Professional Documents
Culture Documents
Internship Report Master Tiles
Internship Report Master Tiles
1.INTRODUCTION:
Master group of Industries is the trendsetting leader in sanitary fittings, wall and floor tiles and
bathroom accessories. The constant quest for perfection at Master spreads over more than three
decades. These decades have witnessed
unprecedented.Growth i f b r a n d e q u i t y , m a r k e t l e a d e r s h i p , p r o d u c t i n n o
v a t i o n , h u m a n r e s o u r c e development, training and application of reliable management
systems. The combination has really worked. Master today is not only the market leader in Pakistan
but is also well positioned in the quality and service standards of the world leaders in its categories
of business Master group of industries is in business from 1982, now with more than 8
different industrial units:
• Master Tiles & ceramics
• Master Granite
• Master Sanitary
• Master Poly Plastic
• Master Baby(dipper)
• Master Ballpoint
• Master Poly Pack
• Master PPRC pipes
Executive Summary:
Master Tiles was formed in 1995 by Sheikh Mahmood Iqbal. Master Tiles is
oneo f t h e b i g g e s t m a n u f a c t u r e r s i n P a k i s t a n . M a s t e r T i l e s p r o v i d e s t h e o p p
o r t u n i t y t o upgrade the life style by introducing granite Tiles for the first time in Pakistan with
latest Italian technology. Master Tiles have a capacity to produce more than 3000
Sq/meter Tiles per day. In local market Master Tiles is a well-known Tiles manufacturing
company.
Mater Tiles captures about 60% of local market share. It manufactures both wall and
floor tiles. It manufactures good quality tiles at affordable prices. The marble and granite
processing industry is closely related to the development the building materials and modernization
which leads to progress of the tile industry. In the last two decades people have been using
chips and marble for floor finishing. As the time is changing the traditional
construction styles and finishing materials are also changing into modern construction
which sales the time and cost factors gives people readymade finishing for a life time. The Tile
industry in Pakistan has a huge potential in future. Availability of
rawm a t e r i a l a n d a l s o t h e i n c r e a s i n g d e m a n d m a k e s i t a g r o w i n g i n d u s t r y . P
e o p l e w a n t change. This trend shows increase in the demand of tiles. In future the
local industry is trying to increase the Production capacity.
It is a tale of thirty years, more than 1/4th of a century. It’s a tale of a vision realized a g a i n s t a l l .
It’s a matter of a commitment which reall y matter. It’s an account of a
climbing task transformed into mere peanuts through a clear vision, narrow focal point, sheer
devotion, meticulous hard work, dependable belief and stable quest for fineness.
MASTER GROUP OF TILES AND CERAMIC INDUSTRY ALI RAZA
I t S t a r t e d i n 1982 a s a s m a l l s e t u p w i t h b i g t h o u g h t s , h i g h i d e a l s a n d h o n e s t
commitment, Master today, stands as an unparalleled leader in world
classwall,floor t i l e s , s a n i t a r y f i t t i n g s a n d p l a s t i c g a r n i s h e s a l o n g w i t h a h o s t
o f o t h e r h i g h q u a l i t y products.
In 1982: launched as company developed and advertising high quality sanitary fittings,
with clarity of concepts, the target at that time was to provide a well-coordinated complete
bathroom to our clients.
In 1987: Established as the pioneer and market leader in world class sanitary fittings,
Master introduced the concept of matching bathroom accessories in technical
collaboration of England and Germany.
In 1995: It a time when the market was busy with import wall tiles as the only quality option,
as they called it, Master once again took the lead. Based on the world’s top of the
line Italian technology. Master launched its range of double fast fired wall tiles. F a r s u p e r i o r
i n q u a l i t y a n d a r t i s t i c v a l u e s t h a n i m p o r t e d o n e s , M a s t e r t i l e s t o o k t h e market
by storm and immediately gained a ma4or share of the market.
In 2000:
Master tiles were such a tremendous hit in the market, to meet the growing demands,
production capacity had to be tripled in the year 2000. Same year, Master added up
world’s best plant and acquired best recipes for in house production of tiles raw materials including
frits and colors. These advanced recipes in frits and colors r e s u l t e d i n g i v i n g a n e n t i r e
new look to the product appearance, quality and finish.
Nature of Organization:
MASTER GROUP OF TILES AND CERAMIC INDUSTRY ALI RAZA
Mission Statement :
The ceramic tiles industry is a ma4or force for the improvement of quality of life across the world.
Master aims to be the leading manufacturer of best quality ceramic tiles and pledges to provide its
customers with latest designs varieties and innovative productsin line with the internationally
changing trends. Through achivement of our aim we will enhance the wealth and well-being
of our stakeholders, employees and communities, whom we serve and in which we operate.
Vision Statement:
Masters vision is to lead the market with innovations in product development to improve the
quality of life and lifestyle of its customers. With timely adaptations to rapidly
developing technologies and meaningful investment in human resource training. Master will strike
to maintain the differentiation edge through provision of unmatched.
Number of Employees:
In Unit number three, there are overall approximately 725 employees including head of
department, senior managers, managers, shift in charges, supervisors, technicians and workers.
Products:
There are following few products which are being manufactured by the Master Tiles.
These products are available in different sites.
Glazed wall tiles
Glaze floor tiles
Granite floor tiles
Homogenized Porcelain tiles
Other products
Strips
Trims
Motives
Mosaics
Product lines:
The product line of master tiles is given as:
1. Raw Material
2. Body Preparation Department
MASTER GROUP OF TILES AND CERAMIC INDUSTRY ALI RAZA
Processes:
The brief detail of the process from raw material to the export of tile is given below
1. Raw Material:
The raw materials used in the production are easily
available in Pakistan. The raw materials are
being purchased from the areas of Kohat,
Mianwalli and other northern areas of
Pakistan. These raw materials are mined
from the northern areas and are easily
available.
From crushers the raw material enters in the ball mills where water is added and a liquid mixtue is
mixed and crushed. There are two ball mills one is continuous and the other is refinery. In refinery
ball mill further is mixed and after the refinery ball mill the liquid past is call “Slips” is stored in
the underground storage tanks.
The slips that don’t fall down enters in the cyclones after recycle in is added with the five percent powder
and the waste is stored in the scrubbers.
Presses:
The stored silos is then enters in the press department where tile is formed. Tiles of various sizes are formed
ranges from small twelve inches to one meter. In unit number three only large tiles are formed.
MASTER GROUP OF TILES AND CERAMIC INDUSTRY ALI RAZA
Horizontal Dryers:
After presses the tile enters in the horizontal dryers where five percent moisture is removed.
Kilns:
The tile is then enters in the furnace, at start the temperature of the kiln is 240 degree Celsius, in
the middle temperature is 1140 degree celcius and at the end its temperature is 240 degree celcius.
MASTER GROUP OF TILES AND CERAMIC INDUSTRY ALI RAZA
There are special air columns attached from which cold air is entered in the furnace and tiled is to
be cold. When tiles leaves the furnace its temperature is about 90-100 degree celcius.
In polish line department the tiles enters in the calibration and are polished with the help of
abrasives. Abrasives are manually changed after every hour since it is consumed to shine the tile.
Sorting line:
In sorting line quality of the tile is checked and is the categorized as scrub, commercial tile etc.
Departments:
In the following departments I served as an intern
Maintenance department
MASTER GROUP OF TILES AND CERAMIC INDUSTRY ALI RAZA
In maintains there were total of 20 employees, at a time there was one shift in charge and
other were technicians. In maintenance department we learned the different faults occurred
in the machinery, we worked their and saw how it was repaired.
Sorting line
In sorting line there were total of 40 employees working in which there were workers, and
managers. In sorting line the operations like squaring, palatizing, packing etc. was being
carried out. And we studied I in detail that how tile is being categorizes and what are the
issues that occure in the tile. Also we studied from where the issue was occurred either
from spray dryer, glaze line or polish line etcetera.
Short-falls:
The production capacity of unit 3 is about 25000 square meter but it is producing 15000-
16000 square meter
Maximum loss occurs in the kilns due to irregular temperature and unskilled labor for the
kilns. Since the temperature of the kilns is high so there must be high protection for labor.
Delay in the cleaning of machinery, machines remain close for many hours for their
cleaning.
Inexperienced technicians took ages to repair the machine, which results in the shortage of
the net production.
Design control systems to coordinate activities and production planning to ensure that
products meet quality standards
Confer with clients about product specifications, vendors about purchases, management
personnel about manufacturing capabilities, and staff about the status of projects
Knowledge Gained:
From my one-month internship in Master tiles and ceramic industry I gained
different kind of knowledge including technical, non-technical, professional,
managemanterial etc. I learned about new tools and techniques used to encounter the
problems. For examples I learned and understand the mechanism of ball bearings,
conveyors, belts, pullies, pump, motors, roller, shaft, wheel, hub, sleeve, load, rings,
flange, spherical rollers and grease etc.
And professionally I learned how to receive different people of different posts and
how to deal with them etc. I also learned how to control and manage such mega
industrial plants and what parameters should I come keep in my mind if I works as
a project manager.
Conclusions:
Recommendations:
As I have been employed as internee at Master Tiles so according to my observations
there are some recommendation by which they can increase their productivity.Few
recommendations are as follows:
• T h e ma i n p r o b l e m t h e i n d u s t r y i s f a c i n g i s o f e n e r g y c r i s i s ,
t o o v e r c o me t h i s problem they should set up their own plant for
generating electricity.
• They should use solar energy system, it would decrease the cost of energy and
there will be continuous production.
• They should also setup a LPG plant so that they could not face any
problem in their production.
• T h e y s h o u l d mi n i mi z e t h e i r c o s t o f p r o d u c t i o n t o c o mp e t e wi
t h t h e f o r e i g n players of this industry.
• They should increase their production due to increase in the demand
of tiles, as tile industry in Pakistan has a great potential.
• They should come up with the low price tiles as the customer are
more attracted towards low price items, the local manufacturers are
producing low quality good sat low price.
• They should make their distribution network stronger; they should also focus
the northern areas of Pakistan.
• The prices of Master Tiles are bit higher than their competitors so
they should adjust their prices according to their competitors prices.
• The structure of the organization should be changed to decentralized structure
so that the managers have the authority of making decisions.
• Training should be given to the employees to increase their productivity.
• They should increase the marketing of the product; they are only
using the old strategies of marketing. They should come up with new
marketing strategies to increase their sales.