the reel automatically starts passing through the next section. In this section at a time two reels are connected to reel stand. One reel starts processing and other one is on stand by. The joint of these reels may be automatic or manual. The process of one is completed in 20 minutes.In the next unit, Festooning, mainly two works are done:It makes the alignment of the reel It makes the paper tight according to the given speed.

The next unit, in feed, feeds the board to the next unit for further process, which is printing.There are six printing units; the necessary printing units are used according to requirement of job. The printing method is Rotogravure.The purpose of varnishing is to protect the board from water and oil effects and also to make shine on it. In the next unit, quality of printing is checked. The machine is totally computerized and without any manual work it can check the quality and if there is any deviation, it can warn the supervisor.

Duplex board Reel

Reel Stand Festooning

In feed Unit

Printing Units

Embossing cylinder

Dispatched

Bundling Cutting & Creasing

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In the section unit, cutting & creasing is done. Dyes are used for this purpose and machine works automatically.

The operator instructs this unit, and after a certain limit the bundles of flaps are collected by the machine and are sent to the last section.

In the last unit dispatching is done manually.

TYPES OF VARNISH:

There are various types of varnishes depending upon the job or customer requirement.

1 simple water based varnish 2 UV-Lacquer 3 Odorless UV –Lacquer for food cartons 4 Matt finish varnish 5 Water barrier varnish for paper cups.

RAW MATERIAL INFORMATION:

The following is the variety of board being used in carton line.

1 white bleached board2 white cardboard3 SS White duplex boards4 white-lined chipboard5 unlined gray board (uncoated)

In addition to the above following are also developed

1 gold-coated board 2 metalized coated board

Also any other variety of board available globally can be arranged depending upon the ordered quantity and frequency

LIMITATIONS OF EACH PRINTING METHOD:

The major limitation in offset printing is the color consistency. Though the job is printed within the limits of shade card reference but unlike rotogravure printing there are various

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No quality, No life. color controlling factors. The inks are in the paste form and oil based. The printing is mostly dependent upon the dot shape, size and pressure of the blanket cylinder on impression roller. It is suitable for short run and half tone jobs. It is capable of giving best

picture results, which are not in the case of rotogravure. Rotogravure is highly suitable for long length jobs like cigarette cartons, detergent cartons and tea cartons. It has higher setup time in case of new job. Once the rotogravure machine is setup, it gives the final output in cut creased form much faster than offset printing route.

QUALITY AND REJECTIONS:

The following are few defects, which causes rejection in cartons.

Color variation.SkinsSmudgingInk SplashesOff settingPoor creasesCut to print mis registrationPrint to print mis registrationTorn creasesPoor GluingOpen seam

For a sale officer, whenever a customer puts a rejection, he must immediately visit him and check the consignment himself .If the problem is rare it should be reported to the production planning immediately so the sorting can be arranged on site, but if the complaint is on the larger scale then a person from production will first check and hen the material should be sent back to factory, as unwanted transportation further damages the material.

ACTION TO BE TAKEN TO SAP:

Whenever a sale officer books an order he puts it in the company records electronically in the form of sales order, similarly the customer rejections the reversal of sales order in

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No quality, No life. which he has issue a credit note request and sent it immediately to production planning for further procedure.

MAJOR CUSTOMERS:

PTC

NESTLE

UNILEVER PAKISTAN LIMITED

NATIONAL FOODS

CPD

COLGATE PALMOLIVE PAKISTAN LIMITED

QARSHI

TREET

SUBDIVISIONS IN CARTON LINE :

CUTTING AND CREASING SORTING AND BREAKING FOLDING AND GLUING

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CUTTING AND CREASING DEPT

INTRODUCTION:

The cutting and creasing department is divided into two main sections.

1 Cutting creasing machines section (production area)2 Die making section

CUTTING & CREASING SECTION (PRODUCTION):

Cutting and creasing process comes after the process of offset printing. The sheets which are printed in a specific layout in offset printing dept, are converted in the form of separate cartons in cutting and creasing dept.. Following processes are done in the C.Cr dept.

Cutting & CreasingEmbossing

Mostly, all the above-mentioned processes are carried out simultaneously, but sometimes it happens that cutting and creasing are done in one operation while the embossing is done in another operation, depending on the nature of the job.The main inputs of cutting & creasing machines are:

Printed sheets from offset printing deptCutting creasing dies from Die making section

The cutting creasing dies are made according to the printing layout, these dies are carried to the cutting creasing machine when the job is to be set for running. The operator sets out the job on the machine and checks the following parameters.

Hard cuttingCreasing pressure and formation of creaseEmbossing pressureCut to print registrationEmboss to print registration

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All these parameters are very important regarding the quality of the product.

DIE MAKING SECTION:

In the die making section, cutting and creasing dies are made for the process on the cutting and creasing machines. These dies are made according to the printing layout for any specific job. This means that for every printing job there will be cutting and creasing die and the layout of the die will be according to the printing layout. The inputs of the die making section are:

Plywood

Cutting blade

Creasing blades

Counter sheets (Pertinex)

Cito

Rubber

Glue

Embossing Polymers

FLOW CHART OF CUTTING AND CREASING

FLOW CHART OF CUTTING AND CREASING

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FLOW CHART OF CUTTING AND CREASING

Local& importedrubbers Pertinex/cito

Cutting & wood Creasing rules 18/12mm

18mm wood

12mm stripping wood

Pre bent blades

C.CrStore

Rubber Cutting

Rule Processor Laser

Cutting

Cito Cutting

Counter Milling

Designing

Broaching

Bending

DIE

Printed sheets

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SAMPLE MAKING:

Sample making is also done in this section. A concern of most of the sales officers with this section is with reference to sample making and new developments. This is very important to note that any new development or new job related to Business Unit Carton has to adopt the route that passes through the die making section, which also serves the purpose of carton line development. Any new development starts with the provision of blank samples of the desire construction and sizes and after approval ordered for bulk production.

FOLDING AND GLUING:

INTRODUCTION:

Three types of operation are being carried out in folding and gluing department.

Folding and gluing manually with machinesWindow patching Paper cups formation

DESCRIPTION OF FOLDING AND GLUING PROCESS:

Cutting & Creasing

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No quality, No life. FEEDER SECTION:

Operator adjusts the feeder according to the size of the cartons. He sets the carton in the middle of the feeder. Feeder gauge is adjusted on the unprinted area of carton. Operator also keeps the gap of 1mm on both sides of cartons between carton and feeder side plates.

PREBREAKING SECTION:

The purpose of prebreaking section is to soften the 1st & 3rd creases for easy opening of cartons at the customers end.

GLUING UNIT:

Gluing unit is set according to the center of gluing flap of cartons. The gluing wheel rotates in the pot of glue and the scraper controls the quantity of glue applied on the cartons. The suitable amount if glue is applied according to the width of the gluing flap of cartons. Normally we are using the 3 mm width of gluing wheel.

FOLDING SECTION:

The folding section is that in which the carton is folded at 2nd &4th creases. The tapper wheels are so set that the left side of carton is folded 1st and the right is overlapped on the left side of cartons .

EJECTING UNIT:

The purpose is to create the distance between the cartons and to help the overlapping of cartons at the streamline. The counter and kicker are set according to the quantity required for packing in corrugated cartons or as per the demand of customers.

PRESS:

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No quality, No life. The purpose of press is to give the curing time to glue, which is applied, at the cartons for sealing. The pressure at the press is adjusted according to the type of carton and the type of glue being used.

HANDY PACK UNIT:

Handy pack unit is used to pack the cartons in the corrugated board boxes more easily at the high speed of machine.

WINDOW PATCHING PROCESS

The purpose of window patching unit is to glue the poly at the internal side of the cartons, which have the window in it like tissue cartons.The process of window patching is that the feeder is set according to the width the cartons and then the conveyor chains are set according to the carton alignment .the stereo is set according to the window of the carton and glue is applied. After the glue application, the cutting of the poly, which is being done with the help of two cutting blades, is pressed at the carton. After this, the carton is left under pressure so that the poly sticks with the cartons.

FLEXIBLE LINE

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No quality, No life. INTRODUCTION:

With improved barrier properties and lower cost compared to rigid packaging, flexible packaging is steadily gaining importance in the packaging industry. Our flexible line makes high quality packaging films and laminates, and offers other specialized services such as rotogravure printing and sleeve making.

Flexible packaging combines different plastic films, aluminum foil and paper to produce laminates of two or more layers for providing layered protection against moisture, gases and odors. used where colorful package design and preserving product quality are important, such as in the food and pharmaceutical industries, flexographic printing offers economy with quality.

The BU (business unit) flexible has 3 major areas

FP (flexible packaging) PC (paper conversion)Planning

FLEXIBLE PACKAGING:

Flexible Packaging was introduced in 1986. The flexible packaging is basically made from the poly grains, which gives the silvery effect to the packaging. It includes the plastic films, aluminum foils and paper or the combination of these. In flex graphic printing two major things are used, stereo and sleeves. The stereos are the designs of the required job, that the customer demands, that are to be made on it. It is pasted over cylinder. The sleeves are almost the same as stereo, but it is pasted over a plastic roll. Flexible Packaging is used for the shopping bags, food products, garments, cigarettes, biscuits, pharmaceutical goods, tooth pastes, cosmetics, toilet soaps etc.

POLYETHYLENE SECTION:

Packages Limited manufactures and prints high density Polyethylene from 12 grams to 60 grams. And in case of low density Polyethylene it is 20 to 150 grams. In the Poly Section Polythene is made.

TECHNICAL EXPERTISE:

Fexographic printingRotogravure printingLamination

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No quality, No life. ExtrusionBag and sleeve making

FLOWCHART OF POLYETHYLENE

DESCRIPTION:

Poly grains are the raw material for poly making. These poly grains are put into a machine named Extruder. Extruder is of two types:

1) Single cylinder2) Five cylinders

Extruder has a main unit. The poly grains from cylinders come to this main unit, where these are melted. After melting air pressure is made and filled in melted poly grains, in this same unit. Due to the air pressure the poly comes out in the form of balloon. Further oxidizing is done. It is a process by which blue rays are passed from the poly, so that the poly can be printable. Further poly is cut into two separate sheets and is rolled separately. Poly is of two types:

Low Density PolyHigh Density Poly

Low and high poly is due to the poly grains used as raw material.

PAPER CONVERSION:

Paper conversion was introduced in 1971. Paper conversion is also made from the poly grains, which are converted into packaging through rotogravure printing. The process thus converts it into the paper and bags, which are in the reel form. There is no board, which is used in the printing of this packaging. In rotogravure printing the paper’s surface is make to look shiny and reasonable, by the poly carination process.

Printing in the Poly & Paper Converting department is done in several forms:

Polygrains Extruders Melting

Air pressureCutting Oxidizing

Poly

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Printing & Conversion of PaperPreparing & Printing Polyethylene bagsPreparing Aluminum FoilsPreparing Gum TapesPaper Cups & Plates

Fine printing is get from Rotogravure printing which is expensive than Flexographic method. The operations are carried out on various machines. Operations include printing, polyethylene extrusion, cutting, creasing, slitting, bag making, waxing etc. The Paper Conversion Department has the following machines. This department split into four sections.

CAPACITY:

Out of four Flexo-graphic machines, one six-color printing and the rest are four color-printing machines. Hence, In Flexo-graphic printing, Packages Limited has the facility to print from two to six colors. In PC Department there is 30 thousand meter per shift production. There are six Slitting machines, which are used for several kinds of slitting. In Flexographic printing water-based ink is used. The machine gets ink from one side and prints it on the other side. All printing machines are imported from Sweden and Germany. The management and operators believe that German machines are very good and their production is also more. The production of six color machines while using Polyethylene is from 1500 to 1700 meters of Polyethylene per hour. Four color printing machine prints about 2400 meters of paper per hour. Total production of these machines per shift is 30000 meters.

In the Poly Lamination Section, Poly Lamination is done on paper’s surface to make the surface seasonable and shiny.

PC PROOF:

In this section, after making the stereo/sleeve, the sample (proof) of the job is taken before the bulk production. Just to verify that work is according to the job requirement.

CONSTRUCTION OF PC DEPARTMENT:

Single side sealed

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No quality, No life. Double side sealedTriple side sealedWrapper formReel form

PLANNING:

The planning is the heart of flexible line. it acts like a central head quarter for the BU Flexible and perform the overall management and planning for PC and FP all the correspondence and business transactions of BU Flexible with sales , CSD , imports, costing , commercial ,reproduction, pre press, production, main dispatch , paper store ,Coates lorilleux, board mill , CPD and Tri pack are carried out by planning . the planning is also responsible for attaining the invoice target and acts as a spokes man and representative for the BU at different forums

The core function of FP planning starts when it receives an ISO (internal sales order) from the sales Dept Job status shows the category of the orders in such a way that it assures that placing of the order in the company and the customer’s profile. The job status shows the cluster o jobs that the product has. This category includes the new, repeated and repeated with change jobs. The new jobs shows that the required kind of print or packaging was not previously ordered by the customer and nor the company ever produced something of the sort. The new job is entirely unique and exclusive. The planning Dept wait for the customer approved co lour print from prepress. After receiving the co lour print, the planning forward the job to the reproduction Dept for the preparation of roto proof. The reproduction Dept uses the co lour print and direction on the job card to prepare roto proof which is then return to the planning Dept .the planning Dept returns it to the pre press which gets it approve d from the customer .the customer’s approved roto proof in conjunction with all the germane instruction is used by production to deliver the final bulk. The repeated jobs shows that they have been ordered before and the customer like the previous product, which is why he is asking for more. The repeated with change jobs shows that the order has been lastly accepted by the customer, but this time he/she wants the same kind of packing and printing but with some amendments in it.

The foremost responsibility of the planning is the issuance of the daily production plans, which encompass the printing, lamination, waxing, extrusion, slitting, cylinder making and cylinder-proofing program. the planning also issues daily program for the transference and dispatch of materials .an other imperative and paramount planning activity is the ordering of the raw materials based on RSF(rolling sales forecast ),projections ,heuristic approach and any capricious situation .it also makes cognizant effort to desiccate the dead stocks and CR(customer return) materials from time to time .The benchmark for the performance of planning is the realization of invoice targets and commitments dates.

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No quality, No life. Thus, the flexible planning Dept is not only a very significant part of the overall supply chain but also acts as a nucleus of the activities for the BU Flexible

.

HIERARCHY:

BU MANAGER:

ALI ASLAM

PLANNING ENGINEERS:

TEAM

BUSINESS DEVELOPMENT MANAGER:

KHALID QUDOOS

TECHNICAL MANAGER:

ISHTIAQ FAROOQI

PRODUCTION MANAGER:

LUQMAN KHALID

AREA INCHARGES:

PRINTING INCHARGRE (ROTO):

NAUMAN NOOR

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PRINTING INCHARGE (FLEXO):

IMRAN IQBAL

WAXING, LAMINATION AND EXTRUSION INCHARGE:

ASIM SHAMIM

FINISHING, SLITTING INCHARGE:

AKHTAR JAVED

BAG MAKING AND SLEEVES INCHARGE:

EMAAD ZUBAIR

FLEXIBLE PRINTING SECTION:

Flexible printing section is based on two methods of printing:

1: Rotogravure printing2: Flexographic printing

Two modes of printing are:

1. Direct printing2. Reverse printing

ROTOGRAVURE PRINTING

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To meet the growing needs of sophisticated quality packaging, Packages Limited established a flexible packaging department in 1986. Here, different plastic films, Aluminum foil and paper are combined to produce laminates of two or more layers for providing barrier properties against moisture, gasses and odors. High barrier laminates preserves the quality of food products and obstruct bacteria entry. Food packaging is made with good barrier properties for consumer convenience.

The rotogravure machines in this section are versatile to print these films and their combinations in up to 8 colors. In rotogravure printing, minute details can be reproduced accurately, making such printing particularly attractive for food packaging.

MACHINES FOR PRINTING:

The department has:

Two kinds of printing machines: (Roto & Cerutti)6 – color printing machine8 – color printing machine

Two kinds of laminating machinesSolnentless laminatorDry/Wet bond laminator

One vexing machine

CONSTRUCTION OF FLEXIBLE LINE:

Reel Form: e.g. poly bags Krunch Golden CrispSleeve Form: e.g. seal packing of Nestle Pure LifeWrapper Form: e.g. packing of Wall’s Cornetto

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No quality, No life. VARIOUS KINDS OF MATERIALS IN FP/PC

Polyethylene Polyester Nylon OPP MOPP Aluminum foil PET

PROPERTIES OF MATERIALS:

PET: Good printing, good strength, Stiffness, Heat Stable, provide aroma barrier, provide flavor barrier, transparent, Machine friendly

OPP: 4-sided stretched CPP, good moisture barrier but low shelf life, no flavor

protection, Poor oxygen barrier, not machine friendly, excellent transparency, print friendly, shrinkable, elongation is possible.

CPP: Non-stretched, seal integrity is good at high temperature, more stiffer than PE.

PE: No barrier property, less stiffer, cost efficient, no transparency.

NYLON: Oxygen and Aroma barrier, poor moisture barrier.

EVOH: very good oxygen barrier, not good water barrier.

PVC: sleeves and labels only. Not temperature friendly, not light friendly.

Aluminum foil paper: Gas barrier, moisture barrier, oxygen barrier its called barrier to all but during processing small holes develop in it which reduce its properties therefore it is used with other materials.

EVA: only use for sealing, costly.

These are the various films that are joint together in order to form a layer inclusive of a sealing layer, tie layer and a barrier layer .all the different films have different characteristics. Aluminum foil is the best barrier against water and oxygen. Polyester is the best material for printing. Nylon when laminated with polyethylene films provides stoppage of oxygen. Hence in this dept various development are made for the customers to provide them the best product.

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MACHINES

ROTOGRAVURE MACHINES:

4 PRINTING MACHINES:

Two machines are of 8 colorOne machine is of 10 colorOne machine is of 6 color

4 LAMINATORS

2 WAXING MACHINES

ROTOGRAVURE PRINTING (FLOW CHART)

BASIC MATERIALS:

PETBOPPPVCPaperAluminum foil

Curing time

Basic materials

Printing on engraved cylinders

Slitting 1st Laminationnnnnn

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Curing time

Curing time

FLEXOGRAPHIC PRINTING;

In FP, the process used for printing is rotogravure and flexographic. Flexographic is the printing that involves photopolymer plates. Both direct and reverse printing is done in FP. four extruders are also mounded in FP section where impotent granules are converted into single and multi layer of poly with the help of two mono extruders and multi layer extruders.

LAMINATION:

Lamination is a very important process in the packaging industry. It is carried out after printing and is based on the client requirement. It gives the product a good aesthetic look that is why it is done on most of the jobs in flexible packaging.The basic procedure of lamination is that we apply the adhesive on one of the two sheets usually the printed sheet. Then unprinted sheet is fed from one side and the printed sheet is fed from the other side and as a result they come in contact with each other as they pass through the NIPROLLER. This NIPROLLER is generally a combination of two rollers; a rubber roller and a steel roller. The rubber is at room temperature and the steel roller is at a very high temperature usually at about 80-85°C. This high temperature is because lamination is an endothermic reaction and requires that much energy to occur. After

Pack&Dispatch

2nd Lamination

Hot melt coating

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No quality, No life. lamination it takes about 24-48 hours (depending on the type of lamination) for drying and for lamination to achieve its desired bond strength. Maximum up to three laminations can occur that involve four materials.

TYPES OF LAMINATION:

There are two types of lamination. They are

Solvent –less laminationSolvent – based lamination

SOLVENT LESS LAMINATION:

Solvent less lamination does involve any solvent to be added with the adhesive. The adhesive unlike other is heated and spread between the sheets uniformly.

KEY FEATURES:

The important features of solvent less laminator that is installed in Packages Ltd. are as follows:

It is manufactured by German company DCW and was installed inPackages Ltd. in 2000.The difference between DCW and the Rotomec is that it does not requiresolvent and the adhesive is directly applied on the printed sheet.Normally the lamination of paper jobs is carried on this machine. Althoughthe second and third lamination can occur on the solvent based laminator,they are usually carried out on this machine.The treating unit is also available on this machine. All types of materialscan be treated using this unit except Al. foilThe adhesive used in this machine consists of two components:

Liofolur7735 100%Liofolur6088 40%

Chiller is not available in solvent less laminator.Maximum power consumption for operating this machine is 14.5kW.

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SOLVENT BASED LAMINATION:

Solvent based lamination is the one in which a solvent is added to the adhesive in order to spread it uniformly on the surface. It can be used for any kind of material.

KEY FEATURES:

The important features of solvent based laminator that is installed in Packages Ltd. are as follows:

It is manufactured by an Italian company named Rotomec in 1983.The adhesive that is used is adcod 548 and catalyst F or Liofolur 3720.The solvent used is ethyl acetate which acts as a medium.

The speed at which the machine is operating depends upon the type ofjob that is running on the machine and the maximum speed at which itoperates is 125m\min.There mixture of solvent and solution is mixed in proper proportions in adrum and is fed in the mixing unit manually.The oven is divided into three units which are maintained at three differenttemperatures 70, 80 and 80 respectively for gradual heating so that thedrying of the solvent on the printed sheet occurs properly. If all the threeovens were maintained at the same temperature then the skinning effectwould have occurred. In that case heat would not have penetratedproperly throughout the printed sheet and only the top surface would havedried while the middle and bottom layer would have remained wet.The construction of the machine is very simple and it consists of threebasic units. The material on which the adhesive has to be applied isgenerally mounted on the primary unwind unit. The unprinted sheet ismounted on the secondary unwind unit. While the two sheets afterlamination is winded again on a roller in the rewinding unit. All the threeunits are automatically controlled.The lamination takes place as the two sheets pass through theNIPROLLER. The temperature of steel roller is maintained at 80-85°Cdue to oil preheating. The temperature is needed because lamination isan endothermic process that requires heating. The rubber roller is justused to apply pressure for proper lamination.NIPROLLER are followed by two chillers that have chilled water inside.Sometimes after lamination the cooling is needed so chillers areavailable. But this depends upon the requirement of the job.The maximum web size that is available is 1200mm but most of the jobs that run on the machine are not greater than1015mm.

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WAXING:

Waxing is also done on the materials for giving it a shinny look along with providing it a medium for sealing. It is commonly done on the toffee wrappers, bubble-gum and soap wrappers.

WAXING MACHINES:

There are two waxing machine

1 for Food items1 for Soap items

EXTRUSION:

Packages has its own mono- and multi layer extrusion facility that can extrude polyethylene of different grades and colors. Canadian technology with computerized control and monitoring of each layer on our 3 and 5-layer extrusion line enables us to produce high output to meet our customers demand and keep up with new market trends. We extrude a number of specialized films, which include oil, ghee, detergent, and food films. these specialized films are known for their strength and high barrier properties. We also have an on-line slitting option on our line, which makes our system more efficient.

BAG AND SLEEVE MAKING:

Bag making is an integral part of Flexible line. Flexible line has the capability to provide the following variety of bag construction:

SIDE SEALDOUBLE SIDE SEALBOTTOM SEALTHREE SIDE SEALBOTTOM GUSSET BAGSSIDE GUSSET

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SLITTING & SLEEVES:

Slitting is done according to the customer’s requirement for various films. Sleeves are also made in FP Dept. these are commonly made for Sunsilk and Nestle.

POLY CONVERSION:

The poly conversion is the other division of the flexible line it involves various activities like printing, extrusion, bag making, cone making, rewinding, slitting. Poly is printed in

this section by means of flexographic method. It has the capacity to print 8 colors with the latest machine known as F&K Press.

TWO STYLES OF MAKING POLYMER:

OLD STYLE:

After the approval of mechanical negative is made and from this negative polymer is made and then the polymer is mounted for printing.

NEW STYLE:

After approval of mechanical, digital files are transferred to reproduction department and then they make the polymer.

UV RAYS NEGATIVE POLYMER

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UV rays are passed from the negative that creates an image on the polymer.

FLEXOGRAPHIC PRINTING (FLOW CHART)

Extrusion

On PE

PE Resin

PE Film

Flexographic printing

Waxing&Slitting

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FLEXOGRAPHIC MACHINES:

4 PRINTING MACHINES:

One machine is of 8 colorsTwo machines are of six colorsOne machine is of 4 colors

4 EXTRUDERS:

8 SLITTING MACHINES (SAME FOR ROTOGRAVURE AS WELL)

DIFFERENCE BETWEEN ROTOGRAVURE AND FLEXO GRAPHIC PRINTING:

Bag form Reel form

Packing and dispatch

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Rotogravure is comparatively expensive because of the engravers used in this type of printing

In rotogravure high enough resolution is achieved

In flexographic machine running time fast. It has shorter delivery time

Flexographic is compact machine.

Rotogravure is a huge machine and it needs more time to get the job done.

Poly jobs are done only on Flexographic

TOP 20 CUSTOMERS:

Unilever Pakistan Ltd Nestle Milkpak LtdColgate PalmoliveProcter & GambleAsian FoodMitchell's Fruit FarmsContinental BiscuitsStandard FoodsTapal Tea (Pvt.) LimitedHabib Oil MillsPTCEBMLPlastobag Ltd.National FoodsZILICI PakistanKings Food (Pvt.) LimitedReckitt Benckiser Pakistan Ltd.K.S.Sulemanji & Son

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CURRENT JOBS OF FLEXIBLE BUSINESS UNIT:

BONUS FILMSSURFEXCEL FILMSNESTLE NECK SLEEVESAKS SOAP

SABA BEAUTY SOAPBITES MAYFAIRFIZZY FRIENDS MAYFAIRCOW SOAPMAGGI NOODLESCORNETTOSUPREMEPADAANRIVIANANATIONAL TOMATO KETCHUPBAKE PARLOR TOMATO KETCHUPRAJ MASALA MANGO CURRY PASTEROGAN JOSH CURRY PASTEDULUX ICI SLEEVESNATIONAL FOOD SQUEEEZYROSE PETAL(CPD)DIAMOND WELDING FOODSMINI PAMPERTRUST POLY BAGSUFI SOAPSUFI DURJA AWALALBARKAT SOAPFAIR & LOVELY SLEEVESMAXLAZIZA

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No quality, No life. GOLD FLAKEPHOTOCOPY PAPER

CORRUGATED LINE

INTRODUCTION:

For large-scale packaging, Packages Limited has been manufacturing “Corrugated Cartons” since 1971. These cartons are produced in different sizes and are used for transporting consumer products from manufacturer to retail outlets. The share of Corrugated Department in Packages Limited total sales is almost 20%, which is second after the Carton Line. Corrugated cartons are of great value for the export of fresh fruits, garments and shoes. A wide variety of gums tapes for sealing corrugated cartons are also manufactured. Corrugated cartons vary according to customer demand, size; raw materials used, color and rate.The production process was completed in two halls. Paper needed for this purpose was also prepared within the factory premises at the Paper & Board Mill. Then this paper was first processed through the corrugated machine, which transforms the paper into single wall and double wall as required and mentioned earlier. Afterwards, the corrugated are processed through the Flexo machine where they are shaped according to the requirement

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No quality, No life. of the customer, for example, into a rectangular or square shape. A gluing unit is also attached with the Flexo machine, which sticks the cartons on specific places. Some time stitching is required which is done at another machine.

The corrugated dept is divided into sections.

SHEETING CONVERSION

SHEETING DEPARTMENT

INTRODUCTION;

The main contents of the sheeting dept are:

No. Of machines working in sheeting department Purposes of each & every machineProduction capacity Warehousing capacityQuality control systemRaw materials/InputsCustomersSuppliersOutputsEmployees working on each machine

Wastage during productionMachine handling

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No quality, No life. Processes of each machineImpacts of Kasur project on the total production of the department

In sheeting department there are three main machines which are performing different functions & the sheeting machine is further of three types. Besides, one more machine named as “Core Cutter” is also engaged in producing the cores for slitting machine. This machine works for only 8 hours per day & completely manually handled.

SHEETING MACHINE

Pasaban Sheeting machine SHN Sheeting machine Brouder house

SLITTING MACHINEGUILLOTINE MACHINE

The functions of all these machines are described below in details.

PASABAN SHEETING MACHINE:

PURPOSES OF THE MACHINE:

The primary purpose of this machine is to convert the coated or uncoated white duplex board of different grammages, width & length into sheets. The maximum & minimum widths that can be utilized in this machine vary from 400mm to 1500mm. The paper can be used in this machine for sheeting purpose but till now we have not used. For all the jobs of paper we used another machine that is present in this department.

INPUTS OF THE MACHINE:

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No quality, No life. White duplex board of the following grammages either in coated or uncoated form are the inputs or the raw materials of the this machine. The grammages used in this machine may be varied from 170 to 340. The unit to define these grammages is grams per square meters, e.g. 170g/meter Square.The width of the board may vary from 400mm to 1500mm.The length of the board depends on the wait of the board. Usually 5000m

OUTPUTS OF THE MACHINE:

The output of the machine is coated or uncoated white duplex boards in sheet form are the final product of this machine & then send to the customer via careful hands & covers.

SUPPLIERS OF THE INPUTS:

Basically the supplier of the machine is paper & board department in case of uncoated board & coating department in case of coated board.

CUSTOMERS OF THE FINAL PRODUCT:

There are two types of customers:

MAJOR CUSTOMERS:

The main customer of the final product of machine is offset department & almost 80 %to 90% of the total production is sold to this department.

MINOR CUSTOMERS:

The external market is included in the minor customer’s category.

EMPLOYEES ENGAGED IN ITS OPERATIONS:

Two workers are engaged all the times in its operations & controlling processes in each shift. They are engaged in accomplishing different functions of the machine.

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No quality, No life. NO. OF SHIFTS PER DAY:

The total duration of the shift is 8 hours & thus 3 shifts in a day because the machine is operating for the whole day & contributing towards total production of the department.

AVERAGE PRODUCTION CAPACITY:

It is extremely very difficult to determine the exact production of the machine per minute or per day or per month because of no. of factors which develop variations in its productions. But on the basis of previous data we can calculate its average production which is almost 130000 sheets/shift .The most important variables involved are

Speed of the machineRequired no of sheetsLength of the board width of the board No. of defects in jumbo reelAnd may be some others like machine problems etc.

MACHINE HANDLING:

The external activities of the machine are completely manually handled. This is the most important factor through we can boost the average production of the machine if the operations are controlled automatically via some well-designed computerized system. The internal operations are completely automated & playing a roll of quality control through different instruments like reject gate & knibe blade etc so that customer satisfaction, the primary objective of our organization can be achieved.

WASTAGE DURING PRODUCTION:

Almost 2 to 3 percent of the total material used for sheeting goes into wastage. Many parties are involved in producing wastage. The most important of them are:

Paper & board millCoating departmentInternal operations of machineInterest of employees working on machine

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No quality, No life. AIR PRESSURE:

Air pressure is used to increase the speed of the machine & control the other functions of the machine.

EXTERNAL & INTERNAL DECORATION OF THE MACHINE:

The process of coating machine is mainly consists of seven stages:

Reel standWeb unitShaper & bladesKnibe blade Reject gateDelivery portionPile unit

REEL STAND:

In reel stand the board’s reel is enrolled on the excel of the machine and then passed through some horizontal steels cylinders to continue the sheeting process.

WEB UNIT:

This is actually a combination of different mechanical instruments which all the time engaged in performing different activities like board maintenance, making the board wrinkle free & also sensing the joints in the board with the help of Joint Sensor & stops the machine at each joint automatically. SHAPER & BLADES:

In this stage the purified board is transferred for cutting. The width can be varied from 400mm to 15oomm as per customer’s job & the no. of sheets is set in this unit, means the setting phenomenon is performed here.

KNIBE BLADE:

This is a computerized operation which controls the length of each & every sheet in the machine according to the standard set.

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The sheet which not meets the given instructions is rejected by the knibe blade & goes into rejected portion through rejected gate.

PILING UNIT:

This is the delivery unit where the finished product of this machine in terms of sheets is piled up & then with the help of some moveable vehicles is shifted out of the delivery unit to the final use or to warehouse of the department. Here are some drawbacks regarding to its operations which are completely manually handled.

SHN SHEETING MACHINE

SHN sheeting machine also comes under the same umbrella of sheeting & slitting department. This is the 2nd machine performing the same job of sheeting. All the activities performed by this machine are similar to the Pasaban sheeting machine. Only the difference exists in length of the final sheet that may be varied from 560mm to 1782mm & down time required in piling stage is comparatively less than the time consumed in Pasaban sheeting machine. The average production capacity of this machine is almost 150000 sheets/shift & two shifts per day. The board as well as paper both can be used in this machine.

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EXTERNAL & INTERNAL DECORATION OF THE MACHINE:

1. Reel stand

2. Web unit

3. Shaper & blades

4. Knibe blade

5. Rejected unit

6. Piling unit

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SLITTING MACHINE

PURPOSES OF THE MACHINE:

The primary purpose of this machine is to slit the jumbo reel into smaller reels of different width depending upon the size of Shaper Shalft. The length of the shaper shalft is 1280mm & the minimum size of the smaller reel that we can obtain from this machine is 25mm which is not used usually. Till now we have been used this machine for minimum size of 69mm.

INPUTS OF THE MACHINE:

White duplex board of the following grammages either in coated or uncoated form are the inputs or the raw materials of the this machine. The grammages used in this machine may be varied from 170 to 340. The unit to define these grammages is grams per square meters, e.g. 170g/meter Square. The maximum length of the jumbo reel that can be used is almost 5000m.

OUTPUTS OF THE MACHINE:

The output of the machine is smaller reels of the used inputs.

SUPPLIERS OF THE INPUTS:

Basically the supplier of the machine is paper & board department in case of uncoated board & coating department in case of coated board

CUSTOMERS OF THE FINAL PRODUCT:

The customers of the final products are:

PTC JehlumP & G

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Uni leverColgate PalmoliveTawas Khan cigaretteCutting & creasing departmentLemanic machine etc.

EMPLOYEES ENGAGED IN ITS OPERATIONS:

Two workers are engaged all the times in its operations & controlling process. One is responsible in its operations control & the other is engaged in supporting the operator.

NO. OF SHIFTS PER DAY:

The total duration of the shift is 8 hours & thus 3 shifts in a day because the machine is operating for the whole day.

AVERAGE PRODUCTION CAPACITY:

It is extremely very difficult to determine the exact production of the machine per minute or per day or per month because of no. of factors which develop variations in its productions. But on the basis of previous data we can calculate its average production, which is almost 25000m/shift. If we place an order to the department, the time required depends on the customer’s job. But the sample can be delivered in 2 to 3 hours.

MACHINE HANDLING:

The external operations of the machine are completely manually handled. But the internal are both manually as well as automatically handled. This is the most important factor through we can boost the average production of the machine if the operations are controlled automatically via some well-designed computerized system.

AIR PRESSURE:

Air pressure is used to increase the speed of the machine & control the other functions of the machine. With the help of air pressure the core of the smaller reels are tightened.

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EXTERNAL & INTERNAL DECORATION OF THE MACHINE:

REEL STAND:

In reel stand the board’s reel is enrolled on the excel of the machine and then passed through some horizontal steels cylinders to continue the slitting process.

WEB UNIT:

This is actually a combination of different mechanical instruments which all the time engaged in performing different activities like board maintenance, making the board wrinkle free & also sensing the joints in the board with the help of Joint Sensor & stops the machine at each joint automatically.

1. Reel stand

2. Web unit

3. Cutting unit

4. Delivery unit

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CUTTING UNIT:

In this unit the required widths are cut down with the help of blades & the sides are maintained by shapers.

DELIVERY UNIT:

In this unit the slitted reels are rewind on cores of different sizes & then covered with polythene to shift to the final customers.

POLY LAMINATING MACHINE

Poly laminating machine also comes under the same umbrella of coating department. This is the last & final operation occurring in this department.

PURPOSES OF THE MACHINE:

The fundamental purpose of this machine is to protect the paper or board from water contents and thus strengthen the paper or board & so causes to enhance the life of the paper or board by sandwiching the polyethylene with the paper or board. This machine is also used for alfile lamination of the paper or board. The detailed of the process will be discussed in the later part of the machine.

INPUTS OF THE MACHINE:

White duplex board and paper are the inputs or the raw materials of the Poly laminating machine. The details of the paper and board have been described earlier

OUTPUTS OF THE MACHINE:

The output of the machine is poly laminated paper & board which is the final product of the poly laminating machine & then send to the customer via careful hands & covers.

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SUPPLIERS OF THE INPUTS:

Basically the supplier of the machine is paper & board department but sometimes we use the final products of coating machine as well as doctoring & slitting machine. Not every roll of paper & board comes for poly laminating but only those which are the requirement of the customer.

CUSTOMERS OF THE FINAL PRODUCT:

There are two types of customers:

MAJOR CUSTOMERS:

The main customer of the final product of poly laminating machine is CPD(consumer products department).

MINOR CUSTOMERS:

The external market is included in the minor customer’s category.

EMPLOYEES ENGAGED IN ITS OPERATIONS:

Three workers are engaged all the times in its operations & controlling process.

NO. OF SHIFTS PER DAY:

The total duration of the shift is 8 hours & only 2 shifts in a day because the demand of the product is responsible for its two shifts. When there is no demand of poly laminated paper or board then the machine is shut down& the operators are shifted to the other machines working in this department.

AVERAGE PRODUCTION CAPACITY:

It is extremely very difficult to determine the exact production of the machine per minute or per day or per month because of no. of factors which develop variations in its

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No quality, No life. productions. But on the basis of previous data we can calculate its average production which is almost 35000m/shift to 40000m/shift.

The most important variables involved are:

The demand of the customerGrammages of the boardWidth of the board And may be some others like machine problems etc.

MACHINE HANDLING:

The operations of the machine are completely manually handled. This is the most important factor through we can boost the average production of the machine if the operations are controlled automatically via some well-designed computerized system.

HYDRAULIC SYSTEM:

Hydraulic system is used to increase the speed of the machine & control the other functions of the machine.

EXTERNAL & INTERNAL DECORATION OF THE MACHINE:

The poly-laminating machine is mainly divided into six parts:

Unwinding unitWeb linerExtruderChill cylinderSecondary unwinding unitWinding unit

UNWINDING UNIT:

In unwinding unit the process is similar to the doctoring & slitting machine. The board or the paper’s roll is enrolled on the excel of the machine and then passed through some horizontal steel’s cylinders to continue the process.

WEB LINER:

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No quality, No life. In this division the sides i.e. the width of the paper or board is maintained according to customer’s job and the damaged sides are automatically being cut down.

EXTRUDER:

In this unit the board or the paper is provided with melted polyethylene & then one layer of paper or board & the other layer of poly go hand in hand under a high temperature.

ABOUT POLYETHYLENE:

We import low-density polyethylene named as “LOTRENO” from Qatar. The material is available in Pakistan’s market but actually the aim of the Packages is to provide the quality product to the ultimate customer. Since the quality available in this market is not up to the mark. That’s why we not purchase the polyethylene from our market.

CHILL CYLINDER: In this unit the poly plus paper or board are chilled with the help of chill cylinder which operate at very low temperature. This is the last process of the machine. Here the final product is completed & the paper or board is poly-laminated.

REWINDING:

In this step the finally completed product is rewinded with the help of some automatically moving excel on a core.

SECONDARY UNWINDING UNIT:

In this unit some sort of sandwiching functions take place. That sandwiching includes alfiling of the paper or board under some specified temperature.

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TYPES OF CORRUGATED SHEETS:

KLP (Kraft line board)

CMP (Corrugated medium board)

WDB (white duplex board)

PROCESS FLOW OF MAKING CORRUWALL (CWCS) SHEETS:

Reels/ liners

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MACHINE FOR MAKING CORRUWALL SHEETS:

Flute Plant

C Flute

Dispatching

Corruwall Sheets

Cutting & Creasing

Heating & Gluing

Double Baker

B Flute

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No quality, No life. The machine used for making or preparing Corruwall sheets, is named as UCHIDA (it is the company name). It has imported from Germany. It has six units. These six units are as follow:

1st Unit (C Flute)2nd Unit (B Flute)3rd Unit (Double Baker/Facer)Heating SectionSlitter & Scorer SectionAuto Down Slugger Section

TYPES OF CORRUWALL SHEETS

Single Wall

C – flute B – flute

Double Wall B+C flute

Single Facer E – flute

MACHINES FOR PRINTING:

There are three machines for the purpose of printing.

Two 2-color machines (ISOWA <Latest>)

One 3-color machine (SRINKO)

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CAPACITY OF PRINTING MACHINES:

The printing machines used in Corrugated Division have the capacity of printing 250 Corruwall cartons per minute.

CONSTRUCTION OF CONTAINERS:

Regulated Slotted Containers (RSC) Glued Containers Stitched Containers DI – Cut Containers

MAJOR CONSUMER AREAS:

Sports Product Textile Industry Food & Beverages Yarn and Poly Products Match Industry Fruit Cartons

MAJOR CLIENTS:

Pepsi Cola, Pakistan Mineral Water Pakistan Tobacco Company Lever Brothers Nestle Rupali Group Murree Brewery Kunjah Textile Mills

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No quality, No life. PROCESS FLOW CHART FOR CORRUGATOR

INTERNAL SALE ORDER

CONFIRMATION SLIP

PRODUCTION ORDER

TRIM PLAN FOR SHEETIG

SHEETING

PRINTINGSTITCHING

RELEASEBY Q.C.

DESPATCH

PURCHASE ORDER TO P&B MILL

BFIN MATERIL FROM P & B MILL

STOCK BFIN

ISSUEE REQUESTION

PURCHASE ORDER TO DIC (COATES)

INK FROMDIC (COATES)

STOCK OF INKS

ISSUE REQUESTION

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No quality, No life. PORTFOLIO ANALYSIS

Portfolio Analysis is a tool by which management identifies and evaluates various businesses making up the company.

BCG MATRIX:

THE CONSUMER PRODUCTS DIVISION (CPD)

STAR

CASH COW

DOG

QUESTION MARK

Market Growth Rate

Market Share

Flexible & Corrugated Cartons

Cartons

Corrugated Cartons & Cartons

Flexible

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INTRODUCTION:

Since the inception of Packages Limited, it dealt only with industrial goods. In 1981, company entered into a new era and started dealing in consumer goods as well. Initially, it was decided that the Industrial Sales Division will also look after the affairs of consumer products. In 1985, the distribution functions of the consumer products were handed over to TETRA PAK. But in 1986, Packages Limited got back the distribution facility from Tetra Pak and established a new division with the name of CONSUMER PRODUCT DIVISION (commonly known as CPD). Since then CPD is responsible for the consumer products.

HISTORY OF THE PRODUCTS OFFERED BY CPD:

Packages Limited started producing consumer products with the introduction of ROSE PETAL (Facial Tissues) in April 1981. With the passage of time the consumer products family increased. A brief history of all the consumer products is given below:

Luxury Pack of Rose Petal (Facial Tissues) in 1981.Tissues of pink color were introduced in 1982.Toilet Rolls in 1983Economy size pack of Rose Petal Multi color tissues were also introduced in 1984.Production of Table Napkins started in 1985.In the end of 1985, the distribution is handed over to Milk Pack for only three months.Multi purpose rolls were introduced in October 1986.In November 1986 facial tissues were offered in pocket pack.The production of Paper Plates and cups was started in 1987.Perfumed tissues were launched in 1987.In 1988 Feminex was launched.In 1989 Wet Tissues were introduced.In 1990 Feminex Stick on was manufactured.In 1992, they manufactured a special kind of wet tissue which is used to clean the glasses of spectacles. But the commercial production is still not started.

In 1993, CPD introduced imported tissues with the name of COTTENELLE.

CPD is responsible from the production to the distribution of all these products. Each Sales Officer deals with the particular brand assigned to him. Before the establishment of

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No quality, No life. CPD products used to take 12-15 days before reaching to the customer who had placed the order. After its establishment this problem was removed and CPD has around more than 100 distributors which covers the whole country. Before the introduction of FLYING TISSUES, Packages Limited has the sole monopoly over the tissue market in the country. But right after its introduction, it gave a tough time to the Rose Petal family. Although CPD people don't accept that Flying is giving them a tough time. But after its introduction they improved their quality by making tissues on a new machine which is far better than the previous one.

PRODUCT LIFE CYCLE:

The facial tissues and toilet rolls are still in the early maturity stage but are definitely the cash cows. As a convenience product the tissues need heavy advertisement and Packages Limited has currently immense advertising, as high as they should. They paper plates and cups are also in the growth stage. But their use is very limited. no advertisement is sponsored for them. I think, if want to get a good turn over, then first they should aware the general public about these things. Cottonelle tissues are in their introduction stage. Still many people don't know about it. It is actually an imported tissue(imported from USA). It also needs heavy advertisement. Its target customers are those who has high purchasing power and are status conscious. Feminex is also in its growth stage. In this regard heavy advertisement is placed in the magazines etc. The ink product at the Packages Limited, with the collaboration of Coates Lorrileux Pakistan Ltd. This venture is the earlier collaboration of Coates of England and Lorrileux of France and now introduced in Pakistan through Packages Ltd itself. Although some other companies are purchasing this ink from them. Rice was introduced by Packages Ltd. but it lost its share in the very earlier stages and the project was closed down in the introduction stage. The reason for the failure of the Rice were: It was very expensive due to good packing, brand name and also its over heads were huge enough to stop it.

MAJORS COMPETITORS:

One can not imagine about a business without competition. Packages Limited has also some competitors for its consumer products. So far as facial tissues are concerned, there used to be no competitor in early 80s except the foreign brands. Then companies like FAY, MOVITA competed for some time but Packages Limited superseded them very soon and start enjoying their monopoly. Then it was FLYING Tissues which came, and were placed at good position in market. Flying people gave some tough time to Packages Limited. But it was good, because after introduction of Flying tissues they improved the quality of their products.

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ACTIVITIES:

I was assigned the CUSTOMER SERVICES/SUPPORT DEPARTMENT (CSD) of Packages Limited, Lahore. It is combined with the industrial sales and marketing department. It is managed by SIR ATHAR RASHEED BUTT (CSM) The SALES Department is headed by MS HUMAIRA SHAZIA There are five members in CSD department. Four are female and one is male and their rank is assistant manager (CS). Their specific tasks are explained below.

I was assigned to do a project of collecting samples of different categories like carton line, flexible line and poly. Therefore I visited several related departments for the fulfillment of my project. On the very first day I visited the biggest line in packages “the carton line”. There I saw the working of different machines, how they print. We saw two machines for printing. One is old and the other is new. The new one is known as lemanic and only PTC jobs are running over there. How cutting and creasing is done manually and automatically through different machines, then how folding and gluing is being one on the cartons according to the customers requirements. I noted all the working there and noted all the important points. Then at the end of the day I report to my manager, asked related questions. I did all the work on excel and word

Then after completed carton line I visited flexible line. Flexible packaging was introduced in 1986 .the flexible packaging is basically made from the poly grains which gives the salivary effect of packaging. Flexible packaging is used for the shopping bags, food products, garments, cigarettes, biscuits, pharmaceutical goods, tooth paste. Cosmetics, toilet soaps etc. I collected different samples of flexible line and note down their material combinations. I made a complete round of the production house and saw the procedure of the production of flexible line.

Although in my assignment corrugators samples are not required but I visited corrugators too and saw complete production process there .I gained complete introduction of machines and saw their functions.

I visited Art dept and saw the designing of the wrappers of different products of all the three lines from the chewing gum to the surf. Then I saw the making of mechanicals of different new designs which is the sample design of any new product which has to approve by the respective customer and the packages as well.

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No quality, No life. During my internship, I visited Reproduction dept, where new orders are reproduced after approval ,pre press planning where the record of production is maintained, CPD production house and saw the making of tissues their printing, packing ,rolling, creasing and finally dispatch.

Finally I made a complete survey of paper and board mill . There I saw its four main sections that are NFL(New Fiber Line),CRP(Chemical Recovery Plant), SLP(Straw and Linter Preparation) AND BLEACHING HOUSE .I collected all the related information and finally reported to my manager at the end of the day.

SECTION 7:

STRAINS AND STRESSES

PROBLEMS AND RECOMMENDATIONS

CONCLUSION

STRAINS AND STRESSES:

No work can be carried out with out any stress. Therefore, it is sometime become more helpful to create some stressful situation for getting more productivity or making people more serious. As far as Packages Limited is concerned there are also few stressful situations present at different levels of management, which are enlisted here.

Excessive work load.FavoritismLate sittingLack of opportunity for promotionMore responsibilitiesTop management pressure

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No quality, No life. FINDINGS AND ANALYSIS:

Packages Limited, Lahore is a good organization in terms of discipline,

cleanliness and infrastructure.

It has a well-established structure.

Delegation of authority is not a common practice. Centralized decision making is

there.

Line of authority is followed throughout the organization.

There are various employees benefit programs such as Worker’s Participation

Fund, Social Security, Employee’s Old Age Benefits Schemes, Group Insurance,

Provident Fund, Worker’s Children Education and Federal Education Fee

Scheme.

There is low accident rate because safety of environment is maintained at every

step of production.

Various entertainment facilities are provided to the employees such as Basant,

Rose Festival, Library facility, gymnasium arrangement etc.

A well-managed mess is there in the company’s premises providing clean, and

hygienic food to all the employees and internees as well.

Continuos improvements of employees skills and knowledge through

Management Training programs conducted in association with LUMS and

through In House training.

Packages have highly motivated employees.

It has well-developed system of distribution.

It is an environmentally conscious company

Packages has strong financial backing

It is market leader in Packaging industry

It has strong relationship with suppliers

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No quality, No life. It has huge production capacity

It is having its own power generation plant

Advanced technology is a big strength of the company

Fully integrated operations

Opening up of the Asian economies is a big opportunity for Packages Limited

Packages Limited is an ISO certified company.