1 // Plastic Cluster Aurangabad - Design Awareness Programme by NIFT Mumbai Need Assessment Survey Report Plastic Cluster, Aurangabad Survey by NIFT Mumbai Supported by MCED Aurangabad, NID Ahmedabad, & Design Clinic Scheme by Ministry of MSMEs Govt. of India 2014 www.designclinicsmsme.org
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Need Assessment Survey - Plastic Cluster, Aurangabad
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Design Clinic Scheme is a tested strategic model of design intervention, where a solution to an existing design problem is diagnosed and remedial steps suggested by a multi-disciplinary team of design experts. In this scheme, the value additions to an idea or a concept are imparted through interaction at a lesser cost to a specific industry/sector. It applies to a sector that requires intervention, like manufacturing etc. as the existing conventional models of design consultancy and training are not viable. These models bring design exposure to the door-step of industry clusters for design improvement, evaluation, analysis and adopting even long-term consultancy/design related intervention
The main objective of the Design Clinic is to bring the MSME sector and design expertise into a common platform, to provide expert advice and solutions on real time design problems, resulting in continuous improvement and value addition for existing products. It also aims at value added cost effective solutions. These Design Clinics in clusters of the country are to usher in a continuous competitive advantage to the MSMEs.
The broad activities planned under the scheme include creation of Design Clinics Centre along with four regional centres for intervention on the design needs of the MSME Sector. Further these centres will have linkages with engineering, management, design institutes of the country.
The scheme is under operation in a Public Private Partnership (PPP) Mode.
http://www.dcmsme.gov.in/schemes/DesignClinic.htm
FRONT COVERInjection Moulding at Darshan PlasticsMIDC, Waluj, Aurangabad
BACK COVERFinal Packing of finished products at Darshan Plastics MIDC, Waluj, Aurangabad
Design Awareness Programme (DAP) is part of the Design Clinic Scheme, an initiative of the Ministry of Micro, Small & Medium Enterprises (MSME), Government of India (GOI) & National Institute of Design (NID).
The National Institute of Design, Ahmedabad, acts as the nodal agency for the Design Clinic Scheme. The Maharashtra Centre for Entrepreneurship Development (MCED) associated with National Institute of Fashion Tech-nology (NIFT), Mumbai; set up by Ministry of Textiles, Govt. Of India; to leverage the expertise of the institute in the arena of design education and its commitment to contribute to society.
The main objective of the Design Clinic Scheme is to provide a common platform for the MS&ME sector and Design experts for mutual sharing of ideas and form symbiotic relationship for creating sustainable growth envi-ronment for the MSME sector.
DAP initiative aims to evaluate real life issues and provide practical solutions for value addition in the current context while not ignoring the long term survival and growth potential.
Synopsis
Finished Products being packed at Snehal Plastic Industries, MIDC, Waluj, Aurangabad
We would like to express our sincere gratitude to Ministry of Micro, Small and Medium Enterprises (MSME), Government of India and National Insti-tute of Design (NID) Ahmedabad, for giving us the opportunity to be a part of the Design Clinic Scheme.
We would also like to extend our special thanks to The Maharashtra Centre for Entrepreneurship Development (MCED) to select us to do the project.
Our gratitude is also due to Mrs. Nilima R. Singh, Director-National Insti-tute of Fashion Technology, Mumbai for providing us guidance and support to successfully complete the report.
Our heartfelt thanks to all the Owners and workers of the units surveyed who took time out of their busy schedule and spent time in explaining the modus operandi of their business to us.
Acknowledgement
PET jar being manufactured at V. P. Pet Polymer, MIDC, Waluj, Aurangabad
The Plastic cluster at Aurangabad was contacted through MCED. An interview schedule was planned with all the unit owners who agreed to be a part of the survey.
Objective: The primary objective of need assessment survey is to collate detailed cluster information in order to understand the business and supply chain issues like:
• Existing product design and packaging and scope of intervention or R&D for re-designing/ packaging changes or diversifying into different product categories.
• Current state of technology and scope of modernization• Visual identity and branding and other collaterals• Forward and Backward linkages for Marketing and Raw materials• Competitive structure and rivalry in the Industry• Infrastructure, ergonomics and environment factors• Manpower recruitment, availability of skilled labour, training and skill up‐
gradation opportunities.
Methodology:• Interview with unit owners (27 units).• Discussion with unit owner and workers.• Business Process observation.• Questionnaire survey of manufacturing units.• Self observation and analysis.
Need Assessment Survey
NEED ASSESSMENT PROCESS AND TOOlS
Expected outcome:This research aims to provide qualitative and detailed data of the plastic cluster to develop an understanding and generate insights into the business dynamics of the cluster. This would help identify the existing problems and future scope in the area for design intervention and business development.
Agricultural Sheet net being manufactured at Yogesh Plastic Industries, MIDC, Shendra, Aurangabad
IntroductionDCS for MSMEsMCEDNIDNIFTPESTEl AnalysisSWOT AnalysisIntervention Pathwaylist of ClustersInd. Attractiveness & Govt. Initiatives About the Plastic ClusterIntervention Pathway
PurposeTo increase awareness about the value of design and establish design learn-ing in MSMEs. To increase competitiveness of MSME products and services through design.
Objectives• To create a sustainable design ecosystem for the MSME sector through
continuous learning and skill development.• To promote use of design by MSMEs for developing products and services
that are market led.• To focus on building the design capability of MSMEs to enable them to
improve business performance as well as compete in the global market.
Key principles• Adopting a rigorous, yet applicant friendly, process.• Promoting and disseminating design concepts in regional or local languag-
es understood by the MSMEs. Establishing benefits without overwhelming the MSMEs.
• learning from other successful design-support programmes.• Establishing systematic processes for R&D in MSMEs.
Scheme descriptionFor easy percolation of design thinking and philosophy and maximum benefit for MSME units the Design Clinic Scheme is divided at 3 broader levels. These activities are helpful in smooth transition in to several levels of design inter-vention in industrial and business activities of MSMEs.
Design Awareness SeminarThe design sensitisation seminar is aimed to create a platform for MSME units
to improve the manufacturing competitiveness. The seminar will help MSME participants to interact with design experts/speakers to understand design methodology and benefits of design to MSME in their business, product, process, service and operations. To take design to a higher level of manufactur-ing functions, it is very important to develop an understanding of the design scenario and environment at an early stage of conception.
Design Awareness ProgrammeThe design awareness programme is focused on exploring industrial functions and activities to develop a holistic map of MSME clusters and units. The design expert/s will generate design information about products, market scenario, technology, communication, research and development, and various industrial functions along with human factor study for ergonomics, safety, convenience, learning and skill up gradation through design research. The programme will also provide design remedies for identified opportunities through the design clinic workshop.
The design awareness programme is conducted in two stages:• Need Assessment Survey• Design Clinic Workshop
Design ProjectsDesign projects are identified during the need assessment survey and discussed during the design clinic workshop. Project which require intensive design observation and interventions can be taken up as design projects with the help of design experts. The project can be related to design intervention in area of product/process /strategic areas where design can help in generating solutions and value for individual or group of MSMEs.
Role of Design in Improving CompetitivenessDesign is an approach, process and methodology. Design is indented, purpose-ful, contextual, which is aimed to create advantage, distinction and futuristic outcome as a result. Design is systemic and holistic in nature, there fore helps in generating more creative, impactful and sustainable solutions. In manufac-turing, design is commonly associated with industrial product design – specif-ically the ‘aesthetics and appearance’ of a product at a surface level interaction. However, the application of design is much broader, for example designing for functional appeal, ease of manufacture, consumption and sustainability. De-signing may also be done for reliability or quality or business processes. Service designs are primarily to cater to customers experience of the delivered product and service.
The larger purpose of design is to do things in a better manner, to improve a situation and to make a positive difference. The role of design in business is to create value. A company can use the design process to add value to products, services, and the organisation. A well-designed product, service, or organisa-tion is always more valuable.
Design, innovation and growth are linked. Innovation and design are not simply about new products or technology. They are also about how to improve products for everyday use, leading to reduced costs, increased usability and new business opportunities. Design is recognised as an innovative discipline that can help MSMEs to sustain and grow in an increasingly competitive mar-ket.
MCED has been a pioneer in espousing social and economic entrepreneurship since 1988. It is one of the foremost institute working in the areas of Entrepreneurship development.
MCED conducts special training programs, Seminars and skill development courses for young and budding entrepreneurs and encourages them to solve their problems in respective start-ups.MCED benefits the self employed people greatly by sharing the knowledge and success of the industry experts.
MCED has its offices all over Maharashtra. Beyond Maharashtra, MCED has offices in Delhi, Assam and Goa.
Need Assessments Survey Approach Process:Steps below are followed to meet the objective of Need Assessment Survey
• Questionnaire survey of Units.• Process Observation of the Unit.• Interaction with Unit management.• Opportunity areas finding.
On April 7, 1958, Charles and Ray Eames presented the India Report to the Government of India. The India Report defined the underlying spirit that would lead to the founding of NID and beginning of design education in India. The Report recommended a problem-solving design consciousness that linked learning with actual experience and suggested that the designer could be a bridge between tradition and modernity. The Report called upon future de-signers to re-examine the alternatives of growth available to the country at that time.
Based on the recommendations made in the India Report, the Government of India with the assistance of the Ford Foundation and the Sarabhai family estab-lished the National Institute of Industrial Design, as it was originally called as an autonomous all-India body in September 1961 at Ahmedabad. This unique curriculum and revolutionary educational philosophy remain part of NID to the present day.Today the National Institute of Design is internationally acclaimed as one of the finest educational and research institutions for Industrial, Communication, Textile and IT Integrated (Experiential) Design. It is an autonomous institution under the aegis of the Ministry of Commerce and Industry, Government of In-dia and is recognised by the Department of Scientific and Industrial Research, Government of India as a Scientific and Industrial Research Organisation.The aim is to provide design intervention for craft, handloom, rural technol-ogy, small, medium and large scale enterprises, and outreach programmes for capability and institution building and sustainable livelihood, employment opportunities and economic growth.
NID has been a pioneer in industrial design education after Bauhaus and Ulm in Germany and is known for its pursuit of design excellence to make Designed in India, Made for the World a reality. NID’s graduates have made a mark in key sectors of commerce, industry and social development by taking role of catalysts and through thought leadership.
National Institute of Fashion Technology (NIFT) is an institution of Design, Management and Technology. It was set up in 1986 under the aegis of the Min-istry of Textiles, Government of India and NIFT has been granted statutory status under the act of Parliament of India in 2006, empowering the Institute to award degrees and other academic distinctions.
In 2006, the Parliament passed the National Institute of Fashion Technology (NIFT) Bill, 2006, thereby receiving a statutory status and empowering the in-stitute to grant its own degrees and other academic distinctions. It also counts among the coveted list of an Institute of National Importance by the Parliament of India.
With its head office in New Delhi, NIFT has centers at Mumbai, Kolkata, Kan-gra, Gandhinagar, Hyderabad, Chennai, Bangalore, Raebareli, Patna, Shillong, Bhopal, Kannur, Bhubaneswar and Jodhpur where it offers four-year bachelor and two-year master programmes in the areas of Design, Management and Technology.
NIFT’s graduates have made a mark in key sectors of entrepreneurship, com-merce, industry and social development by taking the leading responsibilities as design and business leaders.
A PESTEl analysis is a framework or tool used by marketers to analyse and monitor the macro-environmental (external marketing environment) factors that have an impact on an Industry/Organization.
Social Forces
LegislativeForces
Environmental Forces
TechnologicalForces
Organization
PoliticalForces
EconomicForces
PESTEL stands for:• P – Political• E – Economic• S – Social• T – Technological• E – Environmental• l – legal
As the Plastic Cluster in Aurangabad is similar in its dynamics to an indus-try barring its size, the PESTEl analysis of Aurangabad becomes pertinent to identify the key variables that drive the Plastic Cluster.
The PESTEl Analysis - Aurangabad
POLITICAL
Social Forces
LegislativeForces
Environmental Forces
TechnologicalForces
Organization
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EconomicForces
History:A prime minister of the Muslim Kingdom of Ahmednagar, Malik Ambar established a town at a village called Khirki. later, his son Fateh Khan named the town as Fatehpur in 1626. Mohammad Bin Tughlaq tried to switch over the capital of his Delhi sultanate to Fatehpur in 14th century keeping in mind the strategic location of the town. The town was at the centre of India, and the region was considered the safest from the marauding armies of the Afghan and Central Asian raiders.
When Aurangazeb took over the Deccan kingdoms, he changed the name of the town to Aurangabad in 1653. Aurangazeb used the town as the strategic point to suppress the rising power of Shivaji. Aurangabad was taken over by the Nizam of Hyderabad after the death of Aurangazeb in 1707 that retained control till it was merged with Maharashtra in 1956.
Current Scenario: The BJP-Shiv Sena alliance is ruling the Aurangabad Municipal Corporation (AMC). Aurangabad comprises of 9 talukas and 1344 villages, covers an area of 10,107 sq km out of which 141.1 Sq. Km is urban area and 99,587 sq. Km is rural area. The population of around 36.95 lacs. There are no minerals availa-ble in Aurangabad. In Aurangabad district total forest area is 135.75 Sq.Km.
ECONOMIC
Social Forces
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Environmental Forces
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Maharashtra Industrial Development Corporation established a number of industrial estates at various locations in and around Aurangabad, which con-tributed immensely to the economic growth and development of the area.
Key Economic Drivers: AurangabadIndustry Established Industries: Automobiles, Auto components, Pharmaceuticals,
Breweries, Food Products, Plastic, Rubber, Paper & Paper ProductsTourism World heritage sites of Ajanta, Ellora and other tourist destinations of
Daulatabad, Bibi-ka-Makbara attract large number of touristAgriculture Cotton, Sugar-cane, Maize, Bajra, Jowar, Soyabin, Sunflower, etc.Education Engineering, Management, Medical and vocational fieldsHealth Availability of ample medical facility with hospitals viz. Govt. Hospital, MGM
Hospital, Nandlal Dhoot Hospital, Dr. Hegdewar Hospital, Kamalnayan Bajaj Hospitals, Etc.
• Speciality in Automotive, Auto components, Pharmaceuticals, Breweries, Con-sumer durables, Plastic processing, Agriculture and Biotech. Among these Re-combinant Insulin Manufacturing Plant of Wockhardts (Wockhardt Biotech Park) is the largest Bio-pharmaceutical plant in India.
• The Shendra, Chikalthana and Waluj MIDC are prominent industrial zones on the outskirts of the city, with various major multinational groups having set up manufacturing or processing plant in and around the city.
Aurangabad has 3,405 medium and small scale units generating about 36,871 jobs with an investment of Rs. 404.86 Cr. It is estimated that by year 2020 these units will grow to 9000 nos, generating about 95,000 jobs with an investment of Rs. 1050 Cr.
Large Scale Enterprises in the District:
• Aurangabad has around over 195 units of large scale enterprises or Indus-trial Enterprises Memorandum (IEM) which has generated 80,500 jobs with total investments of Rs. 7,384 Cr.
23% 30%
7%29%
11%
21% 30%
8%29%
12%
Sector wise Units Contribution -2010 Sector wise Units Contribution -2020
Engineering
Manufacturing Machinery
Beverages & Food Products
Pharmaceuticals
Rubber & Plastic
Engineering
Manufacturing Machinery
Beverages & Food Products
Pharmaceuticals
Rubber & Plastic
• It is estimated that by year 2020 these units will grow to 343 units generat-ing over 1,95,000 jobs with total investment of Rs. 1,79, 590 Cr.
Currently has 5 MIDCs and 2 Growth Centres.•PlasticandRubberProducts
Comparative Analysis of Industrial Districts:
SOCIO-CUlTURAl
Social Forces
LegislativeForces
Environmental Forces
TechnologicalForces
Organization
PoliticalForces
EconomicForces
The rule of the “ Satavahanas” witnessed the era of peace and prosperity and hence the district of Aurangabad then centered around Pratishthan the capi-tal of the Satvahanas for centuries together, became the hub of socio-cultural activities of the Deccan.
The Satvahanas gave incentive to trade and commerce and monopolised the Greeco-Roman markets as far textile goods namely Paithani the high-class silk-en sarees of Paithan is concerned.
The current day Aurangabad offers a wonderful opportunity to step back to past history. Ajanta and Ellora caves and Bibi-Ka-Makbara bring back the visi-tors to the past history of the town.
Key Festivals and Fairs in Aurangabad:Ajanta and Ellora Festivals: It is the festival of classical dance and music under the backdrops of the Ellora Caves. The festival usually falls in March. The festi-val showcases best talents from across India. Maharashtra government organiz-es the festival.
Aurangabad Festival: Aurangabad Festival promotes the rich local culture, tal-ent, art and heritage of the city. The festival is organized to explore the hidden talents and to increase the vibrancy of this historic city. The festival generally falls in December. The Aurangabad Festival Committee organizes it.Buddha Jayanti: Buddha Jayanti is organized in the city as an important fes-tival. Community halls and public places are remained crowded for mass prayers. Religious processions are also taken out on this day.
Dussehra: Dussehra is celebrated for ten days. On the tenth day, a fair is held when people greet each other with offerings of ‘Apta’ leaves that symbolize good luck. Source: http://www.maharashtratourism.net
Current social scenario:Population: According to the census of 2011 the Male Vs Female population of Aurangabad is 1,928,156 Vs 1,767,772 respectively.Traffic is minimal, the roads are barely motorable and the errant traffic sense of
its residents is no different than in any other Tier II town.
However, the southern side is the face of new wealth: A stretch of sprawling bungalows dotting the streets. Jalna Road, an arterial road that connects the city, is the nerve centre. Practically everything is located in and around this stretch.
The evidence of prosperity and change are clearly visible; from the four-month-old 800,000 sq ft Prozone mall, which is the largest and only mall in the city, to dealerships of automobile brands like Skoda, Nissan and Maruti Suzuki and eateries and hotels like the Taj and lemon Tree.
In the last five years, the city has morphed well beyond its status as Maharash-tra’s tourism capital into a hotbed of industrial activity, primarily led by the automobile and engineering cluster. In more recent times, the growth has been spurred by agriculture and real estate development. Cotton farming has grown in the surrounding villages.
Farmers have thrived thanks to cotton prices hovering at an all time high of around Rs. 4,500 per quintal. Residential real estate prices have zoomed. Prop-erties were valued at around Rs. 20 lakh an acre in areas like Nashik Road, Old Bombay Road and Beed Road in 2006. Prices have risen five times in the last four years.
The IT sector promotion was initiated in Aurangabad since year 2003 along with the formation of HTPI office and IT park in Chikalthana in vicinity to Pune and Mumbai.
Good educational base, existence of local IT units and industrial maturity of the city due to manufacturing segment, low cost of operation are plus point of the city for the future IT sector growth.
i) Currently, around 22 IT units are operational employee 2500 professionals. The city has 6 registered HTPI, 100% EOUs exporting services worth Rs, 7 crores per year to USA, Germany, Neatherland, among others.
ii) In past two years, BPOs have been established which are providing services in various languages to local customers and also to few international clients. Aditya Birla group, Vodaphone are extending services to their clients, through BPOs at Aurangabad.
The key machines used by the plastic cluster are:• Injection• Extrusion• Compressor
• Grinder
The key software used in the plastic cluster:• Tally(foraccounting)• MicrosoftExcelandWord
ENVIRONMENTAl
Social Forces
LegislativeForces
Environmental Forces
TechnologicalForces
Organization
PoliticalForces
EconomicForces
The total area of Marathwada region is of 64,813 km. and is bounded by the Vidharbha region on the North, by Andhra Pradesh on the East and South-east, by Karnataka on the South and by Western Maharashtra on the West. The entire region is situated at an average height of about 300-650 m. above Mean Sea level gradually sloping from West to East, and is traversed by hill ranges origination from the Sahyadris in the West and the Satpudas in the North.The weather is generally dry and moderately extreme. The average day tem-perature ranges from 27.70 C to 38.00 C while it falls from 26.90 to 20.00C during night. Similarly summer and winter temperature also varies greatly. The highest during summer day being about 43.30C while the lowest during winter nights about 6.00C. Relative humidity is extremely low for major part of the year (between 35 to 50%) while it is highest (85%) during monsoon.
The rainy season is considered from middle of June to the end of September which is followed by a sultry period from about the end of September to the middle of November. The winter season commences from the middle of No-vember and ends by the end of the January followed by a dry hot summer from February to middle of June. Summers are in general full of gusty winds. The normal average rainfall is about 90 cm but is rather variable form year to year.
Aurangabad and Nanded districts covers more forest area than the others. There are Teak, Sandalwood, Anjan, Moh, Tembhurni, Ain and other kinds of trees in these forests. In Aurangabad district, Gautala is a well known sanctu-ary, Jayakwadi is also famous for bird sanctuary. Thorny scrub forests are hav-ing major trees like Bor, Babul, Aloe-voera etc. The major agricultural crops of the Marathwada region are Cotton, Oil seeds, Bajra, Jowar, Groundnut, Wheat, Safflower and irrigated crops like Sugarcane which is one of the important irrigated crop.
lEGAl
Social Forces
LegislativeForces
Environmental Forces
TechnologicalForces
Organization
PoliticalForces
EconomicForces
MICRO, SMAll & MEDIUM ENTERPRISES DEVElOPMENT (MSMED) ACT, 2006
Definition of Micro, Small and Medium Enterprises :(a) Enterprises engaged in the manufacture or production, processing or pres-ervation of goods as specified below:
i. A micro enterprise is an enterprise where investment in plant and machin-ery does not exceed Rs. 25 lakh;
ii. A small enterprise is an enterprise where the investment in plant and ma-chinery is more than Rs. 25 lakh but does not exceed Rs. 5 crore; and iii. A medium enterprise is an enterprise where the investment in plant and machinery is more than Rs.5 crore but does not exceed Rs.10 crore.
Key initiatives by the Government:a) As per announcement made by the Governor in the Annual Policy Statement 2005‐06, a scheme for strategic alliance between branches of banks and SIDBI located in clusters, named as “Small Enterprises Financial Centres” has been formulated in consultation with the Ministry of SSI and Banking Division, Ministry of Finance, Government of India, SIDBI, IBA and select banks and circulated to all scheduled commercial banks on May 20, 2005 for implementation. SIDBI has so far executed MoU with 15 banks (Bank of India, UCO Bank, YES Bank, Bank of Baroda, Oriental Bank of Commerce, Punjab National Bank, Dena Bank, Andhra Bank, Indian Bank, Corporation Bank, IDBI Bank, Indian Overseas Bank, Union Bank of India, State Bank of India and Federal Bank).
b) Targets for lending to Micro and Small enterprises (MSE) sector by Domestic Commercial Banks and Foreign Banks operating in India.
c) Issue of Acknowledgement of loan Applications to MSME borrowers.
d) Banks are mandated not to accept collateral security in the case of loans upto Rs.10 lakh extended to units in the MSE sector. Banks are also ad-vised to extend collateral‐free loans upto Rs. 10 lakh to all units financed under the Prime Minister Employment Generation Programme of KVIC.
e) A composite loan limit of Rs.1 crore can be sanctioned by banks
to enable the MSE entrepreneurs to avail of their working capital and term loan requirement through Single Window.
f) Public sector banks have been advised to open at least one specialised branch in each district. As per the policy package announced by the Govern-ment of India for stepping up credit to MSME sector, the public sector banks will ensure specialized MSME branches in identified cluster/centres with preponderance of small enterprises to enable the entrepreneurs to have easy access to the bank credit and to equip bank personnel to develop requisite expertise.
g) UDYOG SETU:Objective: To establish new industries, give information & guidance regarding: •Variousrules®ulationsofGovt.•Variousincentiveschemes.•PermissionrequiredfromGovt./SemiGovt.Institutes•Clearancecertificates.•Variousservicesasperneedofapplicant.•Allaboveservicesatonecounter&withinpredeterminedtimelimit
Strength:1. Historical background of the District useful for Foreign Investor.2. Tremendous scope for ancillarisation of industries Especially in Engineering units3. Central location of India.4. Good communication system available.5. Good Transportation Connectivity available i.e. Road, Rail & Air, with all over India.6. A strong young first Generation Entrepreneurs in Aurangabad.7. Skilled & unskilled man power Available at very low cost.8. Good dealer network & logistic facility is Available.9. Educational Intuition like ITI/Engg. College/IGTR/ CIPET/MCED to facilitate and support to industries.10. Due to major financial institute running in Aurangabad, finance is made easily available to the Industries.
Weakensses:1. Poor Water Supply System.2. Improper maintenance of available Infrastructure3. lack of coordination with different Govt.. Depts.4. Inadequate Working Capital from F.I. & higher rate of interest.5. R & D / Technology up gradation Facilities are not available.6. low level of Business exports7. Awareness Camps/seminars are not organized so frequently.8. High level of skilled man power is not available
Opportunities:1. MIDC has plan to develop Additional MIDC’s in the region which creates good opportunities for industries. (MIDC - Maharashtra Industrial Development Corporation )2. Cluster development programme of Central Govt.. boost for creation of jobs
SWOT Analysis of District Aurangabad
/ skilled & unskilled man power.3. Expansion project of CIPET is playing vital roll for plastics mfg in the region.4. DMIC (Delhi Mumbai Industrial Corridor) Project develops the Region.5. Scope for tourism due to Historical background.6. Major Investment & Job creation due to State Govt.. Mega Project policy.7. Wide Scope for retail sector.
Threats:1. Shortage of Power.2. labour policy to be reviewed.3. Pollution (17th rank district)4. Non availability of Agriculture labour5. Dependency on large scale Industries for ancillary Industries.6. High costing of Industrial land.7. labour union problems. Experts from DIC (District Industries Centre ) document published online.
The cluster comprises of small and medium industries manufacturing product parts for various industries like Bajaj Auto, Crompton Greaves, Verroc group, Videocon, Tata Motors, Piaggio.
The cluster makes sub-components for the OEM’s (Original Equipment manu-factures ) and Tier 1 & Tier 2 suppliers. The products from the MSME units to their customers are tail lamp, foot rest cover, poly-wraps, pet jar, PVC irriga-tion pipes, automotive plastic components, water tank, case for mirror
The key machines used by the plastic cluster are: Injection, Extrusion, Com-pressor, Grinder etc.
The key software used in the plastic cluster are: Tally (for accounting), Micro-soft Excel and Word.
Institutions at Aurangabad•DistrictIndustriesCentre,Aurangabad•MaharashtraIndustrialDevelopmentCorporation(MIDC)•Micro,Small&MediumEnterprises–DevelopmentInstt.Aurangabad–Abranch office of MSME-DI, Mumbai.•MSME-ToolRoom,Aurangabad(IGTR)•NationalSmallIndustriesCorporation(NSIC)•MSME–TestingCentre,Mumbai.•BureauofIndianStandards(BIS)•EngineeringExportPromotionCouncil(EEPC)•SmallIndustriesDevelopmentBankofIndia(SIDBI)•IndianInstituteofTechnology,Mumbai(IIT)•MITCON•MaharashtraCentreforEntrepreneurshipDevelopment(MCED)•Govt.Engineeringcollege,Aurangabad
Category of companies in AurangabadCategory – 1 Suppliers of raw materialsCategory – 2 Plastic Component manufacturers (Tier 1, 2 or 3 suppliers)Category – 3 Part Assembly unitsCategory – 4 Precision Plastic product mfrs.Category – 5 Testing & Analysis unitsCategory – 6 Plastic products small manufacturers & retailers Category – 7 lead Firms (such as Bajal Auto ltd., Crompton Grieves ltd., Videocon, Varroc)Category – 8 Plastic Equipment SuppliersCategory – 9 Outsourcing Companies, Merchant & Traders, Market AgentsCategory – 10 Clearing Agents, CA firms, etc.
Salient features of cluster1. Good infrastructure with RCC buildings and-roads2. Frequent Job orders from customers3. Availability of Business education through MCED.4. Financial assistance from banks for Machines & Infrastructure.5. Sustained growth over the years6. Cluster association looks into welfare of all units.
Survey to arrive at SWOT for each unit and understand their future goals and aspirations
Workshops to identify their training needs and competencies to chalk out a customised growth plan by mutual consent
• Evaluation of success
• Consolidation of learning
• Modifying systems and processes wherever possible
Intervention on:• New Product development• Market linkages• Branding• Display• Sign-ages• Website development and
online marketing• Awareness about Govt. Rules,
Regulations and schemes• Common Facility Centres
• Forming associa-tions or groups to disseminate learning
• Documenting the success stories for reference by others as Best Practices
• To ensure that the cluster becomes sustainable
The 5-E process of Solution- Focused Intervention
Step 1: Eliciting - Obtaining a clear understanding of the Client’s goals at the outset of intervention.Step 2: Exploring – Delving deeper into issues to arrive at possible alternatives.Step 3: Expanding – Enabling the client to expand his success and resources to other areas and encouraged to “do the exception” more frequently.Step 4: Evaluating – Clients’ judgement is yardstick to evaluate the success of intervention.Step 5: Empowering – When desired results are achieved, the focus shifts towards empowering these people to maintain the changes on an ongoing basis by rou-tinely employing maintenance strategies on an ongoing basis.
Turning Process at Mould Technology, MIDC, Waluj, Aurangabad
Survey - Plastic ClusterA total of 27 companies were surveyed
Colour Coding:The following pages have different coloured circles over the photographs to indicate the effectiveness of the process. These are colour coded and also vary in size to indicate relevancy.
Good process/product feature/practice
Decent process/product feature/practice, can be improved further
Name of the Unit: Annu IndustriesAddress of the Company: F – 60, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9225364633 (Vishal Panjabi, Plant head)Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2010
Type of Company: Proprietorship
Company’s Specialization/Product/Services: Nylon automotive parts like chain cover, foot rest cover
Details of the Owners / Partners:
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1 Mr Niraj Goel
55 yrs Owner Graduate
Company’s Initial Investment: 30 lacs
Loan/Financial Assistance taken since the start of the company: Not taken
Annu IndustriesMIDC, Waluj, Aurangabad
Vendor Code Details: It is available for Kumar elastomer Pvt ltd., Tata motors and PIAGGIO for products such as Tail lamps, chain cover and foot rest cover.
Types of Customer:Type Total number of
CustomersNames/List of Customers Products
ManufacturedAutomotive 2 Kumar Elastomer and Tata
Motors
Total number of Employees at the company: 45
Types of Business: As a Tier 2 Supplier to OEM for products such as Chain cover, foot rest cover, tool lamp
Area of the Unit: Plot area is 7000 sq. ft.
Certifications: TPM
Audit Reports: Yes
Types of Machines: 12 injection moulding, grinder, Mixer, etc.
Raw materials: Nylon
Warehouse/Storage of Raw material (Inventory Control Techniques)Order Quantity: As per customer requirementOrder Process: Direct from SupplierQuality Control: Yes as per requirement
Marketing and BrandingEffectiveness of the company logo Medium
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Exhibition/trade shows visits: Plexpo and PlastIndia as visitors
Online services Yes
Human Resource ManagementEmployment recruitment rules On The Basis of
• Education• Work Experience in which company• Asking questions• Practical test
Male & Female Employees: 43 Males & 2 Female
Covered under ESI/EPF/Gratuity: Yes
Contract Worker Policy: N. A.
Assistance required from Government in the following areas:• Expansion• Up-gradation• Subsidies on raw material, new product development and business devel-
opment Assistance by CIPET, IGTR, ITI, MCED Aurangabad: N. A.
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement Space arrangement is a concernNew Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No marketing
for business growthHuman Resource Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Need to developWebsite Need to develop better one
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-
gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: Company is supplying 90% of its production to single company. To reduce the business risk Company need to diversify into other products instead of focus-ing on single company.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• A company website needs to be developed on an urgent basis so that the
customer reach can be extended.• As the company need to venture into other products, it requires more pub-
licity on retail level. A proper branding strategy should be formalised to get maximum visibility in the market.
• The brand identity (logo) needs to be more creative, to make a place in the customers perception.
• A proper career growth plan should be formalised, so that the attrition rate is reduced.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• Company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the develop-ment process.
Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Guide bush, switchgear
unit componentsCGl, Toshiba, ERl, BMC, S. M. Auto, Badve Eng.
As a Tier 2 Supplier to OEM Washer and auto parts Kumar elestomer Pvt. ltd.
Area of the Unit:Plot Area 1300 Sq. FeetTotal Built-up Area 1300 Sq. Feet
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2009-2010 6820629 1387497 6475492010-2011 7325062 2224451 13526632011-2012 9444973 2815519 19332112012-2013 10024783 2412054 1395007
Quality Control PlanProject Documentation: Does the company maintain Documents for every Project?
Yes
Quality Control Procedure: (In house/ External agency)
In house
Testing of Raw Materials (Incoming - Quality Control Techniques)
Raw material quality control done by the suppliers. Using test certificates at the MSME’s end
Name of Testing labs for Raw Mate-rials (tie-ups for Raw Materials)
S. N. Metallurgical
Name of Testing labs (tie-ups for Finished Products)
S. N. Metallurgical
Testing of Finished Products It is done in house by manually
Quality Standard for Product:Sr. No. Product name Specification Strictly followed (Yes/No)1 V4 – 3 1079 All dimensions Yes2 K 39217924 All dimensions Yes
3 CAP – 12kv - 005 All dimensions Yes
Quality Manual: Sequence of Interaction of Process
Design & DevelopmentWhat is Design? “Design is the creation of a plan or
convention for the construction of an object or a system. It is a strategic approach for someone to achieve a unique expectation”
Design Process of existing products (choose any top one product that is being manufactured at the company for a OEM or a Customer)
Design Process/Plan for a new Product innovation: APM Plast has decided plan for near future to acquire Horizontal injection moulding machine to produce plastic articals which are more than 250 gms by weight. M/S Easun Reyrolle ltd Bangalore has given concept to produce such items for them.
Secondaly as our current business is vendor base, we propose to produce households items such as plastic buckets, Mugs, jugs and Glass.
To work out this plan we needs assistance in acquiring machine of appropriate capacity additional land for machine and running capital to run the business.
We had already started one project of key holder for entering in to retail mar-ket prototype of this is being made. Final touches will be given by the 2nd week of Feb 2014
ITEM CODE lDA00010DESCRIPTION Washer NylonVENDOR CODEVENDOR NAME APM PlASTPlACE AURANGABADMOD NO 0RM SPECIFICATIONS NylonCOlOUR NaturalRM RATE-BASIC Rs/Kg 205.00 RM RATE-lANDED Rs/Kg 215.65 UV STABIlISER %ge Rs/Kg 0 0.0000 UVS CHARGES Rs 0.0000 NET WEIGHT Grms 0.1400 RUNNER WEIGHT Grms 0.0900 MElTING lOSS %ge 2.5 0.0058 less UVS WEIGHT Grms 0.0000 GROSS WEIGHT Grms 0.2358 RM COST Rs 0.0508 CONVERSION COST DE-TAIlSMACHINE TONNAGE SEMI AUTOMATMACHINE SHIFT RATE Rs 650.0000 NO OF CAVITY 10.0000 CYClE TIME Sec 40.0000 EFFICIENCY - IN %ge 95.0000 PROD PER SHIFT 6840.0000 MOUlDING COST Rs/each 0.0950 FINISHING COST (Rs) Rs 0.0200 OTHERS
CONVERSION COST Rs 0.1150 0.0000 0.0000 0.0000
BOUGHT OUT ITEM COST Rs 0.0000 PROFIT (%ge) : RM 10 0.0051 PROFIT (%ge) :lABOUR 10 0.0115 I C C (%ge) 0 0.0000 SAlES TAX IMPACT (%ge) - 0.0000 REJECTION (%ge) 0 0.0000 PACKING 0.0200 TRANSPORT 0.0200 TOTAl COST --> 0.2225
-->--> 0.22
Raw material break upBASIC 205.0000 EXCISE 12 25.3380 TOTAl 230.3380 SAlES TAX 5 11.5169 TOTAl 241.8549 TURN OVER TAX 0 0.0000 SURCHARGE ON ST 0 0.0000 TOTAl 241.8549 OCTROI 2.75 6.6510 COlOURING (RS/KG) 0 0.0000 TRANSPORT AND HANDlING 4.0000 TOTAl 252.5059
lESS ST SET OFF 5 11.5169 lESS EXCISE CREDIT 100 25.3380
RM lANDED (RS/KG) 215.6510
Explain the Distribution Process. Backward Linkages and Forward Linkages (Supply Chain): Direct sale to customer. No distributor chain
Human Resource ManagementEmployment recruitment rules There are no special rules for recruit-
ment but for operator education is at least 10th pass.
Money charged (in Rupees) by contractors for each worker/staff in case the workers/staff are recruited through Contractors
Rs. 10,000
Training Policy for the new recruits and already employed with the company:For New Recruits For Already Employed
Machine Operator Competence review attached
And training needs
SupervisorManagerHelper/Cleaning Staff
leave Policies: N. A.
Overtime Policy: N. A.
Insurance/Medi-claim Policy: Covered under EsIC / Covered under WCT
Wage Rate Policy:Staff Wage Rate PolicyMachine Operator 150 – 250 Rs. Per day basicSupervisor 300 Rs. Per day basicManager 35000 Rs. Per MonthHelper/Cleaning Staff 150 – 200 Rs. per day
Salary Structure::Staff For Fresher (in
Rupees)With experi-ence of 3 years (in Rupees)
Training required, if yes then please mention the training
Machine details if produced In house
Machine Oper-ator
250 275 N. A. N. A.
Supervisor 400 600 N. A. N. A.Manager 3500 40000 N. A. N. A.Helper/Cleaning Staff
• One horizontal injection moulding machine of 200 T
Assistance by MCED, Aurangabad:• Entrepreneurship Development Programme is beneficial for our Managers• MCED always helps us by giving information about plastic clusters and
other surveys
SWOT Analysis of the CompanySTRENGTHS• Technical expertise and core
knowledge in plastic moulding polyurethane and epoxy mould-ing with more than 25 years of experience.
• Tailor made products as per cus-tomer demands.
• Supplying products to different types of industries which includes Automobiles, Electrical, Switch-gear, Packaging, Pharmaceutical, Furniture
WEAKNESSES• Horizontal moulding machine
and appropriate land is not avail-able.
• Plastic products weighting more than 200gms cannot be manufac-tured with current machinery
THREATS• Almost 70% of the business
comes from one customer.• lack of advanced technology and
production.
OPPORTUNITIES• To create ever growing demand of
heavy plastic products (more than 200gms) in nearby waluj, Paithan and shendra MIDC
• To supply epoxy and polyure thane parts weighting more than 5kg to switchgear industries.
Future Plan of the CompanyTime-lines
Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months To manufacture components weighting more than 250gms for industrial as well as domestic market
Finance, land and Machinery
With increase in production ca-pacity sales will increase there by employment will be generated.
1 year N. A. N. A. N. A.3 years N. A. N. A. N. A.5 years N. A. N. A. N. A.
Product Design BriefDesign Brief
Design & development of new plastic products and estimated cost for the same up to 10 lacs to 30 lacs
Plan of the Design ProjectProduct Design Brief specifications Plastic injection moulded compo-
nents weighting 250 gms and aboveProposed Design Process N. A.Timeline 6 months June, 2014Budget Rs. 30 lacsTeam members & Skills Required N. M. Kawathekar / S. Y. Deshpande /
A. N. KawathekarBenefits for the Company Increase in product capacity will lead
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergo. Need to improvePlant layout Im-provement
• Space arrangement is a concern as the plant area is congested
• No use of Natural light• No Workstation or work arrangement for labours
NPD No in-house product development process followedPackaging Need to improveMarketing • Market awareness is a problem. No marketing for business
growth• Good branding material available• Sample swatches are available
Human Resource Focus on manpower training by chalking out customized train-ing programs and evaluation of the workers after undergoing the programs.
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid
pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) luggage. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Branding exercise needs to be conducted on priority basis as the company
aspires to get into the household product segments. Trademark registration should be taken to protect equity and prevent litigation in future.
• There is a huge dependence on one customer which might harm the busi-ness in the long run. Increasing the customer base is mandatory for long term sustenance and growth.
• Assistance should be provided to the company to set up their stall in exhi-bitions to highlight their products to the retail and manufacturing partners.
• Re-structuring of the website to increase vendor accessibility.• As the company plans to get into retail consumer segments like plastic
buckets, jugs, mugs etc. it should develop its distribution channel to reach out to the right target market.
Name of the Unit: Rajesh K. SanghaviAddress of the Company: B-72, M.I.D.C., Waluj, Aurangabad, Pin: 431136, Maharashtra, Indialandline number: 0240 - 2556612, 2555855Fax : 0240 - 2555902Mobile Number: 9371135475, 9371135480Company e-mail id: [email protected]: www.sanghavigroup.co.in Company started in: 1998
Types of Machines: Injection Moulding, Hopper, Mould Temperature & Mix-ers
Raw materials: Average cost of Raw materials is Rs. 100 to Rs. 250/kg• Poly-propylene• lDPE• HDPE• Nylon 6• Polycarbonate• ABS• Dupont
No. of Shifts/day: 2 (7am – 7pm and 7pm – 7am)
Quality Control Plan• No quality check done for Raw Material. Brand name is an indicator of
quality.• Plating is outsourced.• 80% - 90% importance given to Aesthetic look, Dimensions and Branding
are also checked.• 100% of the products are checked visually.
Design & DevelopmentR&D:• All the moulds are developed in-house. No outsourcing.
• After receiving the order, they study the drawings and check
Inquiry received from
Clients
Drawings are studied
Tolerance issues are
checked with Clients
Clearance taken from
Clients
Moulds are prepared
E.g. Metallic washers converted into Plastic washers, Exploration in market items like Industrial bobbin or spool. No specific budget allocated for R&D. Visited Switzerland for developing a mould.
Softwares used:Deven Infotech, softwares for TPM
Trade shows:Only attended but not participated.• Plastovision• Amtex• Chinaplast• PlastoIndia
Visited China to attend Trade Show.
Safety standards in the Company:All machines are safe and as per the specifications of safety norms.
Effectiveness of the company logo Medium. No need to focus on Brand-ing and Marketing as it is a B2B business and Brand awareness of the company is high in its target market.
Online services No
Company Label: Tags and labels are put on every part. Supplies are made in bins which have replaced corrugated boxes.
Human Resource Management• Total employee strength: 110• Hiring through references or HR contractor.• No qualification required for workers but compulsory for staff.• Weekly off on Friday.• No paid leave for workers.• 5-6 days leave for workers in Diwali, May 1st-labour Day and 2 more days
of leave during other festivals during the year. • All employees are covered under ESIC and yearly health check-up conduct-
ed on campus.• Training is imparted at regular intervals. 4 days of training per month. 12%
- 15% increment per annum. Career path for employees is being worked out and assessment will be made through software.
Views on Government Initiatives taken so far:• Govt. Is not bothered if the company has received payment from vendor or
not. There is no relaxation on interest rates or Sales tax or concessions in Excise Duty.
• Grants are enough. • All India Plastic Manufacturers Association is also working efficiently.• MASSIA cluster and CEPAT are working for their benefit.
SWOT Analysis of the CompanySTRENGTHS• Their Brand Awareness in the
B2B market as their capacity is always full.
WEAKNESSES• No new product development
mechanism• Marketing not in place
THREATS• Chinese products other than mo-
torcycles where the Japan based products sell better.
• Support from OE as there is com-plete dependence on OE market.
OPPORTUNITIES• New customers need to be ac-
quired.• New products need to be devel-
oped with existing machinery
Future Plan of the Company• Entryintothemarketforallelectricalmachines.• 2-3CopyrightedproductsforstrengtheningBrandIdentity.• DonotwanttogetintoRetailbusinessasitisacashbasedbusinessandrequires huge investment in marketing.
FindingsProduct Design & ProcessTechnology High investment in technologyAesthetics As per the product requirementsQuality As per the product requirementsOperations As per the product requirementsWorkplace & Ergonomics Need to improvePlant layout Improvement Well PlannedNew Product Development No dedicated Product Development wingPackaging As per requirementMarketing Brand awareness is high in the B2B marketHuman Resource Satisfactory
Business DesignMarketing Satisfactorylogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Very well managed as per the cluster standards. However, since the company has the potential for becoming a national player, latest machinery and technol-ogy needs to be employed to be in sync with global standards.
Supply Chain & Operations: The company is efficiently handling it’s supply chain and operations but further streamlining might help since the company plans to diversify into different product categories in future.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: The company needs to set up a dedicated product development wing and even collaborate with Govt. bodies to take up consultancy projects for new product development. It can also look at producing cheaper variants of internationally successful products.
Human Resource: Although the company takes substantial initiatives to train its people, more investment in hiring experts might help in new product development process.
Marketing:The company is banking heavily on its brand awareness in the current target market. However, it should not become complacent as new competitors with greater marketing efforts might erode its equity in future.
Participation in trade shows and more online marketing might be effective solutions to tackle the issue.
FindingsProduct Design & ProcessTechnology As per standardAesthetics Good Quality SatisfactoryOperations Safety kits are not provided to the operatorsWorkplace & Ergonomics NeededPlant layout Improvement • Space arrangement is a concern as there is
lot of congestion of machine.• No use of Natural light.
New Product Development Yes, R & D in process for bottling machineryPackaging Yes, goodMarketing Good market presence in bottling automationHuman Resource 1 year training is provided to new recruit
Business DesignMarketing Yes, need to improvelogo Design NoVisiting Card NoBrochures & leaflets NoWebsite Yes
Recommendations• As company has plan for huge expansion, company logo has to more
creative and need to be protected. it has good visibility in market, need to capitalise on that.
• Production layout is not so good. Sufficient space has to be kept between machinery so the better working condition.
• Very less safety precautions are taken by workers, this need to be improved
by providing gloves and other safety gears to workers.• The work area need to be cleaned regularly and scraps and used tools re-
moval process has to be planned. • Need to focus on regular maintenance and servicing of machines to avoid
pre-mature wear and tear.• There is an urgent need for the certification of the company as this will
improve the image of the company in the market. For this proper record keeping in all departments is needed.
• No testing is done on the product during production, so proper quality control procedures need to be formed.
Name of the Unit: Cool EngineeringAddress of the Company: Plot no 23, MIDC, station Road, Aurangabad, Maharashtra, IndiaLandline number: 0240-2321065Mobile Number: 9822019718Company e-mail id: [email protected] No.: 0240-2335968Website: www.coolengineering.co.in Company started in: 1990
Type of Company: Partnership
Company’s Specialization/Product/Services• Custom made machinery, fabrication of refrigerators, chillers
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
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join
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Com
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Pers
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1 S. P. Kale 54 Partner BCom 0 - 9822019718
2 Ajay Sathe - Partner 0 - -
Company’s Initial Investment: 3 lacs
Cool EngineeringMIDC, Station Road, Aurangabad
loan/Financial Assistance taken since the start of the company:Sr. No.
Bank Name / Govt. Assistance
Year Purpose Amount (Rs.) Status (Ac-tive/Closed)
1 Bank of Maharashtra 2013 Machineries 60 lacs Cash credit
Total number and List of Vendors or Suppliers: Two
Total number of Employees at the company: 7 (All males)
Types of Business: OEM
Area of the Unit: 3000 sq ft
Certifications: ISO9001
Competitors: Bluestar and Voltas
Machines & raw materialsTypes of Machines: Compressor, Bending m/c, spot welding, drilling, grinder
Raw materials: Stainless steel sheets, copper tube and pipes
Does the company maintain Documents for every Project?
Yes
Quality Control Procedure: (In house/ External agency)
Yes
Testing of Raw Materials (Incoming - Quality Control Techniques)
Yes
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
No
Name of Testing Labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products Yes
Exhibition/trade shows visits
Sr. N
o.
Exhi
bitio
n /
Show
Part
icip
ant /
V
isito
r
Last
atte
nded
(Y
ear)
Fees
(in
case
th
e co
mpa
ny
part
icip
ated
)
Bene
fits
1 Canton, China Visitor 1993 N. A. N. A.2 Singapore Visitor N. A. N. A.
Marketing and Brandinglogo of company:
Effectiveness of the company logo Medium
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Online services Yes
Human Resource ManagementEmployment recruitment rules On The Basis of
• Education• Work Experience in which company• Asking questions• Practical test
Male & Female Employees: 7 Males & 0 Female
Shift timing: 9 AM to 6 PM (One shift)
Salary Structure: Machine Operator (4000-5000), Supervisor (7000-8000) and Manager (10000)
Covered under ESI/EPF/Gratuity: Yes
Contract Worker Policy: N. A.
Assistance required from Government in the following areas:• Expansion• Up-gradation• Subsidies on raw material, new product development and business devel-
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement Space arrangement is a concern as the plant
area is congestedNew Product Development In-house product development process fol-
lowedPackaging Need to improveMarketing Market awareness is a problem. No marketing
for business growthHuman Resource Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Need to developWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space
allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home appliances.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• A website need to be up-graded on urgent basis so that the customer reach
can be extended.• As the company is venturing into other products, it requires more public-
ity on retail level. A proper branding strategy should be formalised to get maximum visibility in the market.
• A logo needs to be more creative, to make a place in the customers percep-tion.
• A proper career growth plan should be formalised, so that the attrition rate is reduced.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
Name of the Unit: Darshan PlasticsAddress of the Company: W – 71, Near Kamgar Chowk, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 8007800122Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2002
Type of Company: Partnership
Company’s Specialization/Product/Services• Automobile lighting parts• Indicator parts
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
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d.
Phon
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mbe
r
1 Mr. Ashok Thorat - Partner B. E. Mech.
- - -
2 Mrs. Thorat - Partner BSC - - -
Darshan PlasticMIDC, Waluj, Aurangabad
Loan/Financial Assistance taken since the start of the company: Not taken
Vendor Code Details: For Varroc and Videocon
Production capacity of the Unit: 2.5 tons per day in 2013-14
Human Resource ManagementShift Timings: 9 AM to 5:30 PM
Number of Shifts per day: 2 two for operators (12 hours), three for engineers (8 hours) and general shift ( 9 am to 6:30 pm) for other staff
Overtime Policy: Payment according to overtime hours
Insurance/Medi-claim Policy: Yes
Covered under ESI/EPF/Gratuity: Yes
Contract Worker Policy: No
Career Graph Plan for Employees: Growth & continues development under motivation & guidance
Retention Policies and Welfare Schemes: Insurance Policies
Assistance required from Government in the following areas:• Guidance about new product development • Awareness about the new schemes and training programs organized by
various agencies
SWOT Analysis of the CompanySTRENGTHS• Composite moulding• Manufacturing of complex prod-
ucts
WEAKNESSES• 80 % business depend on only
one customer• No new product development
mechanism
THREATS• No threat as such as the product
is more complex and need huge investment for the new entrant
OPPORTUNITIES• New customers need to be ac-
quired.• New products need to be devel-
oped with existing machinery• Enter into mould manufacturing
Future Plan of the CompanyTimelines Plan Assistance required by the
Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months New plant of size 10000 Sq ft under construction
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations SatisfactoryWorkplace & Ergonomics Satisfactory Plant layout Improvement Satisfactory New Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No marketing
for business growthHuman Resource Good training initiatives for the workers
Business DesignMarketing No marketing initiative logo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Need to develop
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-
gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: No new product development process is carried out. Company should look out for the new products that can be manufactured with the existing facilities to increase the customer base rather than depending on single customer.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:Company is supplying products to only single company Verroc. The company should increase its customer base to reduce the risk on the business.
As there is no marketing activity by company, it should start its branding in the market. A website should be formed as early as possible and advertisement should be given to various web portals like indiamart.com and alibaba.com to get more visibility in the market.
As company has plan for huge expansion, company logo has to more creative and need to be protected.
Name of the Unit: Electro Plast IndustriesAddress of the Company: K-49, MIDC, Waluj, Aurangabad, Pin: 431136, Maharashtra, Indialandline number: 0240-2040186Mobile Number: 919890217103Company e-mail id: [email protected] No.: 0240-2040186 Company started in: 1992
Type of Company: Proprietorship
Company’s Specialization/Product/Services:• llDPE Water Tanks ranging from 300 l to 5000 l
Production capacity of the Unit:Year Production capacity2013-2014 1445000 lTR2013-2012 1150000 lTR2012-2011 1050000 lTR2011-2010 850000 lTR2010-2009 700000 lTR
Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Supplier / Tier 3 Supplier
1 Ram Polymers Water Tanks N. A.2 Sarita Tank Water Tanks N. A.3 Spintex Group Water Tanks N. A.4 Saraswati Water
TankWater Tanks, PVC Pipes
N. A.
5 Harsh Industries Water Tanks N. A.
Company Plant and Process FlowCompany’s Plant layout:
Extrusion
Section
Raw Material
Storage
Storage for
Finished Goods
Rotomoulding
Machine
Parking
Tank
Wastage
Storage
Toilet
Office
Chiller
Pulverizer
Powder
Storage
Types of Machines
Sr. N
o.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Spec
ifica
tion
Pric
e of
the
Mac
hine
Year
of
Purc
hase
Loan
/ by
Self
1. Extrusion 1 Raj Engineering, India
110 Mm 7 lakh 2003 By Self
2. Cutter 2 Raj Engineering, India
Cc-1541 50 Thousand 2003 By Self
3. Mixer 1 Raj Engineering, India
35 Hp Motor Qm-F9
1.5 lakh 2003 By Self
4. Grinder 1 Khalil, India 20 Hp Motor Pd-1100m
50 Thousand 1992 By Self
5. Pulveriser 1 Naroto, India 300 Mm Disc 5 lakh 2011 By Self6. Pulveriser 1 Plasmec, India 600 Mm Disc 20 lakh 2012 By Self7. Box- Type 1 Naroto, India 4 Hp Motor
With A/C Drive
8 lakh 2003 By Self
Types of Tools
Sr. N
o.
Nam
e of
M
achi
ne
Qua
ntity
Mak
e of
m
achi
ne
Spec
ifica
tion
Pric
e of
the
Mac
hine
Year
of
Purc
hase
Loan
/ by
Self
1. Hand Grinder
2 Hitachi, India PD 100M 27000 2012 By Self
2. Hand Drill 1 Hitachi, India CC 40 8200 2010 By Self
Information of Workers, Supervisors, Managers and Staff for cleaning:
Shift Timings: 8AM to 8PM and 8PM to 8AM
Number of Shifts per day: 2
Sr. N
o.
Nam
e of
wor
ker
Age
(yrs
)
Gen
der (
M/F
)
Wor
kers
/ Su
perv
isor
/M
anag
er /
Staff
for
clea
ning
Qua
lifica
tion
Ope
ratio
n / F
unct
ion
Year
s of e
xper
ienc
e in
In
dust
ry
Wor
king
hou
rs /
day
1 Wagmare 38 M Operator 12th Pass 12 Years 12 Hour2 Dhani Ram 32 M Helper Matric 5 Years 12 Hour3 Ram Babu 37 M Operator Matric 10 Years 12 Hour4 Shankar 44 M Operator 12th Pass 17 Years 12 Hour5 Mukesh 38 M Operator 12th Pass 7 Years 12 Hour
6 Suresh 28 M Helper Matric 8 Years 12 Hour7 laxmi Devi 32 F Helper Matric 4 Years 8 Hour8 Babu Ram 35 M Helper Matric 5 Years 12 Hour9 Shobha Rani 28 F Helper Matric 5 Years 8 Hour10 Gajanan 29 M Supervisor Graduate 8 Years 12 Hour11 Mobin 25 M Accountant Matric 4 Years 12 Hour12 Mujfar 28 M Sales Graduate 8 Years 12 Hour13 Kavri Devi 34 F Causal 10th Pass 3 Years 8 Hour14 Gouri Shankar 52 M Causal 10th Pass 12 Years 8 Hour15 Rajiv 43 M Sales Graduate 19 Years 12 Hour16 Mera Rani 38 F Causal 10th Pass 4 Years 8 Hour17 Maane 27 M Driver 12th Pass 7 Years 12 Hour18 Patil 35 M Security 12th Pass 4 Years 12 Hour
Functions/Operations in the company:Function / Operation
Quality Control PlanProject Documentation: Does the company maintain Documents for every Project?
No
Quality Control Procedure: (In house/ External agency)
• Standardized Manufacturing Process• Inspection At Pelletizing Stage For
Colour • Inspection Of Powder After Pulveri-
zation For Correct Mesh Size• Inspection Of Final Product Tank For
Aesthetics, Pinholes, leakages.• Inspection For Patches And Delami-
nationTesting of Raw Materials (In-coming - Quality Control Tech-niques)
Product Purchased From Reputed Su-pliers like Gail. Certificate Of Quality Received With Consignments. Occasional Testing at CIPET
Name of Testing labs for Raw Materials (tie-ups for Raw Mate-rials)
CIPET Aurangabad
Name of Testing labs (tie-ups for Finished Products)
In-house testing
Testing of Finished Products Inspection of Final Product Tank For Aesthetics, Pinholes, leakages.Inspection For Patches And Delamina-tion
Quality Standard for Product:Sr. No. Product name Specification Strictly followed (Yes/No)1 Water T-anks Non ISI product
manufactured
Design & DevelopmentWhat is Design? “Design as per dictionary definition
is a plan or drawing produced to show the look and function of a product to be manufactured.”
Design Process of existing products: When the company entered market there were existing established players who had already standardized product design. But at that most tank manufac-turers were using Mild steel moulds in which surface finish of resultant prod-uct was not good.
Electro Plast was one of the few companies who started making tanks in Stain-less steel moulds in which inner surface is very smooth and tanks were also with good surface finish.
The process followed for existing product is studying the accepted norms/de-sign in the industry. Then finding out advantages and disadvantages and then working for improvements required.
Design Process/Plan for a new Product innovation: For any new design the process followed is studying the accepted norms/de-sign in the industry. Then finding out advantages and disadvantages and then working for improvements required in association with machinery manufac-turers and mould manufacturers.
Budget allocated for Research & Development (Annually in Rs.)
No specific budget allocated. Mini-mum Rs. 25000 per year
IT/CAD/Softwares/CAM used in the Company
Help of outside agencies taken. In house designing facilities not availa-ble
Exhibition/trade shows visits: N. A.
Safety standards in the Company:Manufacturing Op-erations
Possible accidents / hazards
Safety measures in the company
Remedies / Medica-tion
Electrical operations Fire Fire extinguishers
Marketing and BrandingBrand of the Company: POlO
logo of company:
POlO Tank is a brand by Electro Plast Industries
Effectiveness of the company logo Medium
Describe the Company’s Target Market: Hardware and Sanitary equipment Retailers
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Online services No
Company label: N. A.
Company Packaging: N. A.
Finance & AccountsCosting: Raw MaterialRaw Material Quantity
(Kgs)Rate (Rs.) Amount (Rs.)
GAIl (Plastic Granules) 100 125 12500Masterbatch 2180 360Processing Charges 102 8 816Total Amount 13676Per Kg cost of making llDPE Powder 134This is per Kg powder cost which is used in water tank 134 per kg
Costing: Water Tank making Cost (1000lts)Items Quantity (Lts) Rate AmountDiesel 2 64 128Powder 21 134 2814Processing Charges 50 50Total Amount 2992This is 1000 lts of water tank cost Rs. 3 per ltr
Human Resource ManagementEmployment recruitment rules Educational qualifications should
be as per job requirement. Previous experience considered. Background check through references given by employee and previous employer
Money charged (in Rupees) by contractors for each worker/staff in case the workers/staff are recruited through Contractors
No involvement of contractor. Direct hiring.
Training Policy for the new recruits and already employed with the company:For New Recruits For Already Employed
Machine Operator Give 10 Days Training in Plant N. A.Supervisor Give 10 Days Training in Plant N. A.Manager Give 10 Days Training in Plant N. A.Helper/Cleaning Staff Give 10 Days Training in Plant N. A.
leave Policies:For New Recruits For Already Employed
Machine Operator Every Friday, local holidays Every Friday, local holidaysSupervisor Every Friday, local holidays Every Friday, local holidaysManager Every Friday, local holidays Every Friday, local holidaysHelper/Cleaning Staff Every Friday, local holidays Every Friday, local holidays
Hometown (Aurangab-ad/Outside Aurangabad but within Maharash-tra/Outside Maharash-tra)
Years of experience in the Com-pany
Machine details if produced In house
Male 14 18 including all Aurangabad Min 3 years N. A.Female 4 N. A. N. A. N. A. N. A.
Covered under ESI/EPF/Gratuity: No
Compensation Plan for workers in case of injury or accidents: Company takes responsibility for any medical assistance required in case of injury or accidents
Career Graph Plan for Employees: Solely on education background and expe-rience merit
Retention Policies and Welfare Schemes: Bonus once in a year
Views on Government Initiatives taken so far: Although there are various schemes implementation is very poor. The paper work is very cumbersome. Moreover there is a lot of red tape and corruption involved.
Assistance by CIPET, Aurangabad: low testing rates for SSI
Assistance by IGTR, Aurangabad: Not Aware
Assistance by ITI, Aurangabad: Not Aware
Assistance by MCED, Aurangabad: Not Aware
SWOT Analysis of the CompanySTRENGTHS• Good product & market
knowledge• low operating cost• Good market credibility• Inhouse powder production
moulded tanks having higher output rates affecting in short term
• Excessive credit offered by bigger companies due slump in demand
OPPORTUNITIES• Knowledge regarding machinery
and experimentation with newer manufacturing processes has opened machinery manufacturing as a new avenue
Future Plan of the CompanyTimelines Plan Assistance required
by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Planning to launch tanks with new attractive design
N. A. N. A.
1 year Rotomoulding Machin-ery manufacturing
• Susbisdy for new ma-chinery
• lower electricity rates
Higher profits for asset creation and employee welfare
3 years • Pulverizer manufac-turing
• Conversion to Pvt ltd company
• Susbisdy for new ma-chinery
• lower electricity rates
Higher profits for asset creation and employee welfare
5 years PET jar manufacturing plant
• Susbisdy for new ma-chinery
• lower electricity rates
Higher profits for asset creation and employee welfare
Product Design BriefDesign Brief 1
New machinery manufacturing plan proposed. New energy efficient design which will save upto 10% of energy heating costs conversion of certain parts of machine to stainless steel from mild steel and introduction of pilot burners.
Design Brief 2
New pulverize manufacturing unit planned with segmented discs which will reduce machine disc cost drastically. Special segments to be made of hardened steel and chrome plated which shall reduce wear and tear.
Plan of the Design ProjectProduct Design Brief specifications
Change of material for certain parts, introduction of pilot burners
Proposed Design Process Design already developedTimeline Upto 31st Dec’14Budget Rs. 8 lac per machineTeam members & Skills Required
Proprietor Shaukat Syed has good contacts with machine shop operators, as he has been always interested in new developments in machinery.
Benefits for the Company lateral marketing concept. We will get into products already associated with our current product market. Net profit Margins are better in machinery, which help create new assets for future expansion and provide funds for employee welfare.
Open wires all around the heaters. These may cause fire and if not attended properly this may give electricity shocks to the workers if these wires come in contact with the workers.
The clutter of pipes seen around the cooling plant.
The window is being used as storage space for the heater cover panels leaving not enough space for the fresh air and light to come in the working area.
The plastic lids are kept outside and in open on their arrival from it’s suppliers. This may soil the lid or damage before it is sent to the retailers.
No proper placement for the fire extinguisher unit.
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement Space arrangement is a concern as the plant
area is congestedNew Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No marketing
for business growthHuman Resource Training initiatives for the workers need to
improve
Business DesignMarketing Needs to improvelogo Design Needs to developVisiting Card Needs to developBrochures & leaflets Need to developWebsite Need to develop
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear and thus the productivity of machines can be im-proved. More amount to be spent on research and development work to devel-op new products which are smaller in size and can cater to larger market.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: n order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: Company currently producing only one type of product, it should venture into other categories to reduce the business risk. Product testing should be done at various levels and report can be prepared to increase customer confidence.
Human Resource: To reduce Employee attrition rate, the salary levels need to be revised to attract better skilled manpower.Proper training should be formalised to improve the skill of the workers.
Marketing:• A website need to be developed on urgent basis so that the customer reach
can be extended.• It requires more publicity on retail level. It urgently requires a modifica-
tion in a logo so that customers identity the product with the company. A proper branding strategy should be formalised to get maximum visibility in the market.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• A company should participate in trade fairs and exhibition related to plas-tics to attract new customers
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
Name of the Unit: Jayshree EnterprisesAddress of the Company: Plot No. M-19, MIDC, Waluj, Aurangabad Maharashtra, IndiaLandline number: N. A.Mobile Number: 8888805868
Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Platina Tail Cap, D-105
Tail CapBottom Cap
Badve Engineering ltd. -VRubber
Rohit Exhaust Systems Pvt ltdAs a Tier 2 Supplier to OEM K G Cover Darshan Plastic
Area of the Unit:Plot Area 6000 Sq. feet.Total Built-up Area 2700 Sq. feet.
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2010-2011 4,70,580/- 1,86,692/- 1,86,692/-2011-2012 23,15,471/- 8,64,420/- 2,29,404/-
8 M/C tarrif Rs./shift 1200.009 Cost of preheating Rs./shift 0.0010 Cycle time Sec. 30.0011 No. of shots/8 hrs shift due to lower volume Nos. 96012 No. of cavity Nos. 213 No. of pieces/shift Nos. 192014 Prod. by efficiency@90% % 172815 Moulding cost Rs. 0.69416 Finishing cost Rs. 0.00017 Prod. with 1% Rej Rs. 0.0118 Total cost of moulding comp. Rs. 0.6919 Total effective cost Rs. 4.00920 Profit 10% on effective cost Rs. 0.41021 Total cost of component Rs. 4.41022 ICC on RM - 3% 0.09923 Reprocess cost per piece Rs. 0.00024 Packing cost Rs. 0.05025 Transportation cost Rs. 0.04026 Final rate with RM per piece Rs. 4.60
Distribution Process:Finished product dispatched to customer by transport or customers directly purchased from our factory premises by their own vehicle.
Human Resource ManagementEmployment recruitment rules
• Minimum 3 yrs of work experience • Good manpower handling skill• Well knowledge of plastic injection Moulding Machine
Leave Policies:Staff Leave PolicyMachine Operator Inform before 10-15 days
Supervisor Inform before 10-15 daysManager Inform before 10-15 daysHelper/Cleaning Staff Inform before 10-15 days
Overtime Policy: Overtime is given as per their working hours
Insurance/Medi-claim Policy: United India Insurance company
Wage Rate Policy: As per their skill
Salary Structure:Staff For Fresher (in Rs.) With experience of 3 years (in Rupees)Machine Operator 150/shift 190/shiftSupervisor 200/shift 250/shift
Hometown (Aurang-abad/Outside Au-rangabad but within Maharashtra/Out-side Maharashtra)
Years of experience in the Company
Machine details if produced In house
Male 5 1 Supervisor, 1 Accountant, 1 Production Head, 2 Operator
With-in Maharashtra 2
Female 2 De-flashing With-in Maharashtra 2
Views on Govt. Initiatives taken so farAssistance required from Government in the following areas:• Electricity Rate Very High Compare to other State• Government Scheme is not aware of new business men• Road Facility is not good for transport • Develop New Plastic industries
FindingsProduct Design & ProcessTechnology As per standardAesthetics As per the product requirementsQuality As per the product requirements Operations Need to improveWorkplace & Ergonomics Workplace need to be properly managedPlant layout Improvement Need to be more efficiently managedNew Product Development No in-house product development process
followedPackaging Yes, satisfactoryMarketing Not much visibility in marketHuman Resource Training is provided to new recruit
Business DesignMarketing No marketing, need to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Need to create a website
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Very less safety precautions are taken by workers, this need to be improved by providing gloves and other safety gears to workers.
Financials: n order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:Company is supplying products to only single company Badwe Engineering. The company should increase its customer base to reduce the risk on the busi-ness. As there is no marketing activity by company, it should start its branding in the market. A website should be formed as early as possible and advertise-ment should be given to various web portals like indiamart.com and alibaba.com to get more visibility in the market. As company has plan for huge expan-sion, company logo has to more creative and need to be protected.
Quality Control:A quality control procedure has to be formed as there is no formal testing is done on products; products only checked visually for quality
Name of the Unit: Jyoti Industries (sister concern of Sushma Industries)Address of the Company: D – 107, MIDC, Shendra, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 8928187703, 9404012247, 9822193777Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2007
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergonomics Need to improvePlant layout Improvement Well plannedNew Product Development No in-house product development process
followedPackaging As per requirementMarketing Brand awareness is high. Kisan PVC Pipes is a
well known brandHuman Resource Needs improvement
Business DesignMarketing Satisfactorylogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Needs to make greater investment in machinery in future to keep pace with the market needs and for scaling up the business.
No software is being used currently. But technology will have to be adopted to manage the business efficiently.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major sectors where the company’s products are used: i) Irrigation, ii) Drinking Water and iii) Electrical. In order to provide regular funding, the company may be linked to the respective corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to become self-sufficient in all the products re-quired for business, they need to undergo product training and even evaluate the feasibility of entering into all the categories vis-a-vis outsourcing the prod-ucts. The balance needs to be worked out.
Human Resource: Currently the number of employees is only 10. Three members of the family manage the business operations. The company perceives it to be a cost advan-tage. However, the outlook needs to change and more number of qualified people need to be hired to strengthen the business and enter into new markets.
Marketing:The company is banking heavily on its brand awareness in the current target market. However, it should not become complacent as new competitors with greater marketing efforts might erode its equity in future. Participation in trade shows and more online marketing might be effective solutions to tackle the issue.
Name of the Unit: Mitali EnterprisesAddress of the Company: Plot No. S-1, opp. Good year tyre, MIDC, Waluj, Aurangabad Maharashtra, IndiaLandline number: 0240-2554011Mobile Number: 9767100466Company e-mail id: [email protected] website: N. A. Company started in: September 2010
Total number and List of Vendors or Suppliers:• Total Supplier - 04 nos• Badve Engineering ltd• Swagat Plymers• Shri Vyankatesh Plymer• Poly Gran India Pvt ltd.
Organization Chart:
Milind Kashide(CEO)
Shift I operators:-1. Ramesh Kapde
2. Anil Dhule
Shift II Operators:-1. Ramnath Dhage
2. Vishnu Kulte
Account Head(Narayan Bhagure)
Quality Head Raju Rudrakshwar
Production Head Sanjay Katolkar
Mrs. Pramila Kashide (MD)
Area of the Unit:Plot Area 3000 Sq. feetTotal Built-up Area 2000 Sq. feet
Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Cowling BM 150 BOXER Plati-
na Side Cover Cap COWlING MIDDlE ASSlY
Badve Engineering ltd
As a Tier 2 Supplier to OEM K G CASEJ D CAPChain Cover
1. Tulja Enterprises2. Darshan Plastics
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2011-2012 36.15 10.22 0.232012-2013 102.90 15.76 1.442013-2014 (expected) 150 N. A. N. A.
Certifications:Certification Description of the
CertificationYear taken in
Local Agent
ISO 9001:2008 Quality Management Sys-tem
2013 Ajit Rajendra
Audit Reports: ISO 9001:2008
Business Competitors:Sr. No.
Competitor’s name
Competitor’s Product Spe-cialization
Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Supplier / Tier 3 Supplier
• For finish product dimensional as well as visual checking is carried out in house
• We are having some of measuring in-strument such as a) Vernier Calliperb) Filler Gauagec) Thread Gauage
Quality Standard for Product:Sr. No. Product name Specification Strictly followed1 K G Case Air Filter No Shrinkage
No Warpage Scratches on insertYes
2 Cowling BM 150 No Scratches, No Weld lineNo shrinkageNo Warpage
Yes
Design & DevelopmentBudget allocated for Research & Development (Annually in Rs.)
15 - 20 lacs
IT/CAD/Softwares/CAM used in the Company
N. A.
Exhibition/trade shows visits:
Sr. N
o.
Exhi
bitio
n /
Show
Last
at
tend
ed
(Yea
r)
Fees
(in
case
th
e co
mpa
-ny
par
tici-
pate
d)
Bene
fits
1 Plast India 2012 Free -2 Plexpo 2013 100 Heavy discount
in spare part3 Advantage Maharashtra Expo 2014 Free -
Safety standards in the Company:Manufacturing Op-erations
Possible accidents / hazards
Safety measures in the company
Remedies / Medication
Manufacturing Fire Fire Extinguisher First Aid Kit
Marketing and Branding:logo of company:
Effectiveness of the company logo Medium. No need to focus on Brand-ing and Marketing as it is a B2B business and Brand awareness of the company is high in its target market.
Describe the Company’s Target Market: Auto Auxillary manufacture
Brand Awareness in respective markets; whether B2B or B2C
High
Initiatives taken to promote the Brand and Respective expenses
Finance & AccountsProduct Pricing: Product Pricing of plastic product mainly depends upon its weight and type of machine requires to produce that part.Item Name Unit CapMaterial - PPCPColour - NaturalNet Wt. gms 1.0Runner gms 15Shot wt. gms 1.47Process loss % 1%Recon Wt. gms 1.0Raw Matl. Cost Rs/Kg 127.00Raw Matl. Cost / piece Rs/piece 0.1RM Profit 3% 0.01Net RM Cost per PC 0.14M/C used Tonns 180M/C tariff Rs/shift 1980cavity nos 32Cycle time secs 48Prod. per shift nos/shift 19200Production @ 90% effeciency nos/shift 17280Moulding cost Rs/piece 0.1Rejection @ 3% Rs/piece 0.00Profit 10% on Conv Cost Rs/piece 0.01Moluding Cost Rs/piece 0.13Cost of RM + Conv Rs/piece 0.27Mould Cost(One year) Rs/piece 0.04Inspection cost Rs/pieceFreight cost Rs/pieceTotal Component cost Rs/Piece 0.31
Terms & Conditions# - Freight & Packing cost is not included.# - Above price is basic price Ex. our Works. Other taxes will be as applicable.# - For supply of components payment within 30 days after dispatch from our end.
Distribution process: Finished product dispatched to customer by transport or customers directly purchased from our factory premises by their own vehi-cle.
Human Resource ManagementEmployment recruitment rules Competence requirement of supervisor:
1. Minimum 8 yr of work experience2. Good manpower handling skill3. Well knowledge of plastic injection moulding.
Training Policy for the new recruits/already employed with the company:For New Recruits For Already Employed
Machine Operator Work Experience Work ExperienceSupervisor Work Experience Work ExperienceManager Work Experience Work ExperienceHelper/Cleaning Staff N. A. N. A.
Leave Policies:Staff Leave PolicyMachine Operator Inform before 10-15 daysSupervisor Inform before 10-15 days
Manager Inform before 10-15 daysHelper/Cleaning Staff Inform before 10-15 days
Overtime Policy: Overtime is given as per their working hours
Insurance/Medi-claim Policy: United India Insurance Company
Hometown (Aurangabad/Outside Aurangabad but within Maharashtra/Out-side Maharashtra)
Years of experience in the Company
Male 08 Operator Outside Aurangabad but within Maharashtra
1.5 years
Female N. A. N. A. N. A. N. A.
Covered under ESI/EPF/Gratuity: N. A.
Contract Worker Policy: N. A.
Assistance required from Government in the following areas:• Various schemes to be informed by any communication medium• Reduce Electricity rate• Reduce water rate
Assistance by CIPET, Aurangabad: Various training is carried out in CIPET for worker.
Assistance by IGTR, Aurangabad: N. A.
Assistance by ITI, Aurangabad: N. A.
Assistance by MCED, Aurangabad: Many Entrepreneur development training
and other useful workshop is carried out.
SWOT Analysis of the CompanySTRENGTHS• Customer satisfaction• Quality Material• Good reputation among customer
WEAKNESSES• Number of competitor• Unskilled labour• Insufficient capital
THREATS• Competitor sale product on lesser
amount• Credit sale recovery
OPPORTUNITIES• Export the product• Scope in own product
Future Plan of the CompanyTime-lines
Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Design & development Finance Improvement in turnover
1 year Purchase new 450 tons machine
Finance Improvement in turnover
3 years Expansion of new unit Finance Improvement in turnover
5 years Increase more machine Finance Improvement in turnover
Product Design BriefDesign Brief 1
Proposed product is having heavy requirement in market
Design Brief 2
It is an automobile part of two wheeler.
Design Brief 3
Very few manufacturer are their for proposed product and supply to direct market will give more profit
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement • Space arrangement is a concern as the
plant area is congested• No use of Natural light
New Product Development No in-house product development process followed
Packaging Need to improveMarketing • Market awareness is a problem. No
marketing for business growth• Good branding material available• Sample swatches are available
Human Resource • Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) luggage. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Website need to be developed to showcase the product portfolio and con-
nect to the buyers and customers.• Branding exercise needs to be conducted on priority basis as the company
aspires to get into the household product segments. Trademark registration should be taken to protect equity and prevent litigation in future.
• There is a huge dependence on one customer which might harm the busi-ness in the long run. Increasing the customer base is mandatory for long term sustenance and growth.
• Assistance should be provided to the company to set up their stall in exhi-bitions to highlight their products to the retail and manufacturing partners.
• Re-structuring of the website to increase vendor accessibility.• As the company plans to get into retail consumer segments like plastic
buckets, jugs, mugs etc. it should develop its distribution channel to reach out to the right target market.
An improved safety shaving disposal razor comprising:
• at least one disposal blade sandwich assembly• at least one sandwich assembly holder• at least one piece of shaving blade• a flap• at least one pivot pin or rivet
Name of the Unit: Moraz PlasticsAddress of the Company: Yeshwant Nagar, Navle, PaithanLandline number: N. A.Mobile Number: 9028173531Company e-mail id: [email protected] Website: N. A. Company started in: In process
Abstract of the Innovation:The present invention [particularly discloses the said safety is fold-able device which is mainly used in saloon and parlours for shaving purposes. It comprises of a flap meant for accommodation the disposable blade sandwich assembly along with the sandwich assembly holder. The disposal blade sandwich assembly is snap fitted in the sandwich assembly holder. The sandwich once snap fitted cannot be removed for changing the blade and if any body tries to do so, the snap breaks from its base, thereby avoiding its further use or reuse by inserting a new blade or further use or reuse of said
Moraz Plastic (Innovator)Paithan, Aurangabad
disposable blade sandwich assembly.
Thus it provides a safety to the user which avoids spreading of various dan-gerous and incurable diseases like AIDS, Hepatisis, etc. which are likely to be spread because of the residues remains on the razor blade assembly through infection and contamination while conducting shaving different persons.
Note: limited study has been conducted on this unit as the product develop-ment is in progress.
Name of the Unit: Mould TechnologyAddress of the Company: W – 74 MIDC Waluj, Aurangabad, MaharashtraLandline number: N. A.Mobile Number: 9370656737 Company e-mail id: [email protected]
Website: N. A. Company started in: 2009
Type of Company: Partnership
Company’s Specialization/Product/Services: Mould Making and products manufacturing
Affiliated units/sister concern/subsidiary: N. A.
Details of the Owners / Partners:
Sr. N
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Nam
e of
Ow
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tor /
Pa
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Di-
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Age
(yea
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Educ
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Qua
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Wor
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1 Bhalchandra Bhandare
40 Owner Diploma in Mechanical Engineering
10 -- 9370656737
Mould TechnologyMIDC, Waluj, Aurangabad
Company’s Initial Investment: 25 lacs
loan/Financial Assistance taken since the start of the company:Sr. No.
Bank Name / Govt. Assistance
Year Purpose Amount (Rs.)
Status (Active/Closed)
1 Shyamrao Vithal Co op bank
2010 Purchase of machinery
25 lacs Paid
2 Bank of Maharashtra 2013 18 lacs Cash credit
Customer Details: Sanjay technoplast, Savera moulding, Varroc, Videocon, Ultima plastics, Higher appliances and Aurangabad Electricals ltd.
Production capacity of the Unit: 8-10 moulds/month
Types of Customer: OEM, Tier 1, 2 and 3 suppliers to OEMs.
Types of Business: OEMs in Aurangabad and Ranjangaon
Turnover of the Unit (in Rupees):Year Annual Turnover2009-2010 40 lacs2010-2011 1 crore2011-2012 1.5 crores2012-2013 1.6 crores2013-2014 (expected) 2 crores
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement Space arrangement is a concern as the plant
area is congestedNew Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No marketing
for business growthHuman Resource Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Need to develop
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space
allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) Poultry. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• A website need to be created on urgent basis so that the customer reach can
be extended.• As the company is venturing into other household products like mugs, it
requires more publicity on retail level. A proper branding strategy should be formalised to get maximum visibility in the market.
• A logo needs to be more creative, to make a place in the customers percep-tion.
• A proper career growth plan should be formalised, so that the attrition rate is reduced.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
Name of the Unit: Plast TechAddress of the Company: C-252/6 A4, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9326206512
Loan/Financial Assistance taken since the start of the company: Not taken
Types of Customer:Type Total number
of CustomersNames/List of Cus-tomers
Products Manufactured
Household Products
- - Plastic Moulded Product
Area of the Unit:Plot Area 1700 Sq. feet.Total Built-up Area 1350 Sq. feet.
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2010-2011 40,00,000/- N. A. N. A.2011-2012 60,00,000/- N. A. N. A.2012-2013 42,00,000/- N. A. N. A.2013-2014 (expected) 50,00,000/- N. A. N. A.
Safety standards in the CompanyManufacturing Operations
Possible accidents / hazards
Safety measures in the company
Remedies / Medication
Manufacturing Fire No Fire Extinguisher No first Aid
Marketing and Branding:logo of company:
Effectiveness of the company logo High
Brand Awareness in respective markets; whether B2B or B2C
Medium
Do you operate Online? No
Human Resource ManagementEmployment recruitment rules
• Minimum 3 yrs of work experience • Good manpower handling skill• Well knowledge of plastic injection Moulding Machine
Overtime Policy: Overtime is given as per their working hours
Workers: Makes (8) and Females (2)
Insurance/Medi-claim Policy: United India Insurance companyWage Rate Policy: As per their skill. Machine operators are paid Rs. 8000/mth
Shift Timings: 7 am to 7 pm and 7 pm to 7 am
Views on Govt. Initiatives taken so farAssistance required from Government in the following areas:• Electricity Rate Very High Compare to other State• Government Scheme is not aware of new business men• Road Facility is not good for transport
Assistance by CIPET, IGTR, ITI, MCED Aurangabad: None
SWOT Analysis of the CompanySTRENGTHS• Excellent product quality• Prompt service• Customer Satisfaction
WEEKNESSES• Insufficient Funds• Un-skilled labour
THREATS• Competitor sale product on lesser
amount• Credit sale recovery
OPPORTUNITIES• To achieve zero customer returns.• To achieve 100 % compliance of
deliveries on scheduled time • To improve machine up time.• Reduction in internal non-
conformities.
Future Plan of the CompanyTime-lines
Plan Assistance required by the Govt. (Finance/Training/Design Assistance, etc.)
Hopper is tied with strings to the machine and is also difficult for the workers to feed raw material in the feeder fitted much higher than their reach.
Waste material and scrap material is seen inside the machine
The moulds area is not maintained properly. Water spillage is seen near the moulds
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Safety kits are not provided to the operatorsPlant layout Improvement Space arrangement is a concern as the plant
area is congestedNew Product Development No in-house product development process
followedPackaging Need to improveMarketing • Market awareness is a problem. No
marketing for business growth• No branding material available
Human Resource Focus on manpower training by chalking out customized training programs and evaluation of the workers after undergoing the programs.
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology:Machines are not maintained properly. Water spoilage near moulds may rust
the mould, so more intense cleaning operation need to be carried out. Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: There is no initiative on the new product development so R&D activities need to be carried out for product diversification.
No certification has been taken for the process or product. This needs to be tackled on priority basis
Human Resource: Training period for workers to be increased to avoid the wastage of raw mate-rial, as well as other training on regular basis to be carried out to up-grade the skill of workers.
Marketing:No marketing activities are carried out by the company, no branding is done. So to increase market share or to acquire more customers, proper market-ing activities need to be carried out. A website needs to be designed. Various exhibitions need to be visited by company official and a stall may be put up for awareness among customers.
Considering the long term plan , own transport vehicle need to be purchased for carrying the finished goods so that the transportation cost can be reduced.
Name of the Unit: Rupesh EnterprisesAddress of the Company: Plot No. D–51/10, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: 0240-2476895Mobile Number: 9881243938Company e-mail id: [email protected]
Total number and List of Vendors or Suppliers:• Design steel Pvt. ltd. - Waluj, Aurangabad• Gaurav Enterprises - Waluj, Aurangabad• Shree Sai Cutting tools - Waluj, Aurangabad• Trigon Enterprises - Pune
Total number of Employees at the company: Worker 3 (Supervisor: 01, Oper-ator: 02, Helper: 01)
Types of Business: Tier 2 supplier
Area of the Unit (in Sq. Ft.):Plot Area 650Total Built-up Area 650
Turnover of the Unit (in Lacs):Year Annual Turnover Gross Profit Net Profit2011-2012 23.45 9.86 3.05
2012-2013 19.55 9.33 3.32
2013-2014 (expected) 25.00 11.90 4.20
Company Plant and Process FlowCompany’s Plant layout:
Office
VMC Machine
Entry Gate30 feet MIDC Road
Working Table
Finished Goods
Surface Grinder
Bathroom
RawMaterial
Bench Grinderlathe
Machine
Milling Machine
Comp-ressor
Types of Machines
Sr. N
o.N
ame
of
Mac
hine
Qua
ntity
Mak
e of
m
achi
ne
Spec
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-tio
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Pric
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th
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a-ch
ine
Year
of
Purc
hase
Loan
/ by
Self
1 Milling M/c 1 Kirloskar, India 1mtr X 400mm X 350mm
Quality Control PlanProject DocumentationDoes the company maintain Documents for every Project?
No
Quality Control Procedure: (In house/ External agency)
As per customer requirement
Testing of Raw Materials (Incoming - Quality Control Techniques)
Raw material quality control done by the suppliers
Name of Testing Labs for Raw Mate-rials (tie-ups for Raw Materials)
N. A.
Name of Testing Labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products It is done in house by manually or done by outside
Design & DevelopmentWhat is Design? N. A.
Design Process: Presently design process not done.
Design Process / Plan for a new Product innovation:Design process will be done in house by using technical & qualified employee, and we will developed new design in plastic Agricultural products, household & other products.
Budget allocated for Research & Development (Annually in Rs.)
Rs.15,00,000/- (proposed plan for development)
IT/CAD/Softwares/CAM used in the Company
Presently used DElCAM software for VMC machining programme
Medium. No need to focus on Branding and Mar-keting as it is a B2B business and Brand aware-ness of the company is high in its target market.
Describe the Company’s Target Market:Export the product and develop new products in automobile & plastic & other industries.
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Do you operate Online? No
Company Label & Packaging: N. A. (Not required for moulds)
Finance & AccountsCosting for Die weight 150kgsSr. no. Description Rs.1 Cost of raw material 0.352 +Processing cost 0.623 +labour Cost (wages) 0.104 Total Cost to company 1.075 Margin 0.256 Selling Cost 1.32
Distribution Process:Finished material dispatched to customer by transport or customers directly purchased from our factory premises.
Human Resource ManagementEmployment recruitment rules
No any specific recruitment rules. Employee’s selection on their skilled and work efficiency.
Training Policy for the new recruits and already employed with the company:For New Recruits For Already Employed
Machine Operator Work experience / trail run Work experienceSupervisor Work experience Work experienceManager Work experience Work experienceHelper/Cleaning Staff Work experience Work experience
Leave Policies: 4 days in month and Public holiday for All.
Machine Operator Wages per hourSupervisor Wages per hourManager Salary per hourHelper/Cleaning Staff N. A.
Insurance/Medi-claim Policy: N. A. (Proposed to start)
Wage Rate Policy:Staff Wage Rate PolicyMachine Operator On work experience or fixed on Rs.6000-7000 p.m.Supervisor On work experience or fixed on Rs.9000-10000 p.m.Manager On work experience or fixed on Rs.10000-12000 p.m.Helper/Cleaning Staff Helper / cleaning fixed Rs. 3000-4000 p.m.
Staff Rs.6000 - 7000 p.m.
Salary Structure:Staff For Fresher (in Rs.) With experience
of 3 years (in Rs.)Training required, if yes then please mention the training
Hometown (Aurangabad/Outside Aurangabad but within Maharashtra/Outside Maharashtra)
Years of experience in the Company
Male 04 Supervisor / Manager / Staff
Aurangabad 2 yrs - 3 yrs
SWOT Analysis of the Company
STRENGTHS• Good reputation among customer• Huge works order in hands• Use pure raw material for produc-
tion, not mix any default material like other customer
WEAKNESSES• Unskilled labour• Insufficient capital
THREATS• Competitor sale produce in lesser
amount• Recovery of Credit Sales
OPPORTUNITIES• Export the products• Design & Develop new Products
Future Plan of the CompanyTime-lines
Plan Assistance required by the Govt. (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months ISO Certification -- Develop material quality
1 year Design & develop new products
Finance / Training / Design Assistance
Acquired new work orders
3 years Export sales Finance Export order
Product Design BriefDesign Brief Design & development of new plastic products
Plan of the Design ProjectProduct Design Brief specifications Various types of Plastic productsProposed Design Process N. A.Time-line 2 - 3 yrsBudget Rs. 15,00,000/-Team members & Skills Required 03Benefits for the Company Develop new products
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement • Space arrangement is a concern as the
plant area is congested• Proper use of Natural light
New Product Development No in-house product development process followed
Packaging Need to improveMarketing • Market awareness is a problem. No
marketing for business growth• Good branding material available• Sample swatches are available
Human Resource • Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII, FICCI and build associations with design insti-tutes, national innovation foundations, etc.
Product: Close tie up needed with companies in FMCG, household products manufac-turers, medical products and relevant industries. New product development and business process needs to be top priority.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Branding exercise needs to be conducted on priority basis as the company
aspires to get into the household product segments. Trademark registration should be taken to protect equity and prevent litigation in future.
• There is a huge dependence on one customer which might harm the busi-ness in the long run. Increasing the customer base is mandatory for long term sustenance and growth.
• Assistance should be provided to the company to set up their stall in exhi-bitions to highlight their products to the retail and manufacturing partners.
• Re-structuring of the website to increase vendor accessibility.• As the company plans to get into retail consumer segments like plastic
buckets, jugs, mugs etc. it should develop its distribution channel to reach out to the right target market.
Name of the Unit: Sejal PlasticAddress of the Company: D -81, MIDC, Shendra, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9370150700
Loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt. Assistance Year Purpose Amount (Rs.) Status1 Mortgage of Plot and Building - - 30 lacs Not Closed2 Transferred by MIDC as a Tri-
party Agreement- land - -
Production capacity of the Unit: Mat size=4 ft*6 ft; 1 machine produces 80 mats. Total 960 mats produced in a day.
Types of Customer:Type Total number
of CustomersNames/List of Customers Products
ManufacturedConsumer Products
N. A. Main markets in Hyderabad, Bangalore and Mumbai
N. A.
Area of the Unit: 800 sq metres
Turnover of the Unit (in Rupees):The expected amount is Rs. 65-70 lacs
Types of Business (give product’s name and its buyer): Mats and Mandap Rolls. Main markets in Hyderabad, Bangalore and Mumbai
Types of Machines: Injection moulding, (3 vertical, 2 horizontal), grinding m/c, cooling plant. A total of 12 local made machines: Avg Price- Rs 1.2 lacs to 2.5 lacs produces 3.5 kgs of mats/hour
Raw materials: Avg Cost of Virgin Material = Rs 55/kg. The main raw materi-als are Polypropelene, Tapes, Cotton and Nylon
Business Competitors: Total No.: 40, the main competitors being Sapna, Satyam ad general Mats
Organization ChartBoss
Manager
Supervisor Supervisor
21 workers
Business process - flow chartProducts manufactured
Transported to local hubs like Shendra/Waluj/ Chikalthana
Wholeseller
Retailer
Design & DevelopmentWhat is Design? Quality in focus, useful to consumers,
aesthetic appeal and longer shelf life
IT/CAD/Softwares/CAM used in the Company
Design software outsourced from Sholapur
Marketing and Branding:logo of company:
Effectiveness of the company logo High
Brand Awareness in respective markets; whether B2B or B2C
Medium
Do you operate Online? No
Exhibition/trade shows visits (mention name and place): Not attended till date
Packaging: 80 mats in one High Density Propylene is used
Pricing:Tax Calculation, VAT, Income Tax, Daily Accounts are done by a hired CA. CA is paid Rs 4000/- to 5000/- per month.Cost = Raw Material+ Power+ labor+ Operating Expenses\
Human Resource ManagementEmployment recruitment rules
• Minimum 3 yrs of work experience • Good manpower handling skill• Well knowledge of plastic injection Moulding Machine
Overtime Policy: Generally 1.5 times of regular salary but overtime not al-lowed for more than 4 hours
Employees: 25
Insurance/Medi-claim Policy: Nil
Wage Rate Policy: As per their skill. Machine operators are paid Rs. 8000/mth
Shift Timings: 7 am to 7 pm and 7 pm to 7 am
Leave Policies: Government leaves are given to workers
Salary Structure: Rs. 250/day for 25 days in a month for Machine operators and Rs, 12000 for supervisors.
Views on Govt. Initiatives taken so farCommunication of Govt. initiatives is not done properly. Most of the times they are not aware about the schemes. They are not aware about the process or even whom to approach.
Assistance required from Government in the following areas:Transportation of laborsAssistance in payment cycleWater supply issues
Assistance by CIPET, IGTR, ITI, MCED Aurangabad: None
SWOT Analysis of the CompanySTRENGTHS• Experience in the business• Marketing Expertise• Quality of products manufac-
tured
WEEKNESSES• Unskilled labors• Absenteeism due to lack of con-
veyance issues
THREATS• Break in Payment Cycle• Recession in the Industry
OPPORTUNITIES• Design and Raw Material
Improvement
Future Plan of the Company
Time-lines Plan6 months Streamline operations1 year Purchase new machine2 years Expansion of new unit
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality Needs up-gradationOperations As per the product requirementsWorkplace & Ergonomics Need to improvePlant layout Improvement Well plannedNew Product Development No dedicated Product Development wingPackaging As per requirementMarketing Brand awareness is high in the B2B marketHuman Resource Needs to improve
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: There is a need to invest in premium and more technologically advanced machines as product differentiation is the key to achieve competitive growth in this market. Technology can also enable the company to enter into online operations which it has still not explored.
Supply Chain & Operations: Exploring new raw material vendors and tapping new customers is essential for increasing the market share and be competitive in the industry.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: The company needs to set up a dedicated product development wing and even collaborate with Govt. bodies to take up consultancy projects for new product development.
It can also look at creating new patterns and weaves. Product diversification into the Home Decor industry will enable the company to enter into new mar-kets and de-risk business by reducing dependence only on one or two product categories.
Human Resource: Investment in manpower training, adopting safety measures and providing insurance/medi-claim facilities is crucial. Moreover, the company also needs to chart out career progression path to retain talent.
Marketing:The company is banking heavily on its brand awareness in the current target market. However, it should not become complacent as new competitors with greater marketing efforts might erode its equity in future.
Participation in trade shows and online marketing might be effective solutions to tackle the issue.
Name of the Unit: Siddhi PolyweaveAddress of the Company: Plot No: l-18/1, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 09970053151Company e-mail id: [email protected]: N. A. Company started in: 2012
Leave Policies: Weekly off and additional 20 days in the year
Overtime Policy: Payment according to overtime hours
Insurance/Medi-claim Policy: None
Salary Structure: An average of Rs. 10000 per month. Rs. 300/day for 26 days in a month.
Views on Government Initiatives taken so far:The Govt. subsidies have not been availed so far but would now like to take advantage of the same.
Assistance required from Government in the following areas:• Financial Aid• lower Interest Rate• Awareness about new Technology and quality of Raw Materials
SWOT Analysis of the CompanySTRENGTHS• Good quality Product at low
price• Hard-working team
WEAKNESSES• Financial backing is weak• Margins are very thin (operat-
ing at 5%-8% while it should be around 10%)
• Safety measures• No security at the unit• No design team
THREATS• Prices are moderate. Competitors
sell mats at lower prices.
OPPORTUNITIES• Good market opportunity• Huge demand (currently not able
to fulfil the market demand)
Future Plan of the CompanyTime-lines Plan6 months Tying up with Govt. bodies for availing the benefits of Govt. schemes.
Introduce virgin materials in manufacturing Plastic Mats1 year Plant expansion : Expansion by investing in 8 more machines3 years 5 cr turnover to be achieve5 years Diversification in other engineering product line
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement • Space arrangement is a concern as the
plant area is congested• No use of Natural light
New Product Development No in-house product development process followed
Packaging Need to improveMarketing • Market awareness is a problem. No
marketing for business growth• Good branding material available• Sample swatches are available
Human Resource • Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) luggage. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Branding exercise needs to be conducted on priority basis as the company
aspires to get into the household product segments. Trademark registration should be taken to protect equity and prevent litigation in future.
• There is a huge dependence on one customer which might harm the busi-ness in the long run. Increasing the customer base is mandatory for long term sustenance and growth.
• Assistance should be provided to the company to set up their stall in exhi-bitions to highlight their products to the retail and manufacturing partners.
• Re-structuring of the website to increase vendor accessibility.• As the company plans to get into retail consumer segments like plastic
buckets, jugs, mugs etc. it should develop its distribution channel to reach out to the right target market.
Name of the Unit: Snehal Plastic Industries (10 years back was Sachin Plastic Industries)Address of the Company: M – 127, MIDC, Waluj, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9325212359, 8888837992Company e-mail id: [email protected] No.: N. A.Website: www.snehalplasticindustries.bizporto.com Company started in: 1993
Type of Company: Proprietorship
Company’s Specialization/Product/Services• Injection Moulding (Castor wheel)•Details of the Owners / Partners:
Types of Business:Business Type Products Products supplied toAs a Tier 1 Supplier to OEM Castor Wheel, Spare
Part of Cooler, Mixer and some part of light
Vidieocon, K-stars, Bajaj, Wipro lighting
Area of the Unit: 10000 sq ft
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2012-2013 2.5 crores N. A. 30 lacs (aprox.)
2013-2014 (expected) 3.5 to 4 crores N. A. N. A.
Certifications: ISO9001
Business Competitors: Twenty-five
Machines & raw materialsTypes of Machines: Buffing M/c, Milling M/c, Drilling M/c and lathe M/c
Raw materials: Acrylic, GPPS, PP, PPCP, HD, HD block, Nylon, etc.
Quality Control PlanProject DocumentationDoes the company maintain Documents for every Project?
No
Quality Control Procedure: (In house/ External agency)
No
Testing of Raw Materials (Incoming - Quality Control Techniques)
No
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
No
Name of Testing Labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products Takes place at the buyers place
Quality Standard for Product:Sr. No. Product name Specification Strictly followed1 Pulsar Housing Free from Flash, Welding flow
marks, silver marks Yes
2 612 Holders Free from defect and flash Yes3 Automotive casting Free from silver marks flash Yes4 Dripper Free from flash Yes5 Bottles Free from damage and over deflash-
ingYes
6 Protective Sleeves Free from flash Yes
R & DBudget allocated for Research & Development (Annually in Rs.)
Visitor 2013 N/A Information about latest Technology
Marketing and Brandinglogo of company:
Effectiveness of the company logo Medium
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Online services Yes
Human Resource ManagementEmployment recruitment rules On The Basis of
• Education• Work Experience in which company• Asking questions• Practical test
Male & Female Employees: 14 Males & 1 Female
Covered under ESI/EPF/Gratuity: No
Contract Worker Policy: N. A.
Assistance required from Government in the following areas:• Expansion• Up-gradation• Subsidies on raw material, new product development and business devel-
opment Assistance by CIPET, IGTR, ITI, MCED Aurangabad: N. A.
SWOT Analysis of the CompanySTRENGTHS• Quality – satisfactory customers• Advanced technology• Experienced & trained staff• Development strategies and plans
WEAKNESSES• Financial crunch• No own factory land
THREATS• Development of the firm’s new
design & components (copying) by other competitors.
CostingThe cost of the unit product depends on the design and quality required by the customers. Basic costing depends on the following components such as Raw material cost + pigment (master batch) cost + runner cost + cavity cost + machine shift cost + machine tonnage cost + cycle time (as per hours) + (-) efficiency + finishing + packaging + 5% to 10 % profit + cost of imported component (if applied)
Future Plan of the CompanyTime-lines
Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Purchasing of new land for factory premises and new product development
Finance & Design Assistance Growth of sales & promotion
1 year ISO certification, Building infrastructure development
Finance Better Produc-tivity and build trust and value in market
3 years New product develop-ment and machinery
Finance Growth of sales & promotion
5 years New product develop-ment and machinery
Finance Growth of sales & promotion
Product Design BriefDesign Brief 1
New filter development for 2-wheeler vehicles to increase the mile-age, life and pick up of the vehicle.
Design Brief 2
New design and development of castor wheels
Plan of the Design Project
Product Design Brief specifications
Injection moulded parts
Proposed Design Process Study and designing and researching according to actual available sample
Timeline 1 yearBudget Rs. 15 lacsTeam members & Skills Required
Team includes 5 Members• Designer (2)• Technical Engineer (2)• Marketing (1)
Benefits for the Company It will create brand value inhale confidence and more profitability
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement Space arrangement is a concern as the plant
area is congestedNew Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No marketing
for business growthHuman Resource Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Needs to improve
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space
allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: Company is dependent on only one type of product, it should think about venturing into other products with the existing setup of machineries to reduce the business risk.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Website need to be up-graded on urgent basis so that the customer reach
can be extended.• The company requires more publicity on retail level. A proper branding
strategy should be formalised to get maximum visibility in the market.• The logo needs to be more creative, to make a place in the customers per-
ception.• A proper career growth plan should be formalised, so that the attrition rate
is reduced.• Emphasis should be given on the putting the stall in the exhibitions to cre-
ate awareness among probable customers.• The Company can tie-up with the trade bodies, which give funding for
the new product development, this will be very beneficial to speed up the development process.
Design & DevelopmentDesign Process/Plan for a new Product innovation
No
Budget allocated for Research & Development (Annually in Rs.)
N. A.
IT/CAD/Softwares/CAM used in the Company
No
Marketing and Branding:logo of company:
Effectiveness of the company logo Medium
Exhibition/trade shows visits: Yes as participant
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
No
Online services No
Human Resource ManagementShift Timings: 9 AM to 5:30 PM
Overtime Policy: Payment according to overtime hours
Insurance/Medi-claim Policy: No
Covered under ESI/EPF/Gratuity: No
Contract Worker Policy: No
Career Graph Plan for Employees: Growth & continues development under motivation & guidanceRetention Policies and Welfare Schemes: Insurance Policies
Assistance required from Government in the following areas:• Guidance about new product development • Awareness about the new schemes and training programs organized by
The posture of the workers for long hours will make them suffer from work-related diseases. Also, the machines parts are seen unattended in the working area.
FindingsProduct Design & ProcessTechnology As per standardAesthetics Good Quality SatisfactoryOperations Safety kits are not provided to the operatorsWorkplace & Ergonomics NeededPlant layout Improvement • Space arrangement is a concern as there is
lot of congestion of machine.• No use of Natural light.
New Product Development Yes, R & D in process for bottling machineryPackaging Yes, goodMarketing Good market presence in bottling automationHuman Resource 1 year training is provided to new recruit
Business DesignMarketing Yes, need to improvelogo Design NoVisiting Card NoBrochures & leaflets NoWebsite Yes
Recommendations• As company has plan for huge expansion, company logo has to more
creative and need to be protected. it has good visibility in market, need to capitalise on that.
• Production layout is not so good. Sufficient space has to be kept between machinery so the better working condition.
• Very less safety precautions are taken by workers, this need to be improved
by providing gloves and other safety gears to workers.• The work area need to be cleaned regularly and scraps and used tools re-
moval process has to be planned. • Need to focus on regular maintenance and servicing of machines to avoid
pre-mature wear and tear.• There is an urgent need for the certification of the company as this will
improve the image of the company in the market. For this proper record keeping in all departments is needed.
• No testing is done on the product during production, so proper quality control procedures need to be formed.
Name of the Unit: Sushma Industries (sister concern of Jyoti Industries)Address of the Company: D – 95, MIDC, Shendra, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 8928187703, 9404012247, 9822193777Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2007
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergonomics Need to improvePlant layout Improvement Well plannedNew Product Development No in-house product development process
followedPackaging As per requirementMarketing Brand awareness is high. Kisan PVC Pipes is a
well known brandHuman Resource Needs improvement
Business DesignMarketing Satisfactorylogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Needs to improveWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Needs to make greater investment in machinery in future to keep pace with the market needs and for scaling up the business.
No software is being used currently. But technology will have to be adopted to manage the business efficiently.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major sectors where the company’s products are used: i) Irrigation, ii) Drinking Water and iii) Electrical. In order to provide regular funding, the company may be linked to the respective corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to become self-sufficient in all the products re-quired for business, they need to undergo product training and even evaluate the feasibility of entering into all the categories vis-a-vis outsourcing the prod-ucts. The balance needs to be worked out.
Human Resource: Currently the number of employees is only 10. Three members of the family manage the business operations. The company perceives it to be a cost advan-tage. However, the outlook needs to change and more number of qualified people need to be hired to strengthen the business and enter into new markets.
Marketing:The company is banking heavily on its brand awareness in the current target market. However, it should not become complacent as new competitors with greater marketing efforts might erode its equity in future. Participation in trade shows and more online marketing might be effective solutions to tackle the issue.
Name of the Unit: Suyog PlasticsAddress of the Company: E – 70/27, MIDC, Waluj, Aurangabad, Pin: 431136, Maharashtra, IndiaLandline number: 9923143839Mobile Number: 9923143839Company e-mail id: [email protected] No.: N. A.Website: www.suyogplastics.com Company started in: 2008
1 SBI 2012 C. C. 2400000 Active2 SBI 2013 C. C. Extended 3500000 Active
3 SBI 2013 Term loan 2400000 Active
Vendor Code Details:Vendor Code
Customer Issued in
Criteria/Guidelines to become the Vendor
Products Supplied
Last Audit by Customer
1 Sanjay Techno Products Pvt ltd
2010 ISO Certified Automo-bile
8 months
2 Forcas Impex Pvt ltd
2010 ISO Certified Electrical 1 year
3 Devgiree Forging Pvt ltd
2009 ISO Certified Packaging 2 months
Production capacity of the Unit:Year Production capacity2013-2014 150 M / Tons - Year2013-2012 125 M / Tons - Year2012-2011 100 M / Tons - Year2011-2010 75 M / Tons - Year2010-2009 50 M / Tons - Year
Types of Customer:Type Total number of
CustomersNames/List of Customers Products
ManufacturedAutomotive 2 Sanjay Techno Products • Mirror for two
Total number and List of Vendors or Suppliers:• Devgiri Foreign (Aurangabad)• Navketan Research and Development Pvt. ltd. (Aurangabad)• Sanjay Techno Products Pvt. ltd. (Aurangabad)• John fowler Ocular lens Pvt. ltd. (Aurangabad)• SOM AutoTech Pvt. ltd. (Aurangabad)• l M Wind Power (Bangalore)• Forcas Impex Pvt. ltd. (Ahmednagar)• Nirmal Industries Controls Pvt. ltd. (Mumbai)• Kalyani Thermal Systems ltd. (Pune)• Bharat Forge ltd. (Pune)• Yashoda Industries (Ahmednagar)• FCI OEN Connectors Pvt. ltd. (Cochin)
Quality Standard for Product:Sr. No. Product name Specification Strictly followed1 Pulsar Housing Free from Flash, Welding flow
marks, silver marks Yes
2 612 Holders Free from defect and flash Yes3 Automotive casting Free from silver marks flash Yes4 Dripper Free from flash Yes5 Bottles Free from damage and over deflash-
ingYes
6 Protective Sleeves Free from flash Yes
Does the company maintain Documents for every Project?
Yes. Quality control is process by which entities review quality of all factors involve entities review quality of all factors in-volved in production.Documentation includes testing of prod-ucts to uncover defects & reporting to management to make decision to allow product release. Possible quality defects of a component are noted & steps are taken to reduce or make quality defects. Master samples of each are kept & referred in case of a quality issue in a component.
Quality Control Procedure: (In house/ External agency)
Human Resource ManagementEmployment recruitment rules New recruitment are made based on
the qualities such as experience in the plastic industry leadership qualities good communication skills manpower management skills etc.
Training Policy for the new recruits and already employed with the company:For New Recruits For Already Employed
Machine Operator Training & general ma-chine instructions along with already employed person
Timely support & motivation for the further knowledge.
Supervisor Manpower management shift supervision
Training to understand better aspects of the firm
Manager In house firm manage-ment
Developing & Training for growth of the firm
Helper/Cleaning Staff
General cleaning instruc-tions
General instruction
leave Policies:Staff Leave PolicyMachine Operator 1 month in a yearSupervisor 1 month in a yearManager National Holidays and leave allowanceHelper/Cleaning Staff Not Applicable
Overtime Policy: Payment according to overtime hours
Male 14 Includes all Aurangabad/Out-side Aurangabad but within Maharashtra/Outside Maharashtra
Depend on person to person
Mould-ing m/c (60,80,100, 150,200,500 tons)
Female 4 Includes all Aurangabad/Out-side Aurangabad but within Maharashtra/Outside Maharashtra
Depend on person to person
Mould-ing m/c (60,80,100, 150,200,500 tons)
Covered under ESI/EPF/Gratuity: Yes
Contract Worker Policy: N. A.
Compensation Plan for workers in case of injury or accidents: Covered in Insurance for all workers
Career Graph Plan for Employees: Growth & continues development under motivation & guidance
Retention Policies and Welfare Schemes: Insurance Policies
Assistance required from Government in the following areas:• Subsidy approvals and grant
Assistance by CIPET, Aurangabad:• Testing of Raw Material
Assistance by IGTR, Aurangabad:• Manufacturing of Moulds
Assistance by ITI, Aurangabad:• Helping in recruitment of New Employees (Technical)
Assistance by MCED, Aurangabad:
• Help in development and design in association with NID
SWOT Analysis of the CompanySTRENGTHS• Quality – satisfactory customers• Advanced technology• Experienced & trained staff• Development strategies and plans
WEAKNESSES• Financial crunch• No own factory land
THREATS• Development of the firm’s new
design & components by other competitors.
OPPORTUNITIES• Support from government &
other initiatives for development of the firm
Future Plan of the CompanyTimelines Plan Assistance required by the
Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Purchasing of new land for factory premises and new product development
Finance & Design Assistance Growth of sales & promotion
1 year Purchasing of new machinery & other development
The company has planned to develop an automatic dog food dis-penser. The actual sample has been imported from Canada. The samples is under research by the R&D team.
Design Brief 2
It contains a hopper of 4kg containing dog food. The dispenser works on an automatic timer system once the hopper is filled with dog food and the timer is set on the food is automatically dispensed in the tray. The main advantage of this dispenser is that it does not require time to time manual feeding. It will be very useful in day to days life and is an effective time saving idea. We will be the first on to develop this product in India.
Plan of the Design ProjectProduct Design Brief specifications
Automatic Dog food Dispenser. (six days food storage Timer based automatic dispensing sys-tem)
Proposed Design Process Study and designing and researching according to actual available sample
Timeline 3 monthsBudget Rs. 28 lacsTeam members & Skills Required
Team includes 3 Members• Designer• Technical Engineer• Marketing
Benefits for the Company It will create brand value inhale confidence and more profitability
The moulds are hidden under the stairs. Moulds needs to be arranged in its specified area to keep it damage-proof.
The wrong posture of the workers will make them suffer from work-related diseases, which are further complicated by social, psychological and physiological issues. Overall this will further affect the productivity of the unit
The wrong posture of the workers will make them suffer from work-related diseases, which are further complicated by social, psychological and physiological issues. Overall this will further affect the productivity of the unit
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Workplace need to be properly managedPlant layout Improvement • Space arrangement is a concern as there is
lot of congestion of machine.• No use of Natural light
New Product Development Yes, R & D in process Packaging Yes, goodMarketing Yes , need to upgradeHuman Resource 1 year training
Business DesignMarketing Needs to improvelogo Design GoodVisiting Card GoodBrochures & leaflets GoodWebsite Needs up-gradation
Recommendations• Company has only injection moulding. For product diversification, ma-
chinery expansion is needed. • No design development initiative, completely depend on other companies
for development.• Company needs to focus on becoming a Tier I supplier to increase the
profit margin which is just 2 % in Tier II supplier.
• Depend on the agent for importing moulds from China, and other compa-nies
• Financial planning need to be done for the new product development• Brand communication strategy need to be formalised, no visibility in mar-
ket as the company is tier II. As the company has plan for huge expansion, company logo has to more creative and need to be protected. it has good visibility in market, need to capitalise on that.
• Very less safety precautions are taken by workers, this need to be improved by providing gloves and other safety gears to workers.
Name of the Unit: Swagat PolymersAddress of the Company: Plot no. K-195-196, MIDC, Waluj, Aurangabad, Pin: 431136, Maharashtra, IndiaLandline number: 0240 - 2552347Mobile Number: 9822037318Company e-mail id: [email protected]: www.swagatpolymers.com Company started in: 2002
Warehouse/Storage of Raw material (Inventory Control Techniques)Order Quantity: As per customer requirementOrder Process: As per customer requirementQuality Control: In house testing lab
Information of Workers, Supervisors, Managers and Staff for cleaning
Shift Timings: 7 AM to 7 PM
Number of Shifts per day: 2
Sr. N
o.
Nam
e of
w
orke
r
Age
(yrs
)
Gen
der
(M/F
)
Ope
ratio
n / F
unct
ion
Year
s of
expe
rien
ce
in In
dust
ry
Wor
king
ho
urs /
day
1 Operator (5) M Machine Oper-ator
8 years 8 hrs
2 Helper (5) M Cutting Packing 6 years 8 hrs3 Office Staff (7) M Staff 9 years 8 hrs
Business Process FlowMarketing In various Industries
1 Polythene Bags 140 150 Yes N. A.2 Stretch Film 145 160 Yes N. A.3 Air Bubble 130 145 Yes N. A.
Quality Control PlanProject Documentation
Quality Control Procedure: In-house testing facility available
Testing of Raw Materials (Incoming - Quality Control Techniques)
Material verified as per our requirement
Name of Testing Labs for Raw Materials (tie-ups for Raw Materials)
• Micrometer• Gauze Meter
Quality Standard for Product:Sr. No. Product name Specification Strictly followed1 Pulsar Housing Free from Flash, Welding flow
marks, silver marks Yes
2 612 Holders Free from defect and flash Yes3 Automotive casting Free from silver marks flash Yes4 Dripper Free from flash Yes5 Bottles Free from damage and over deflash-
ingYes
6 Protective Sleeves Free from flash Yes
Design & DevelopmentWhat is Design? “Design is a concept to create a plan
of new theme before it is made”
Budget allocated for Research & Development (Annually in Rs.)
5 lacs
Exhibition/trade shows visits:
Sr. N
o.
Exhi
bitio
n / S
how
Part
ic-
ipan
t /
Vis
itor
Last
at
tend
ed
(Yea
r)
Fees
(in
case
the
com
pany
pa
rtic
ipat
-ed
)
Bene
fits
1 Maha Expo Organisation
100 2010 15000 New customer added
Safety standards in the Company:Manufacturing Op-erations
Possible accidents / hazards
Safety measures in the company
Remedies / Medication
Tubing - - -Cutting Machine Scratches First Aid Box
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations SatisfactoryWorkplace & Ergonomics Need to improvePlant layout Improvement Space arrangement is a concern New Product Development In-house product development process not
strictly followedPackaging Need to improveMarketing Need to improveHuman Resource Training initiatives for the workers need to
improve
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Need to developWebsite Need to improve
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and
emergency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: Company is producing very basic product in which there is lot of competition, so new product development should be looked into.
Human Resource: To reduce employee attrition rate, the salary levels need to be revised to attract better skilled manpower as well as a proper career growth plan should be for-mulised.
Marketing:• A website need to be up-graded on urgent basis so that the customer reach
can be extended.• Marketing is not so effective; it requires more publicity on retail level. A
proper branding strategy should be formulised to get maximum visibility in the market.
• A logo needs to be more creative, to make a place in the customers percep-tion.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
Name of the Unit: Tirumala IndustriesAddress of the Company: Plot no. H-5/41, MIDC, Chikalthana, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9850963136, 7588534243Company e-mail id: [email protected], [email protected] No.: N. A.Website: N. A. Company started in: 2011
Type of Company: Proprietorship
Company’s Specialization/Product/Services• Plastic Water Tank
Total number and List of Vendors or Suppliers: All types of customers like contractor, traders, home user, etc.
Total number of Employees at the company: 7
Ajay Pathrikar (Proprietor)
Manager: 01
Shift in charge: 01
Operator: 03
Helper: 02
Types of Business: OEM
Area of the Unit:
Plot Area 5500 Sq. mtr.Total Built-up Area 3000 Sq. mtr.
Turnover of the Unit (in Rupees):
Year Annual Turnover Gross Profit Net Profit2011-2012 25.40 6.74 2.102012-2013 48.75 9.87 4.60 2013-2014 (expected) 60.00 12.80 5.50
Certifications: N. A.
Audit Reports: N. A.
Business Competitors:
Sr. No.
Competitor’s name
Competitor’s Product Speciali-zation
Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Supplier / Tier 3 Supplier
1 Sintex water tank Plastic Water tank Exporter2 Sarita water tank Plastic Water tank OEM3 laxmi water tank Plastic Water tank OEM4 Ganga Water tank Plastic Water tank OEM5 Vasundara Water
Safety standards in the Company:Manufacturing Op-erations
Possible accidents / hazards
Safety measures in the company
Remedies / Medication
Moulding (Heating process)
Fire fire extinguisher First Aid Kit
Marketing and Branding:logo of company:
Effectiveness of the company logo Medium
Describe the Company’s Target Market: Export the product and develop new products in plastic industries. Special marketing not required for the products. Its easily sales in local market.
Brand Awareness in respective markets; whether B2B or B2C
Medium
Initiatives taken to promote the Brand and Respective expenses
N. A.
Online services Yes
Company Label: N. A.
Company Packaging: N. A.
Finance & AccountsCostingCost Sheet: Part name - 1000 Ltr Plastic water tankCost of raw material Rs. 2160Processing cost Rs. 375labour cost (wages) Rs. 300Transport cost Rs. 65Total cost to company Rs. 2900Margin Rs. 300Selling cost Rs. 3200
Human Resource ManagementEmployment recruitment rules No any specific recruitment rules. Employee’s
Training Policy for the new recruits and already employed with the company:
For New Recruits For Already Employed
Machine Operator Work experience / trail run Work experience Supervisor Work experience Work experience Manager Work experience Work experience Helper/Cleaning Staff N. A. Work experience
leave Policies:Staff Leave PolicyMachine Operator 4 days in months and public holiday Supervisor 4 days in months and public holiday Manager 4 days in months and public holiday Helper/Cleaning Staff 4 days in months and public holiday
Overtime Policy: Payment according to overtime hours
Insurance/Medi-claim Policy: N. A. (proposed to start)
Wage Rate Policy:Staff Wage Rate PolicyMachine Operator On work experience or fixed on Rs.6000 - 7000 p.mSupervisor On work experience or fixed on Rs.9000 - 10000 p.mManager On work experience or fixed on Rs.10000 - 12000 p.mHelper/Cleaning Staff Helper / cleaning fixed Rs.3000 – 4000 p.m
Salary Structure:Staff For Fresher
(in Rs.)With experi-ence of 3 years (in Rupees)
Training required, if yes then please men-tion the training
The gear box is seen damaged. Needs proper maintenance.
The inner wall of the remoulding machine chamber is covered with thick layer of burnt plastic. The inner wall needs proper maintenance to maintain the heat transfer efficiency of the machine.
The lid of the tank is sourced from vendors as a result there is mismatch between the tank and lid w.r.t. the colour. The lid is also seen fitted very loosely.
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations SatisfactoryWorkplace & Ergonomics Need to improvePlant layout Improvement Space arrangement is a concern as the plant area
remains un-utilised for most of the period.New Product Development No In-house product development process fol-
lowedPackaging Need to improveMarketing Market awareness is a problem. No effective
marketing for business growthHuman Resource Training initiatives for the workers need to im-
prove
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Need to developWebsite Need to improve
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space
allocation to provide for ease of movement of workers during daily and emer-gency situations.
There is lot of space remain un-utilised in the work place can be used more efficiently. For example granule grinding machine can be purchased to reduce the cost of raw material.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: Company is dependent on only one type of product, it should think about venturing into other products to reduce the business risk. The colour cap of the tank is always mismatch with the tank colour, effort should be put up to manu-facture the cap in-house.
Human Resource: Employee attrition rate is high so the salary levels need to be revised to attract better skilled manpower.
Marketing:• A website need to be up-graded on urgent basis so that the customer reach
can be extended.• It requires more publicity on retail level. A proper branding strategy should
be formalised to get maximum visibility in the market.• A logo needs to be more creative, to make a place in the customers percep-
tion.• Emphasis should be given on the putting the stall in the exhibitions to cre-
ate awareness among probable customers.• A company can tie-up with the trade bodies, which give funding for the
new product development, this will be very beneficial to speed up the de-velopment process.
Name of the Unit: Trimurty PolythenesAddress of the Company: Gut. No.48, Plot no.12, Opp. Siemens ltd., Near MIDC, Waluj, Aurangabad, Pin: 431 136, Maharashtra, IndiaLandline number: N. A.Mobile Number: 9372005542, 9922245562Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: 2005
Type of Company: Proprietorship
Company’s Specialization/Product/Services• Manufacturer of poly sheet and bags•Affiliated units/sister concern/subsidiary: N. A.
Details of the Owners / Partners:
Sr. N
o.N
ame
of
Ow
ner /
Pr
opri
etor
/ P
artn
ers /
D
irec
tor
Age
(yea
rs)
Stat
us (O
wn-
er /
Part
ner)
Educ
atio
nal
Qua
lifica
tion
Wor
k Ex
pe-
rien
ce p
rior
to
star
ting/
join
ing
the
Com
pany
Pers
onal
Em
ail I
d.
Phon
e nu
mbe
r
1 Misal Bhaskar Harinathr
52 Owner M. Com. DME ap-peared
Purchased of-ficer with Bajaj Auto, Waluj, from 1986 to 2002
Overtime Policy: Payment according to overtime hours
Assistance required from Government in the following areas:• Burden of Excise duty and other taxes should be less• Procedure of various return to be cut down or to be simplify• Excise audit to be simplified to be as audit and not policing
Assistance by CIPET, Aurangabad: For making sample test report prompt in time and at low cost
Assistance by MCED, Aurangabad: Assistance required for new project and for recommendation for financial institutions.
SWOT Analysis of the CompanySTRENGTHS• Quality – satisfactory customers• Advanced technology• Experienced & trained staff• Development strategies and plans
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement • Space arrangement is a concern as the
plant area is congested• No use of Natural light
New Product Development No in-house product development process followed
Packaging Need to improveMarketing • Market awareness is a problem. No
marketing for business growth• Good branding material available• Sample swatches are available
Human Resource • Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) luggage. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Branding exercise needs to be conducted on priority basis as the company
aspires to get into the household product segments. Trademark registration should be taken to protect equity and prevent litigation in future.
• There is a huge dependence on one customer which might harm the busi-ness in the long run. Increasing the customer base is mandatory for long term sustenance and growth.
• Assistance should be provided to the company to set up their stall in exhi-bitions to highlight their products to the retail and manufacturing partners.
• Re-structuring of the website to increase vendor accessibility.• As the company plans to get into retail consumer segments like plastic
buckets, jugs, mugs etc. it should develop its distribution channel to reach out to the right target market.
Name of the Unit: Ulka Plastic IndustriesAddress of the Company: Plot no. B-10, Add. MIDC, Jalna, Aurangabad, Maharashtra, IndiaLandline number: N. A.Mobile Number: 98232984905, 9975656193Company e-mail id: [email protected] No.: N. A.Website: N. A. Company started in: September, 1995
Type of Company: Proprietorship
Company’s Specialization/Product/Services: • Manufacturing Of Krushi Pipes• Manufacturing Of Polythylene Sheets Upto 12’wide• Manufacturing Of Jerry Cans,1lit, 2lit & 5 lit Capacity• Polythylene Bags• Reprocessed Granules
Warehouse/Storage of Raw material (Inventory Control Techniques)Order Quantity: As per Stock RegisterOrder Process: As per Stock RegisterQuality Control: As per Stock Register
Information of Workers, Supervisors, Managers and Staff for cleaning
Shift Timings: N. A.
Number of Shifts per day: N. A.
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1 B. S. KHODKE 50 M Manager SSC Quality & Production
22 12
2 Vijay Reddy 47 M Operator M.com Operator 20 123 K. S. KHODKE 44 M Operator HSC Operator 18 124 KASIM SHAIKH 52 M Operator 9th Operator 12 125 ANKUSH SHINDE 35 M Helper HSC Helper 9 126 MANOJ GAIKE 25 M Helper SSC Helper 6 127 ANSHIRAM
KACHRE30 M Helper HSC Helper 4 12
Functions/Operations in the company:Function / Operation
STRENGTHS• Good market for Krushi pipe• Water supply availability• Supply of electricity for 24 hrs• No pollution.• Enough work space.• Availability of transportation.
WEAKNESSES• Energy consumption is more• low production by machines• labour problems• Mostly manual work• Rate fluctuations by raw material
supplier’s (reliance changes rates for every 15 days.
• low finance, no bank credits• No automation
THREATS• No threats
OPPORTUNITIES• Working for farmers
Future Plan of the CompanyTime-lines
Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
6 months Designing of new products
Design assistance & Training for modification of ma-chines & moulds
Modification & Expansion of unit
1 year Modification & installa-tion of automated ma-chine and start for new product production
Finance min. 90 lacks Modification & Expansion of unit
3 years Production & marketing Cash credit for working Capital
Modification & Expansion of unit
5 years Adoption of latest tech-nology & research for innovation
Assistance for research Modification & Expansion of unit
Product Design Brief
Design Brief
To design, modify & converting old machinery to new latest tech-nology with Atomisation of following products-1. Drip irrigation pipe2.hdpe pipes3.pvc pipes4. Krushi pipes5. Poly sheets for Agriculture farm tank
Plan of the Design ProjectProduct Design Brief specifications
As per machine manufacturer and designer
Proposed Design Process Design of moulds, electric/ electronic panels, heaters, conveyors, take-ups & modify old m/c or purchase of new machine, etc.
Time-line Within 6 monthsBudget 90 lacksTeam members & Skills Required
10
Benefits for the Company Modification and expansion of Unit
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations SatisfactoryWorkplace & Ergonomics Need to improvePlant layout Improvement Space management is a concernNew Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No effective
marketing for business growthHuman Resource Training initiatives for the workers need to
improve
Business DesignMarketing Needs to improvelogo Design Needs to developVisiting Card Needs to developBrochures & leaflets Need to developWebsite Need to develop
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear and thus the productivity of machines can be im-proved. Some research and development work to be done so that the depend-ence on the manual work can be reduced. Some part of profit has to be kept for such activities. Processes need to be streamlined to reduce the electricity
wastage.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations. Forward contracts can be done with the raw material supplier to reduce the variation in the price of raw material.
Financials: Three major categories where the company focuses on are:i) Automobile, ii) Electrical and iii) luggage. In order to provide regular fund-ing, the company may be linked to the respective corporate houses as dedicat-ed vendor through Government interventions involving agencies such as CII and FICCI.
Product: Product testing should be done at various levels and report can be prepared to increase customer confidence.
Human Resource: To reduce Employee attrition rate, the salary levels need to be revised to attract better skilled manpower.
Marketing:• A website need to be developed on urgent basis so that the customer reach
can be extended.• It requires more publicity on retail level. It urgently requires a logo so that
customers identity the product with the company. A proper branding strat-egy should be formalised to get maximum visibility in the market.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
Name of the Unit: V. P. Pet PolymerAddress of the Company: Plot no. E-97, MIDC, Waluj, Aurangabad Maharashtra, Indialandline number: 0240 - 3264000Mobile Number: 9595699555, 9370146402Company e-mail id: [email protected]: www.vppetpolymers.com Company started in: 2007
Type of Company: Proprietorship
Company’s Specialization/Product/Services:• Pet Jar• Pet Bottle• HDPE Bottle and Jar• PP Bottle and Jar
Brand Awareness in respective markets; whether B2B or B2C
High
Initiatives taken to promote the Brand and Respective expenses
• Online marketing• Most Important satisfactory customer• Person to person marketing
Online services Yes
Company Packaging: Polypack and cardboard boxes
What is Design ‘‘Unique products for everyday problems. It should also be aesthetically appealing and market friendly’’
Process of PricingCost break up for Food Rite, IndiaPreform Cost 129Neck Size 96 mmPreform weight (+/- 2 gms) 70Preform rate 9.03Cap rate/piece 1.85Packing rate 0.08Transport rate 0.15Blowing rate 1.15Total 12.26Profit 13% [email protected]% 1.64Total 14.89VAT@5% 0.74FINAL RATE 15.63
Human Resource ManagementEmployment recruitment rules
New recruitment are made based on the qualities such as experience in the plastic industry leadership qualities good communication skills manpower management skills, etc.
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergonomics Need to improvePlant layout Improvement Space management is a concernNew Product Development no in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No effective
marketing for business growthHuman Resource Training initiatives for the workers need to
improve
Business DesignMarketing Needs to improvelogo Design Needs to developVisiting Card Needs to developBrochures & leaflets Need to developWebsite Need to improve
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear and thus the productivity of machines can be im-proved.
R&D budget to be planned to develop new products.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Product: Company currently producing only one type of product (pet jars), it should venture into other categories to reduce the business risk. Product testing should be done at various levels and report can be prepared to increase customer confidence.
Human Resource: To reduce Employee attrition rate, the salary levels need to be revised to attract better skilled manpower. Proper training should be formulised to improve the skill of the workers.
Marketing:• A website need to be up graded on urgent basis so that the customer reach
can be extended.• It requires more publicity on retail level. It urgently requires a modifica-
tion in a logo so that customers identity the product with the company. A proper branding strategy should be formulised to get maximum visibility in the market.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers. A company should participate in trade fairs related to plastics to attract new customers
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
Name of the Unit: Varroc Polymers Pvt. ltd. (Technical Center: R & D)Address of the Company: M – 138/139, MIDC, Waluj, Aurangabad, Pin: 431136, Maharashtra, IndiaLandline number: 0240-6676196Mobile Number: 9673001490Company e-mail id: [email protected] No.: N. A.Website: www.varrocgroup.com Company started in: 2010
Terms & Conditions:• Above price is basic price. Other taxes will be as applicable.• For making of moulds 60 % advance along with PO balance against first
trial.• For supply of components payment within 30 days after despatch from
our end.• Above rates are ex our works K-151, MIDC, Waluj.• Cost is subject to change if there will be any change in material ,product
design or raw material rate.• Packing cost of polybag is extra if needed.• Component wt. considered as per given by you.
Human Resource ManagementEmployment recruitment rules As per policy given by corporate. Recruitment is
done only through references.
Training Policy for the new recruits and already employed with the company:For New Recruits For Already Employed
Supervisor Technical Induction As per new IdentifiedManager Technical Induction As per new Identified
leave Policies:Staff Leave PoliciesMachine Operator NASupervisor As per policy (24 - Pl, 6 – Cl, 6 – Sl)Manager As per policy (30 - Pl, 6 – Cl, 6 – Sl)Helper/Cleaning Staff NA
Mediclaim Policy: Mediclaim Policy from Bajaj Alliance for managers.
Salary Structure: N. A.
Covered under ESI/EPF/Gratuity: EPF
Compensation Plan for workers in case of injury or accidents: Medical Policy
Career Graph Plan for Employees: Career plan as per policy
Retention Policies and Welfare Schemes: As per Policy
Assistance required from Government in the following areas:
Assistance by CIPET, Aurangabad: One year Trainee
SWOT Analysis of the CompanySTRENGTHS• Innovative• The Value Methodology: Value
Plan Assistance required by the Government (Finance/Training/Design Assistance, etc.)
Benefits for the Company
1 year Build In-house Design capability of seats
Design Assistance New Opportu-nity
Product Design BriefDesign Brief 1
300 seat Assembly to be Designed for auto Rickshaw segment. Help needed in market Survey, Market Potential competition analysis, feedback from OEMs.
Design Brief 2
Design calculation of concepts.
Design Brief 3
Product Design with simulation result.
Plan of the Design ProjectProduct Design Brief specifications To be discussed laterProposed Design Process To be decided laterTime-line To be decided laterBudget To be decided laterTeam members & Skills Required To be decided later
Benefits for the Company New Business opportunities
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Needs to improveWorkplace & Ergonomics Needs to improvePlant layout Improvement • Space arrangement is a concern as the
plant area is congested• No use of Natural light
New Product Development No in-house product development process followed
Packaging Need to improveMarketing • Market awareness is a problem. No
marketing for business growth• Good branding material available• Sample swatches are available
Human Resource • Good training initiatives for the workers
Business DesignMarketing Needs to improvelogo Design Needs to improveVisiting Card Needs to improveBrochures & leaflets Detailed and informativeWebsite Needs up-gradation
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Financials: In order to provide regular funding, the company may be linked to the respec-tive corporate houses as dedicated vendor through Government interventions involving agencies such as CII and FICCI.
Product: As the company is planning to get into household products, it can also explore product diversification in the home decor and kitchen products.
Human Resource: Employee retention is high but the salary levels need to be revised to attract better skilled manpower.
Marketing:• Branding exercise needs to be conducted on priority basis as the company
aspires to get into the household product segments. Trademark registration should be taken to protect equity and prevent litigation in future.
• There is a huge dependence on one customer which might harm the busi-ness in the long run. Increasing the customer base is mandatory for long term sustenance and growth.
• Assistance should be provided to the company to set up their stall in exhi-bitions to highlight their products to the retail and manufacturing partners.
• Re-structuring of the website to increase vendor accessibility.• As the company plans to get into retail consumer segments like plastic
buckets, jugs, mugs etc. it should develop its distribution channel to reach out to the right target market.
Name of the Unit: Yogesh Plastic IndustriesAddress of the Company: Plot no. A-114/3, Five Shendra, MIDC, Aurangabad, Maharashtra, Indialandline number: 0240-2622422Mobile Number: 9403759542, 8087428329Company e-mail id: [email protected] Company started in: 2011
Type of Company: Partnership
Company’s Specialization/Product/Services: Agro Shade Net
loan/Financial Assistance taken since the start of the company:Sr. No. Bank Name / Govt.
AssistanceYear Purpose Amount (Rs.) Status (Ac-
tive/Closed)1 State bank of Hyderabad 2011 Term loan 37 lacs N. A.2 State bank of Hyderabad 2011 Cash Credit 25 lacs N. A.
Vendor Code Details: N. A.
Production capacity of the Unit:Year Production capacity2013-2014 80000 kgs p.a. (Proj. Sales Rs. 120.00 lacs)2013-2012 34691 kgs p.a. (Sales Rs. 50.30 lacs)2012-2011 11428 kgs p.a. (Sales Rs. 16.46 lacs)2011-2010 N. A.2010-2009 N. A.
Types of Customer:Type Total number of
CustomersNames/List of Cus-tomers
Products Manufac-tured
Agricultural/Irrigation
20 Farmers Agro shade net
Total number and list of Vendors or Suppliers:• Polygrain – from Pune• Perfect color and plastic – from Daman• Mihir processing – from Rajkot
• A – top polychem – from Rajkot • Om polybland - from Daman
Total number of Employees at the company:• Partners : 03• Operators : 06• Helper : 04
Types of Business: OEM
Area of the Unit:Plot Area 1179 sq. mtr.Total Built-up Area 622 sq. mtr.
Turnover of the Unit (in Rupees):Year Annual Turnover Gross Profit Net Profit2011-2012 16.46 l 5.80 l 0.09 l2012-2013 50.29 l 14.59 l 0.28 l2013-2014 (expected) 120.00 l 36.85 l 2.17 l
Certification/s (If any): N. A.
Audit Report/s (If any): N. A.
Business Competitors:Sr. No.
Competitor’s name
Competitor’s Prod-uct Specialization
Type of Business (Exporter/OEM/Tier 1 Supplier/Tier 2 Supplier / Tier 3 Supplier
1 Rushi Packers Agro shad net N. A.2 Krushi Net Agro shad net N. A.3 Mayura Agro Agro shad net N. A.4 Balaji Agro Agro shad net N. A.
Functions/Operations in the company:Function / Operation Required
Qualifi-cation of workers
Required number of workers
Shortfall of workers
Number of hours /shift
Number of shifts/day
Design & Development of household & other plastic products
DME, BE 03 03 8 hrs 1
Flow chart of Business Process:
Purchase Raw Material > Raw Material With Master Batches & Extra life Chemicals > Heating Process > load in Extruder Ma-chine and Prepare Films > Films Roll loading in Sliting Machine > Weaving in Neting Machine > Folding and Prepare Bales on Press
Flow chart of Manufacturing Process:• RM Mixing with master batch• Heating process• load in extruder• Film roll from extruder machine load in slitting machine• Weaving with neting machine• Folding and prepare bale for dispatch• Weighing
Machine operations:Sr. No.
Machine name No. of labors required per machine
Time required for process
Idle time per shift of 8 hrs
Wastage %
1 Extruder 01 1 hrs – 45 kgs production
350 kgs 2%
2 Slitting Machine 01 2 hrs – 15 kgs production
120 kgs 10%
3 Weaving Machine 01 2 hrs – 15 kgs production
120 kgs 0%
Products manufactured at the Company:Sr. No.
Product name
Cost to Company
Price to Customers
Repeat Order
Supplied to
1 Agro shade net
Yes Farmers, Building construction, Schools, Sport ground, etc. in and around the state of Maharashtra
Quality Control PlanProject Documentation:
Does the company maintain Documents for every Project?
No
Quality Control Procedure: (In house/ External agency)
In house
Testing of Raw Materials (Incoming - Quality Control Techniques)
Raw material quality control done by the suppliers
Name of Testing labs for Raw Mate-rials (tie-ups for Raw Materials)
N. A.
Name of Testing labs (tie-ups for Finished Products)
N. A.
Testing of Finished Products It is done in house by manually
Quality Standard for Product: N. A.
Design & DevelopmentWhat is Design? “Design is new Customers and New
Money earned”
Design Process of existing products (choose any top one product that is being manufactured at the company for a OEM or a Customer): N. A.
Design Process/Plan fora new Product innovation: Design process will be done in house by using technical & qualified employee, and we will developed new design in plastic Agricultural products, household & other products.
Budget allocated for Research & Development (Annually in Rs.)
Total cost to company Rs. 1.45 lacsMargin Rs. 0.05 lacsSelling cost Rs. 1.50 lacs
Explain the Distribution Process. Backward linkages and Forward linkages (Supply Chain): Finished material dispatched to customer by transport or cus-tomers directly purchased from our factory premises.
Human Resource ManagementEmployment recruitment rules No any specific recruitment rules.
Employee’s selection on their skilled and work efficiency.
Money charged (in Rupees) by contractors for each worker/staff in case the workers/staff are recruited through Contractors
N. A.
Training Policy for the new recruits and already employed with the company:Staff For New Recruits For Already Employed
Machine Operator Work Experience / trail run Work ExperienceSupervisor Work Experience Work ExperienceManager Work Experience Work ExperienceHelper/Cleaning Staff N. A. N. A.
leave Policies:Staff Leave PolicyMachine Operator 4 days in months and public holidaySupervisor 4 days in months and public holidayManager 4 days in months and public holidayHelper/Cleaning Staff 4 days in months and public holiday
Overtime Policy:Staff Overtime PolicyMachine Operator Wages per hourSupervisor Wages per hourStaffManager Salary per hourHelper/Cleaning Staff N. A.
Insurance/Medi-claim Policy: N. A. (Proposed to begin for all staff)
Wage Rate Policy:Staff Wage Rate PolicyMachine Operator On work experience or fixed on Rs.6000 – 7000 p.m.Supervisor On work experience or fixed on Rs.9000 – 10000 p.m.Manager On work experience or fixed on Rs. 10000 – 12000 p.m.Helper/Cleaning Staff Helper / Cleaning fixed Rs. 3000 – 4000 p.m.
Salary Structure:Staff For Fresher (in
Rupees)With experience of 3 years (in Rupees)
Training required, if yes then please men-tion the training
Machine details if produced In house
Machine Operator
6000 – 7000 p.m. 7000 – 8000 p.m. Practical work done N. A.
FindingsProduct Design & ProcessTechnology Needs up-gradationAesthetics As per the product requirementsQuality As per the product requirementsOperations Need to improveWorkplace & Ergonomics Need to improvePlant layout Improvement Space management is a concernNew Product Development No in-house product development process
followedPackaging Need to improveMarketing Market awareness is a problem. No effective
marketing for business growthHuman Resource Training initiatives for the workers need to
improve
Business DesignMarketing Needs to improvelogo Design Needs to developVisiting Card Needs to developBrochures & leaflets Need to developWebsite Need to develop
RecommendationsInfrastructure & Technology: Need to focus on regular maintenance and servicing of machines to avoid pre-mature wear and tear and thus the productivity of machines can be im-proved.
Some research and development work to be done so that the dependence on
the manual work can be reduced. Some part of profit has to be kept for such activities.
Supply Chain & Operations: Need to improve the layout of the manufacturing floor by re-working the space allocation to provide for ease of movement of workers during daily and emer-gency situations.
Wastage and spoilage of the material can be reduced to improve the through-put of material, thus reducing the cost of manufacturing.
Product: Company currently producing only one type of product, it should venture into other categories to reduce the business risk. Product testing should be done at various levels and report can be prepared to increase customer confidence.
Human Resource: To reduce Employee attrition rate, the salary levels need to be revised to attract better skilled manpower. Proper training should be formalised to improve the skill of the workers.
Marketing:• A website need to be developed on urgent basis so that the customer reach
can be extended.• It requires more publicity on retail level. It urgently requires a modifica-
tion in a logo so that customers identity the product with the company. A proper branding strategy should be formalised to get maximum visibility in the market.
• Emphasis should be given on the putting the stall in the exhibitions to cre-ate awareness among probable customers.
• A company should participate in trade fairs and exhibition related to plas-tics to attract new customers
• A company can tie-up with the trade bodies, which give funding for the new product development, this will be very beneficial to speed up the de-velopment process.
• First Generation Entrepreneurs• Eagerness to take challenges and risks• Predisposition to scaling up the scope of business and modify prod-
uct offerings as per changing market demands• Efficient production capabilities for Product Designs & Specifications
provided by customers Easy availability of Raw Materials in desired quality & quantity
• A good dealer network• low Real Estate prices and easy availability of land / Industrial Plots• Government policies supporting the access to by entrepreneurs• Government Incentives for investment and credit availability
WEAKNESS:
• Increased competition in same type of manufacturing• The cluster operates on very low margins with some companies oper-
ating on margins as low as 3%• Dependence on single / two companiesw• No own Products. No investment in IPR• lack of funds for R&D • lack of trained manpower and no structured plan for skill up-grada-
tion• No standard practice of visiting Trade Fairs which results in lack of
Market Awareness• First Generation Entrepreneurs hence limited risk absorbing capacity• No structured growth plan in place• low awareness levels for Government schemes and policies
SWOT - Plastic cluster• Inadequate water and power supply• Infrastructure is not upgraded to meet the changing industry require-
ments• Focus only on making basic products• Reliance on customer to provide all design inputs• Absence of product benchmarking as basic Quality control process is
followed• Moderate to high wastage• Slow Technology Up gradation and basic to minimum use of software
which lengthens lead time• Ergonomics and Medical facilities
OPPORTUNITIES:
• MIDC has planned to develop Additional MIDC’s in the region which creates good opportunities for industries.
• Cluster development programme of Central Govt. boost for creation of jobs /skilled & unskilled man power.
• Expansion project of CIPET is playing vital role for plastics manufac-turing in the region.
• Government initiatives like DMIC Project, Shendra-Bidkin Industri-al Park, Revised Seed Money Scheme, Prime Minister Employment Generation Programme etc.
• Development of retail sector.• Growth possibilities through mutual cooperation.• Government incentives for Infrastructure and Technology Up-grada-
tion.• Awareness regarding importance of training. • Positive attitude towards product diversification.
• With the growth in the size of the cluster, there will be greater availability of cheaper raw materials due to industry forces.
THREATS
• Skill up-gradation is crucial for keeping pace with changing technological needs.• Increasing pace of competition while the customers remain limited.• limited product innovation might make the companies redundant in future.• No safeguards for reducing environmental waste which might result in problems in future.• Slow pace of market expansion by targeting new customers.• The export market has not been tapped.• No testing labs which might lead to issues while dealing with international companies with stringent quality norms.• No plans for making the business self-sustaining.
The survey presents the findings focussing on the lack of MSMEs’ exposure to new markets as most of the units is catering to OEM based job work wherein each and every detail is specified by the client not leaving any scope of design intervention in terms of product design and development.
Si. No. Current Status Impact on Business1 Most of the units in the
cluster are focussed on making component parts for the OEM market.
The job work kind of business identity prohibits any kind of product development as the product designs are provided by the customers and the units are just supposed to execute the same.
2 No substantial efforts at attending Trade Shows.
The units lack market awareness about the cur-rent product requirements of the industry.
3 No substantial marketing or branding efforts.
It increases dependence on a smaller customer base which increases the business risk.
4 lack of commitment for Research & Develop-ment.
The units continue to make similar products which prohibits innovation and product diver-sification which might result in weakness in the face of increasing competition.
5 Extremely small margins in the product because of the units making basic products and competing of rates.
Generation of moderate to minimum profits which cannot be ploughed back in business. Hence, the units cannot become self-sufficient.
Some of the Unit owners have ideas about the products they want to diversi-fy with, but the problem is the market awareness. There is an urgent need to create an awareness about the opportunities at common business platform for the entire cluster where people can share there strength and weakness, come up with a cumulative solution wherein everybody gets benefited w.r.t. the focussed design research, processes, emerging technologies, new target market, etc.
The cluster may contribute towards developing a common market place in their area where all the manufacturers can individually showcase and market
Findings - Highlight observations at cluster leveltheir products and processes continuously.
Technology:Most of the units uses conventional machines such as semi-automatic ma-chines. Also, due to the high cost of new machines the units generally uses the second hand machines which leads to high energy consumption and decreased productivity. Investment in technical up-gradation is low. The units hardly use IT technology. There is no any tie up with technical and R&D institutions.
Infrastructure: limited growth scope in basic infrastructure. The units are not able to main-tain delivery schedules due to logistics bottlenecks in region due to bad roads and connectivity. The social infrastructures are also inadequate at Aurangabad region. There is an alarming gap between supply & potential demand for the infrastructure required for high growth.
Raw Material:The frequent increase in raw material prices is adding up to the input costs of the production. The easily procurement is also a big problem faced by the small units in the cluster.
Design Process and Product Development:Most of the companies depends on the design and specifications which are provided by their clients. The production is done as per the job work. As a result the units do not get opportunity to implement design processes required to come up with better designs and increasing the intellectual capability of the units. Barely any units have product innovation facility and most of the cluster units do not have their own products as they are manufacturing on job work for bigger units.
Target Market:Most of the target market is local clients except a few units who manufacture products sold directly in retail markets through dealers. Due to increasing
competition the units and are always under pressure to keep prices low in spite of rising input costs. The units have enough critical mass to promote their common brand subject to form the marketing consortia.
Production Capacity:Due to fewer and low capacity machines the units have low productivity. Most of the units uses second hand machines which requires frequent maintenance and effects the productivity. Also, the production is tightly defined by the cli-ents and their requirements.
Logistic, Packaging & Transportation:Most of the production being manufactured for the local clients the products are packed in polythene bags and corrugated boxes.
Plant Layout:In most of the units the layout is not according to the process flow of raw ma-terials and the manufactured items. When a item moves haphazardly during processes it leads to increased time periods and overall efficiency of the work-ers and the unit itself. The travel distance increases and also its material han-dling or transportation cost increases. layout shall be reviewed in the light of process flow to reduce the travel-distance of the items in the unit.
Ergonomics:In most of the units finishing, assembly and packing and final packaging op-erations are being done by persons sitting on floor or against a wall. This puts more strain on work , thereby reducing the productivity. The wrong posture of the workers will make them suffer from work-related diseases, which are further complicated by social, psychological and physiological issues. Overall this will further affect the productivity of the unit. Arrangements should be made to make work stations in such a way that workers work while standing. For workers working on machines gravity chutes etc. may be used.
Material Handling:Most of the units the raw material and finished goods are moved by manually. Only in a bigger units material handling trolleys are being used which are used manually. Use of Fork lifters, Pallet lifters and hoists or cranes is used by a
very few units. There is a need to identify and start using mechanized material handing system.
Skills & Training:The skill of the workers in most of the units have deficit in the area of Produc-tion techniques, Machine know-how, 5S, Information technology, Machining & Programming, design & testing of financial Management. Workers are most-ly focusses on one type of skill and are not multi talented. Higher attrition rate of the skilled employees due to lack of career planning and promotion avenues.
Entrepreneurs & Enterprise:Majority of the units are family owned. Barely any fresh talents are recruited from outside which restricts the sense of innovative w.r.t. to products or busi-ness. There is very low level exposure and awaress among the workers and staff about the technological development around the world. There is also very little awareness about the training programmes and promotional schemes of the state and central government. The risk taking capacity is least seen among the smaller units. There is also a poor co-ordination and trust level between cluster units. Majority of the entrepreneurs in the cluster are with artisan background and have attitudinal constraints and not open to the changes in new technolo-gy and modern management practices.
Finance and Credits:The financial planning, control & accounting system is not properly main-tained by most of units get these important work done by external agents such as local Chartered Accountants due to lack of adequate resources and exposureDue to lack of financial management skills the return on investment in low as planned by them. The relationship between the cluster units and borrower & financial institutions seems to be weak.
Business Processes:Currently the manufactures in the plastic cluster are working on the various types of products catering to automobile to the household industry. While interacting with the participants under this survey, they opened up with their problems of supply chain, managing the capital, labour issues and majorly the marketing aspects. Here we will try to focus on the some of them:
Profit Margin:It is clear from the information given by the respondents of this survey that profit margin is very tight in this sector. This is because competitors from man-ufacturers of other industrial area are producing the goods with same specifica-tion at very reasonable rate. Major reasons that the respondents said are: • Higherelectricitycharges• Highertransportationcosts• Fluctuationsintherawmaterialprices• NosubsidyfromGovernmentinanyform• Noinitiativeontheexpansionofthemarket
Higher raw material costs:The major component of the total cost is raw material; which is around 85%. The raw material required for most of the units in the cluster is of similar nature and as per respondents the issue that the prices are changing every 15 days. This issue can be sorted out by placing a combined order from all manu-facturers. This will reduce the raw material cost by economies of scale and buyer can also negotiate with the supplier for trade discount.Alternate source of raw material can be found out to reduce dependency on one supplier.
Research and development:Very few companies are engaged in the new product development process, either because of they don’t have skilled manpower to do that or they lack the
funds required for it. Also no company is taking benefit of the synergy and developing the new product. A platform should be provided to the manufactures so that they can share the ideas, resolve the issues or problems and come up with the strategy to solve the major concerns of the cluster. Cash rich big companies can also fund the development activities of the small units facing financial problems.
Transportation:The overall infrastructure specially the condition of roads is not in such a good condition. This hampers the growth of the business by increasing the lead-time. A better and efficient logistics means faster movement of the raw materi-al and finished goods, thus reduces the business cycle for a company.It is also evident that the market for most of the manufacturers is common and very nearby. To reduce the overall cost of transportation, the products from all the supplier going to the same market place can be combined together thus reducing the transportation cost per unit. A delivery schedule can be planned as per the market place and variety of goods produced by different manufactures are transported in the same vehicle on a particular date. As per the demand the transportation frequency can be increased.
Power:Currently a plastic cluster at Aurangabad is facing problems in supply of electricity. The fluctuations in the power supply hamper the efficiency of the machines as well as the defects in the products. A smooth and regular power supply is the need of the hour as it will increase the throughput and reduce the wastage and spoilage.
Starting of Common Facility Center (CFC):A common facility center can be formed to sort out following issues:• Acombinedbulkpurchaseorderofrawmaterialforallthemanufac-turers to get trade discount,• AcommonR&Dunitforalltheparticipants,• Managementofcommontransportationfacility• Stringenttrainingscheduletoconverttheunskilledlabourtoskilledworkers
Porter’s view:There are three approaches to run an organization are referred to as “generic strategies”, because they can be applied to products or services in all industries, and to organizations of all sizes. They were first set out by Michael Porter in 1985 in his book Competitive Advantage: Creating and Sustaining Superior Performance. Porter called them Generic Strategies.
Porter’s generic strategies are ways of gaining competitive advantage – in other words, developing the “edge” that gets the sale and takes it away from the com-petitors.
“Cost leadership” (no frills): it involves being the leader in terms of cost in the industry or market.
“Differentiation” (creating uniquely desirable products and services): making products or services different from and more attractive those of competitors. And
“Focus” (offering a specialized service in a niche market): concentrate on particular niche markets and, by understanding the dynamics of that market
and the unique needs of customers within it, develop uniquely low cost or well-specified products for the market. He then subdivided the Focus strate-gy into two parts: “Cost Focus” and “Differentiation Focus”. The terms “Cost Focus” and “Differentiation Focus” can be a little confusing, as they could be interpreted as meaning “A focus on cost” or “A focus on differentiation”. Cost Focus means emphasizing cost-minimization within a focused market, and Differentiation Focus means pursuing strategic differentiation within a focused market.
How to choose which generic strategy to adopt?STEP 1: The units need to conduct a SWOT analysis of their individual units or discuss with the experts to take an outsider view of their unit.
STEP 2: This should be followed by a Porter’s Five Forces Analysis of the clus-ter.
STEP 3: This will enable the units to identify which Generic Strategy will suit them the best on the basis of their vision for the company.
Collaborations & Exhibitions:
The unit owners in the cluster should collaborate to organize an exhibition every six months to showcase their new product developments to the industry. This exhibition can be promoted with the help of Government agencies.
The unit which exhibits most unique product development or process improve-ment may also be rewarded by signing up deals or contracts with the business houses.
Design clinic workshop held for the Plastic Cluster was a combination of pres-entation and interactive sessions on interactive design study and need assess-ment, design seminar and design clinic activity. The design expert/s presented the opportunities identified from need assessment. The design seminar pres-entation from design expert/s and guest design speakers focussed on design topics and case studies relevant to the plastic cluster and participants. During the design clinic, design expert/s diagnosed solutions for existing design prob-lem/opportunity and suggested on the spot remedial steps, during the work-shop. The workshop helped the participants to get quick remedies on identified opportunities for design intervention from existing problems taken up from their respective work areas.
Objective: Objective of Design Clinic Workshop was to create a platform where partic-ipants were able generate the holistic perspective for their scenario with the help of design expert/s guidance. The design expert helped participants in identifying opportunity areas in their respective units and cluster with the help of interactive design study insights. The expert also helped in providing on the spot design solutions to problems taken up by participants from their respec-tive backgrounds of products, process, communication and design strategy.
The major activities of design clinic workshop was as following:
• Discussion of opportunity areas identified from interactive design research • Design presentations by guest design speaker/s • Provide remedies to design problems taken up by the participants
Guest Speakers/Experts: Mr. S G Rajput, GM, DIC AurangabadMr. T R Sharma, Dy Dir. MSME AurangabadMr. S K Thote, Regional Officer, MCED Aurangabad
Mr. Thaware D U, Project officer, MCED AurangabaadMs. Bharti Sose, Project Officer, MCED AurangabadMr. Sanjay Bondekar, Dy General Manager, NSIC AurangabadMr. Anidya Pal, Dy General Manager, SIDBI AurangabadMr. Pravin Bachhav, Sr. Technical Office, CIPET AurangabadMr. Vinayak Garkhedkar, Project Consultant, AurangabadMr. Tanmay Kandekar, andMs. lipi Choudhury
Date Day Time Session Speakers8th March, 2014 1 10 AM – 10:30 AM Registration Process
Inauguration
Welcome Address
MCED teamMr. S G Rajput, GM, DIC AurangabadMr. T R Sharma, Dy Dir., MSME AurangabadMr. S K Thote, Regional Officer, MCED AurangabadMr. Thaware, D U, Project officer, MCED AurangabaadMs. Bharti Sose, Project Officer, MCED AurangabadMr. Saurabh Kumar, NIFT MumbaiMr. Tanmay KandekarMs. lipi Choudhury
10:30 Am to 12:30PM Introduction to DCS Workshop Mr. Saurabh Kumar12:30 PM to 12 :45 PM Tea Break12:45 PM to 2:00 PM Trends in New Products Innovation Ms. lipi Choudhury2:00 PM – 2:30 PM lunch2:30 PM – 3:30 PM Personal discussion with participants Mr. Saurabh Kumar, NIFT Mumbai
9th March, 2014 2 10:00 AM to 11:00 AM Schemes for MSMEs Mr. T R Sharma , Dy Dir MSME Aurangabad 11:00 AM to 11:30 AM DIC Schemes for MSMEs Mr. S G Rajput , GM, DIC Aurangabad11:30 AM - 12.00 PM Design & Trademark Protection & Issues Mr. Tanmay Kandekar 12:00 Noon – 1:30 PM Design Process & Design Case Studies Mr. Saurabh Kumar1:30 PM to 2:00 PM lunch2:00 PM – 3:30 PM Personal discussion with participants Mr. Saurabh Kumar, NIFT Mumbai
10th March, 2014 3 10 AM – 1:30 PM live Clinic: Personal Interaction with Twelve MSMEs - Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification
Mr. Saurabh Kumar & Mr. Tanmay Kandekar
1.30 PM – 2:00 PM lunch2:00 PM – 5:30 PM live Clinic: Personal Interaction with Six MSMEs
- Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification
Mr. Saurabh Kumar & Mr. Tanmay Kandekar
Schedule of the WorkshopACTION PlAN - 5 DAY workshop (5DW) for PlASTIC Cluster, AurangabadMarch 8th - March 12th, 2014, Co-ordinator: Saurabh Kumar (NIFT Mumbai) & MCED team
10th March, 2014 4 10 AM – 1:30 PM live Clinic: Personal Interaction with Nine MSMEs - Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification
Mr. Saurabh Kumar & Mr. Tanmay Kandekar
1.30 PM – 2:00 PM lunch2:00 PM – 5:30 PM live Clinic: Personal Interaction with Six MSMEs
- Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification
Mr. Saurabh Kumar & Mr. Tanmay Kandekar
12th March, 2014 5 9:30 AM – 10:00 PM live Clinic: Personal Interaction with One MSMEs - Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification
Mr. Saurabh Kumar & Mr. Tanmay Kandekar
10:00 AM – 11:00 AM Schemes of NSIC for MSMEs Mr. Sanjay Bondekar, Dy General Manager, NSIC Aurangabad11:00 AM – 11:30 AM Schemes of SIDBI for MSMEs Mr. Anidya Pal, Dy General Manager, SIDBI Aurangabad11:30 AM – 12:30 PM Support Schemes of CIPET for MSMEs Mr. Pravin Bachhav, Sr. Technical Office, CIPET Aurangabad12:30 PM– 1:30 PM Design Process & Design Case Studies Mr. Saurabh Kumar1:30 PM – 1:45 PM Project Proposal for Bankable loan for MSMEs Mr. Vinayak Garkhedkar, Project Consultant, Aurangabad1:45 PM - 2.15 PM lunch 2:15 PM – 2:45 PM live Clinic: Personal Interaction with One MSMEs
- Brainstorming for Design Innovation/Product Ex-ploration/Product Diversification
The workshop was inaugurated by the esteemed guests. Mr. T. R Sharma Dy Dir. MSME Aurangabad congratulated MCED on this initiative to streamline and bring structured design thinking to the Plastic Cluster. The esteemed panel of guests were facilitated by the MCED representatives.
The event was attended by the key stakeholders of the Plastic Cluster at Aurangabad like Electroplast, Yogesh Plastic, Darshan Plastic, Snehal Plas-tic, V. P. Pet Polymers, Mitali Industries, etc.
The inaugural session was followed by a session on developments in the Plastic cluster with Ms. lipi Choudhury. The session was interactive in nature with design ideas being shared and discussed by everyone present.
Presentation by Ms. Lipi Choudhury on ‘New Product Development’
The session concluded with a question and answer session moderated by Mr. Tanmay Kandekar. The Cluster representatives and the entrepreneurs discussed about various bottlenecks in terms of finances, awareness about schemes for MSMEs, teamwork and capacity building.
The day started with presentation on Policy Initiatives & Schemes of Govt. of India for Development of MSMEs by Mr. T. R. Sharma Dy. Dir. MSME, Aurangabad. He informed the present MSME units about the Schemes & Programmes such as Credit linked Subsidy Scheme (ClCSS) for Technology Upgradation of MSEs, Cluster Development Programme, CFC & its funding pattern, Credit Guarantee Fund Trust for Micro Small Enterprises, ISO Reimbursement Scheme, Schemes for Capacity Building, Credit Rating Scheme of NSIC, National Manufacturing Competitiveness Programme - components. later the presentation by Mr. S G Rajput , GM, DIC Aurangabad further informed the units about the Cluster Develop-ment Programme.
Presentation by Mr. T. R. Sharma on ‘Policy Initiatives & Schemes of Govt. of India for Development of MSMEs’
During the second phase of presentations Mr. Tanmay Kandekar interact-ed with MSME Units about the Design & Trademark Protection & Issues. He emphasised on the importance of Design protection for creating sus-tainability and long-term growth prospects for the business.
As the day progressed Mr. Saurabh Kumar presented design case studies relevant to the plastic cluster and participants. During the workshop he discussed the diagnostic solutions for existing design problem/opportu-nity and suggested on the spot remedial steps, during the workshop to the MSME units.
Day 3 was dedicated to live Clinic for MSME units. During this session one to one interactions were carried out with twelve MSME units in order to brainstorm for Design Innovation, Product Exploration and Product Diversification. The workshop helped the participants to get quick reme-dies on identified opportunities for design intervention from their Unit’s existing problems taken up from their respective work areas. The list of twelve MSME units is as follows:• APM Plast• AR Polymers• Electroplast• Mitali Enterprises• Moraz Plastic
Live Clinic on Day 3 with Mr. Yogesh Parmar of Yogesh Plastics
The expert also helped the MSME units in providing on the spot design solutions to problems taken up by participants from their respective back-grounds of products, process, communication and design strategy.
live Clinic continued on Day 4 with the next set of nine MSME units for exploring possible product diversification and new product development opportunities. The list of nine MSME units is as follows:• Cool Engineering• Concept Engineering• Darshan Plastic• Jyoti Industries• Mould Tech• Plast Tech• Sunrise Auto Pack• Sushma Industries• Suyog Plastic
Live Clinic on Day 3 with Mr. Ashok Joshi of Swagat Polymers and MSME unit
The expert helped the MSME units in providing on the spot design solu-tions to problems taken up by participants from their respective back-grounds of products, process, communication and design strategy.
The Design expert along with the MSME unit members discussed oppor-tunities for New Product Development. The Design briefs were generated for the MSME Units to go ahead to the third phase of the DCS i.e. the Professional Design Projects .
On the final day of the workshop representatives from NSIC and SIDBI were invited to give inputs about loan and financial schemes. Mr. Pravin Bachhav, Sr. Technical Office, CIPET Aurangabad was invited for creating awareness about the various technical programmes run by CIPET. He also discussed the various facilities than can be availed by the MSMEs like raw material and product testing, prototyping, pilot production by associating with CIPET.
live Clinic was conducted for V. P. Pet Polymer for exploring possible product diversification and new product development opportunities.
Mr. Vinayak Garkhedkar, Project Consultant, Aurangabad discussed and
Mr. Shaukat Syed of Electro Plast Industry addressing the Closing ceremony and giving the vote of thanks to all the participating members.
presented the process involved in creating Bankable Project Proposals for loans.
Mr. Saurabh Kumar presented Design, Prototyping and Communication case studies to the MSME unit members. The session was made interactive involving the unit members to raise their concerns and together discuss-ing the solutions for the same. The Unit members also took opportunity to express their enthusiasm and willingness to work further with the DCS and the MCED team for Professional Design Projects.
Design Briefs - by MSME Units of Plastic Cluster, Aurangabad
The Design Briefs generated during the 5-Day Workshop is given below:
Design BriefsSr. no. Name of Unit Name of Proprietor/
OwnerProducts Design brief
1 Annu Industries Vishal Panjabi Automotive Parts. N. A.
2 APM Plast Ajinkya Nandkumar Kawathekar
Engineering Plastic Products Design of a new Mobile cover case which can carry cards and documents
3 AR Polymers Rohit S. Deshpande Injection moulded products Design of a new Key case for storing multiple keys4 Blue Star Engineers Rajesh K. Sanghavi Plastics M. V. & Home Appli-
ances Parts.N. A.
5 Concept Auto Pack-aging
Rahul S. Neele Fully Auto on line Care Pack-ers.
N. A.
6 Cool Engineering S. P. Kale Water Chillers, Industrial Re-frigerators
N. A.
7 Darshan Plastic Ashok B. Thorat Plastic Injection moulded Com-ponents.
Design & Development of lighting Solutions for Household, Automobiles and Two wheelers.
8 Electro Plast Industry Syed Shaukat Abdul Rauf
Inter Storage Tank • Design of a new Water Tank for household and industrial use. • Design of new lid for Water Tanks.• Design of new Pet Bottles
Design & Development of Poultry Farm Equipments. The products to be manufactured using Injection molding, blow molding and extrusion molding technology.
14 Plast Tech laxman Irana Man-dkar
Appliances spare parts N. A.
15 Rupesh Enterprises Godavari Dattrao Narwade
Plastic Mould & Dies Design of a new mould for household products/toys
16 Sejal Plastics Santosh Vajantrao Joshi
P. P. Mats N. A.
17 Siddhi Polyweave Shashikant Nagnath-rao Ernale
P. P. Mats Design & development of Plastic Mats using Floral patterns, Geometric pat-terns, Promotional branding, etc.
18 Snehal Plastic Indus-tries.
Bharat Hariba Shindi-kumate
Caster Wheel Design of Plastic Castor Wheels for application in multiple products/Mul-ti-purpose
19 Sunrise Auto Pack Raju Suresh Neele Flyash Bricks. N. A.20 Sushma Industries Parvati Mahadeo
Design & Development of Drip Irrigation Equipment.
22 Swagat Polymers Ashok R. Joshi Packaging Products Design and Development of Food-grade Food Wrap Film with dispenser and Wall Mounting System. The product may dispense Film, Foil and Paper Nap-kin.
23 Tirumala Industries Ajay Annasaheb Patharikar
Plastic Water Tank Design of new Water Storage Tank for Household, Farming and industrial use
24 Trimurty Polythenes Misal Bhaskar Hariha-ranrao
Poly Bags & Sheets For India. Design & development of a new Garbage Bag for Household, Hospitals, Hotels, etc.
25 Ulka Plastic Industries Sachin S. Thete Krishi Pipe, polymers Sheets Design of a new Drip Irrigation Pipe system26 V. P. Pet polymer Jayshree N. Somase Pet jars , pet bottles N. A.27 Varroc Polymer Pvt.
ltd. Tech. Centre Ritesh Solanke Seat Assembly, Air Filter, Body
Parts & Mirrors.N. A.
28 Yogesh Plastic Indus-tries
Yogesh Vrajlal Parmar Plastic Shed net. • Design a range of Agricultural nets using different patterns, e.g. floral, geometric, branding, etc.
• Database of District Industries Centre regarding MSME, large enterprises• Database of Directorate of Industries regarding Mega Projects, SEZs• MIDC office information regarding existing and proposed MIDC• Infrastructure and DMIC Employment Self Employment data from Assistant Director employment and self employment• Maharashtra Economic survey 2009-10• Sales tax information from Assistant Commissioner Sales tax• Suggestions from committee members, industrialist, experts