A Project Report On “Total Consumption Of Polymer In Automobile Sector In Pune Region” With Special Reference To Submitted To In Partial Fulfillment Of The Requirement For The Award Of Degree Of Master Of Business Administration By Under The Guidance Of Mr. (Professor,) A!Q 1
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Total Polymer Consumption in Automobile Sector in Pune Region Appl Industries Pune Marketing
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A
Project Report
On
“Total Consumption Of Polymer In Automobile Sector In Pune
Region”
With Special Reference To
Submitted To
In Partial Fulfillment Of The Requirement
For The Award Of Degree Of
Master Of Business Administration
By
Under The Guidance Of
Mr.
(Professor,)
A!Q
1
CERTIFICATE OF SUMMER TRAINING COMPLETION
This is to certify that Project Report titled “Total Consumption Of Polymer in Automobile
Sector In Pune Region” has been completed satisfactorily in partial fulfillment of Master Of
Business Administration course for the academic year 2004-2006 by Mrinal Khajuria, Student of
“Vishwakarma institute of management” pune-37.
Place: Pune Director,
Date: Vim, pune-37
2
GUIDE CERTIFICATE
This is to certify that Mr. Mrinal Khajuria “student of Master of business administration course
with specialization in Marketing, for the session August 2004- July 2006 prepared project report
entitled “Total Consumption Of Polymer in Automobile Sector In Pune Region” at Aalekh
polymers PVT. Limited. From15th June to 30th July under my guidance and supervision.
I wish him all success in life.
Prof. Yuvraj lahoti
(Marketing)
3
4
TABLE OF CONTENTS
S.No TOPIC PAGE No.
1. INTRODUCTION 10-11
2. COMPANY PROFILE 13-14
3. PRODUCT PROFILE 16-20
4. OBJECTIVES OF THE STUDY 22
5. RESEARCH METHODOLOGY 24
6. OBSERVATIONS AND FINDINGS 26-45
7. CONCLUSIONS & SUGGESTIONS 47-49
8. ANNEXURES 51-56
5
ACKNOWLEDGEMENT
I take the occasion to thank “Aalekh polymers private Limited” for giving me the opportunity to
work on this project, which has immensely helped in gaining & developing my knowledge &
experience. I would like to thank my institute VIM as well as Director sir Dr. Sharad L Joshi to
provide me such a wonderful opportunity.
I especially thank my project guide Mr.Yuvraj Lahoti (professor, VIM) for his valuable guidance,
co-operation & encouragement throughout the project.
I am also Grateful to Mr.Arun Sharma (senior head marketing) and Mr.Inder Jain (CEO) for
providing their valuable thoughts and inputs throughout the project & kindly accepting the
suggestions & recommendations given by me.
I am very thankful to god as well as my family who really helped me during the project work
without there ally and support it its not possible to study here in a very pleasant atmosphere.
Lastly I would like to specially thank the subordinates & their superiors for their co-operation and
also would like to thank to all the respondents of the survey, members of the faculty & all my
other fellow summer trainees for their co-operation & co-ordination in the project along with me.
Place-Pune
Mrinal Khajuria
6
EXECUTIVE SUMMARY
Objectives: -
1) To know the total polymer consumption in the automobile sector
2) How many injection moulding companies are using polymers for automobile industry in Pune
Region?
3) What are the prices at which injection moulding companies are buying raw materials from
other manufacturers
4) To know the availability of substitutes and grade of polymers in Pune region
5) To find out the awareness of the product in the market
6) To know the strengths and weaknesses of the companies
7) To know various parameters whatever the business rivals of APPl. are following:
o Marketing strategy
o Pricing policy
o Credit policiesvQS
Findings: -
Polypropylene is used readily in automobile sector because we can enhance its properties by
adding filler for example: glass, mica, talc, etc. as per the requirement of the product. Appl
produces PP + Filler as per the customer requirements. Polypropylene is used in bumpers,
dashboards, fuel tanks etc. Polypropylene is used frequently because:
1) There is no problem in the availability.
2) Its trends do not vary.
3) It is cheaper then metal.
4) Properties are more or less same as of metals.
5) The weight is lesser then metals which helps in increasing average of the vehicle.
7
Recommendations: -
The company should increase sales
The company should try to reduce the cost of production
Growth opportunities in public transport and commercial sectors
Material handling
Sourcing of materials
Proper inputs from customer
Trend analysis
Limitation of the study: -
Sometimes consumers are not aware of the new product
Due to limited sample representation population may not be that much accurate
I, here by declare that this project report entitle “Total polymer Consumption In Automobile
Sector” with special reference to APPL Industries Limited Pune, Which is the outcome of the
summer training undergone by me from 15th June 2005 to 30th July 2005. The empirical finding
of the study is entirely based on the data collected by myself.
8
INTRODUCTION
9
INTRODUCTION
History and significance of polymers
Plastics are polymers. What is a polymer? The simplest definition of a polymer is something
made of many units. Think of a polymer as a chain. Each link of the chain is the "mer" or basic
unit that is made of carbon, hydrogen, oxygen, and/or silicon. To make the chain, many links or
"mers" are hooked or polymerized together. Polymerization can be demonstrated by linking strips
of construction paper together to make paper garlands or hooking together hundreds of paper clips
to form chains.
Polymers have been with us since the beginning of time. Natural polymers include such things as
tar and shellac, tortoise shell and horns, as well as tree saps that produce amber and latex. These
polymers were processed with heat and pressure into useful articles like hair ornaments and
jewelry. Natural polymers began to be chemically modified during the 1800s to produce many
materials. The most famous of these were vulcanized rubber, gun cotton, and celluloid. The first
synthetic polymer produced was Bakelite in 1909 and was soon followed by the first semi-
synthetic fiber, rayon, which was developed in 1911
Even with these developments, it was not until World War II that significant changes took place
in the polymer industry. Prior to World War II, natural substances were generally available;
therefore, synthetics that were being developed were not a necessity. Once the world went to war,
our natural sources of latex, wool, silk, and other materials were cut off, making the use of
synthetics critical. During this time period, we saw the use of nylon, acrylic, neoprene, SBR,
polyethylene, and many more polymers take the place of natural materials that were no longer
available. Since then, the polymer industry has continued to grow and has evolved into one of the
fastest growing industries in the U.S. and in the world.
Characteristics of Polymers
The two major groups of polymers are thermoplastics and thermosets. Thermoplastic and
thermosetting nature is based on the heat response of polymers. The light transmittance of
polymers includes the description of materials as being transparent, translucent, or opaque.
Transparent polymers are those that you can see through, translucent are those that you cannot see
through but allow light to pass through, and opaque polymers are those that you can neither see
10
through nor allow light to pass through. Light penetration qualities are dependent on the degree of
crystallization of the polymer and the presence of additives.
Every polymer has very distinct characteristics but most polymers have the following general
attributes.
1. Polymers can be very resistant to chemicals
2. Polymers can be both thermal and electrical insulators
3. Generally, polymers are very light in mass with varying degrees of strength
4. Polymers can be processed in various ways to produce thin fibers or very intricate parts
As a leading manufacturer of engineered thermoplastic compounds having largest capacity in
India with multilocational compounding base, thus providing the complete solutions for
Automotive and Appliances Industries.
Research and Development
Manufacturing is fully supported by a team of dedicated Research and Development officers. A
laboratory scale Extruder very similar to the production machines has been installed in our R & D
department. This ensures that the scale up is smooth from R&D to production. In house R&D also
helps us to develop new materials in the shortest time period to meet our customer's new and
exacting requirements. R & D department is well dedicated to upgrade our material time to time
as per customer's requirements.
11
COMPANYPROFILE
12
Company Profile
About APPL
APPL Industries Limited, which has been formed by the merger of three groups of companies –
Aalekh Polymers (P) Limited, Aalekh Industries (P) Ltd., and Prateek Enterprises, is one of the
leading compounder of engineered thermoplastics in India. We have been providing material
solutions to our customer for over 15 years. Today, we offer precoloured compounds based on
Polyolefin’s and engineering plastics modified with minerals, glass fiber/beads, wood flour, flame
retardants etc. We also offer blends and alloys of various plastics, colour concentrates and
additive master batches.
Article I. APPL Facilities
Production units at multiple sites - strategically located to meet customer's requirements.
Latest fully Computer controlled state-of-the-art compounding systems from Germany, Japan
offer Advanced Materials Technologies.
International standard Quality Control Laboratory.
APPL has established highly sophisticated Polymer Compounding units at IMT Manesar near
Delhi and at Pune in Maharashtra with a total installed capacity of 30,000 MTA, and by the end of
2006, APPL will set up its third compounding unit at Hosur, Tamil Nadu with additional 10,000
MTA capacities.
APPL PROCESS
Twin Screw Super Compounders – Co-rotating and counter-rotating type
Gravimetric Loss-in-Weight feeders from Brabender Technologies, K-Tron
Automation of material handling
Our production equipment and its variety allow us to match each product to the right process,
highest and consistent product quality in shortest lead-time.
VISION
To be a multilocation company engaged in production of Engineered Thermoplastic Compounds
based on Polyolefin’s and Engineering Plastics, thereby attaining a top-performing compounding
industry dealing in multiple products and developing new applications close to customers.
13
MISSION
To provide materials based on advanced technology to our esteemed customers, which meet
challenging demands.
To respect the strength and capability of all our employees, customers and associates. To
honour all commitments we undertake.
ACHIEVEMENTS
1990: - The Company was established at New Delhi to manufacture Color Concentrate.
1995: -Manufacturing Plant dedicated for Black Masterbatch was set up at Rajasthan.
1998: - Two compounding line from Japan were installed at Delhi for PPAM compounds.
2001: - Two state-of-the-art compounding line from Theysohn Maschinenbau, Germany were
installed at pune.
2002: - Commissioned IMT - Manesar plant with two lines from Japan and two more
Compounding Lines from Theysohn, Germany.
2003: - Obtained ISO - 9001:2000 accreditation.
2003: - Automated Feeding system was installed at IMT – Manesar Plant.
2004: - Appointed as consignment agent of Ciba Speciality chemicals for plastics additives for
Eastern India.
2005: - Accelerated Weather meter instrument was set up at Pune plant.
2005: - Two state-of-the-art compounding lines from Coperion were installed at Pune and IMT
Manesar plant.
2005: - Two Research & Development purpose compounding lines from Coperion were installed
at Pune and IMT Manesar plant.
2006: - One Counter Rotating Twin screw extruder from Japan was installed at Pune
14
PRODUCT
PROFILE
15
SEGMENT DESCRIPTION TRADE NAME
Engineered Plastics based on Commodity Resins
Advanced Polypropylene Compounds
APPCOM
Advanced Styrenic Compounds
APPSTRON
Advanced Colour Masterbatches
APPCOL
Speciality Additive Masterbatches
APPLENE
Engineered Plastics based on Advanced Plastic Resins
From the above information we come to know that Renata plastics is using 25 % of nylon 6 & PBT, 24 % of ABS + filler and 13 % polycarbonate and nylon 66 + filler.
45
Abs+(filler)
Nylon6
Nylon66
Polycarbonate
PBT PP+Filler
H.I.P.S
PCABS
PCPBT
GPPS
Nylon +30% GF
Acrylic
HDPE
Nylon66
Polycarbonate
26.9%
43.5%
21.2%
6% 6.7%
99.3%
10.5%
1.2%
1% 10%
21.5%
17%
72.65%
21.25%
6%
46
CONCLUSIONSAND
SUGGESTIONS
47
CONCLUSION
Actually the main function of the company was to find out the consumption of polymers in
automobile sector in pune region so as to find out the potential in the market. From the total
polymer consumption chart mentioned earlier we come to the conclusion that polypropylene is
used readily in automobile sector because we can enhance its properties by adding filler for
example: glass, mica, talc, etc. as per the requirement of the product. Appl produces PP + Filler as
per the customer requirements. Polypropylene is used in bumpers, dashboards, fuel tanks etc.
Polypropylene is used frequently because:
There is no problem in the availability.
Its trends do not vary.
It is cheaper then metal.
Properties are more or less same as of metals.
The weight is lesser then metals which helps in increasing average of the vehicle.
As a student I have got a wonderful opportunity to work with such a good company as from
this study I have learnt a lot, I have given the work of research throughout the whole Pune
region that what are the steps company should follow in regard with their competitors, that
was indeed to be the best phase of my project when the recommendations given by me were
accepted and the company is following some steps which they think the most important
among all of the suggestions given by me. As well as I am thankful to all my subordinates and
my project guide Mr. Arun Sharma, as without their support and ally it was difficult to work
or attain something.
48
SUGGESTIONS
After studying all the aspects of the company I have certain suggestions, which are as follows:
The company should increase sales in such areas where it is lacking in sales in other
words company have to first take care of its marketing strategy that whether the
company is meeting as per the demands of the customers or not because a customer
accepts what he expects.
The company should try to reduce the cost of production by way of automation, if this
would be taken in consideration then the supply of the company automatically meets
the ordered quantity and it saves time too which is very important as money spended
on idle time would be saved and cost of production must be low.
Growth opportunities in public transport and commercial sectors
o As being a polymer industry a company have a wide scope in public as well as
commercial sector because still these transport companies are using metals
other then polymer
Material handling
o Proper utilization of resources so that there should not be any wastage
o Take care of the rejected lot
o Transportation issue is the biggest or considered to be the most vital because of
the expectation of the consumer V/S the delivery of the product.
Sourcing of materials
o Analysis of the market trends as demand changes as per the trend therefore
company have to adopt a policy of trend analysis because with the help of this
a company can change its standardization of the product which plays a very big
or essential role to attract consumers towards their own product.
Proper inputs from customer
o A company have to produce as per the specifications lead by the customer what
are their actual wants and desires what are the things which they are looking in
their purchasing behaviour
49
Market study must be done time to time as to know the behaviourial aspect of the
customer and to become aware about their wants and desires
Meetings must be done separately with each and every customer to add some new
inputs to the product, this is considered to be the best way to retain a customer for a
long time, as customer has become a part of production in this process.
Dealing with customer on several aspects such as
o Credit policies
o Complaints and customer care issues
o Salesmanship (personal interaction with the customer)
Personal visit must be done by a marketing head by presenting seminars on monthly
basis and each and every customer must be given a sense of participation so that they
can raise their issues regarding anything
50
ANNEXURES
51
ANNEXURES
Our Original Equipment Manufacturers:
Our Major Customers:
MARUTI UDYOG LIMITEDTATA AUTO PLASTICS SYSTEMS
LIMITED
TATA MOTORS LIMITEDVARROC ENGINEERING PRIVATE
LIMITED
BAJAJ AUTO LIMITED VARROC LIGHTING PRIVATE LIMITED
HONDA MOTORCYCLES INDIA LIMITED BRIGHT BROTHERS LIMITED