CHAPTER 1

INTRODUCTION

Gemini Plastic Industries was established by Late C. Govindan, a noted industrialist and
businessman in Thalassery. It was the blooming of a dream by a great entrepreneur and visionary
called C. Govindan. Thus, a SSI Unit was set up at Thalassery in 1987 with latest Windsor
injection molding machines, state of the art infrastructure and technicians to manufacture quality
plastic household articles.

Growth through innovation and customer satisfactions are the prime drive of the organization.
The firm is situated in the industrial estate Playad. GEMINI PLASTICS INDUSTRIES is
engaged in the production of 59 different plastics items and it's marked with the trade name
GEMPLAST. The firm itself handles production and marketing.

1
 CHAPTER 2

INDUSTRIAL PROFILE

Plastics are indispensable part of daily life. In the developed countries our plastics are put to a
variety of industrial use, requiring high precision and strength. They posses so many advantages
over conventional material. Today plastic play a significant role in most of the key sector of the
economy. These include agriculture and water management, automobiles and transportation,
construction, telecommunications electronic and engineering. Besides these defense and
aerospace, computers and power transmission are also expected to be significant o end users of
plastics by the turn of century. The Indian industries are well-known even before the western
countries came to know the plastic industries. Cottage industries give subsidiary income to the
people of the village and towns. Small scale industries play a significant role I in our national
economy. Most of the advanced countries are now highlighted that importance of plastics and
now in most of the western countries there are houses which are completely made up of plastics
by polymerization and other modern techniques. We can produce plastics of much higher
strength even stronger than iron and substances. Polymerize plastics a reacted much slowly with
air and that increases their yields and now most of places, iron is successfully replaced by
plastics and that is a positive effect of science and technology.

Our day today household articles, appliances, communication system, electrical, automotive,
paramedical, packaging and what not everything need that the usage of this miracle product and
that speak for itself that, our plastic industry should be given the essential commodity status.It
truly deserves and all the benefits that accompany that status Plastics may be red for
environmentalists but its green stuff for agriculturists. The price of the plastic is much lower than
other substances and the polymerized plastics can be prepared by the simple techniques. We
know that in olden times water pipes are made-up of iron pipes and then changes of reliability is
one third of that of plastics, and now the water pipes are mainly of pour vinyl chloride and that
will also reduce diseases which are caused by iron and they reduce the chance of leakage. Now
we are also using water tanks also made up of plastics and even the parts of aircrafts are also
made out from plastics. One thing is sure that any of the plastic manufacturers are not winning to
2
make people aware that using plastics helps people to take away diseases Now a day many of our
needs are being satisfied with plastics. We can't think about a life without plastics. Our major
benefit is that easy to carry and also we can produce plastics of any shapes without much
difficulty. Our scientists are also engaged in producing the quality plastics products Now as a
result experiment, We could produce plastics of high thermal stability In India, now there are
several companies which are producing plastics, plastics products and some are meant for
household needs and for using the outside the houses. Hence, most of the holder types are being
replaced with plastic and now we are using ornaments also which mare made up of plastics.

3
 CHAPTER 3

COMPANY PROFILE

GEMINI PLASTICS INDUSTRIES is partnership types of organization and was established in

the year 1987. Growth through innovation and customer satisfactions are the prime drive of the
organization. The firm is situated in the industrial estate Playad, Sri K Ramesh Kumar is the
Managing partner of the firm and Sri. Sreenivasan as the Manager.

GEMINI PLASTICS INDUSTRIES has a subsidiary firm called LAXMI ENGINEERING

ENTERPRISES. It is engaged in manufacturing dyes and modules used in producing plastic
products.

GEMINI PLASTICS INDUSTRIES is engaged in the production of 59 different plastics items

and marked with the trade name GEMPLAST. The firm itself handles production and
marketing of Gemplast. The firm started with an initial invests mental of 25 lakh. The machine
for manufacturing purpose is brought from KLOCKNER,WINDOSOSR INDIA LTD,
Bombay.

TRADE MARK

The trade mark of GEMINI PLASTICS INDUSTRIES is the picture of a baby in a bucket.

OBJECTIVES

Growth through innovation and customer satisfactions are the main objectives of the
organization.

4
 CHAPTER 4

BASIC FACTS

Name : Gemini Plastics Industries

Address of Location : Gemini plastic industries

Industrial Estate ,Palayad

Thalassery. 67066l

Year of Establishment : 1987

Holding Office : Thalassery

Bankers : SBI

Founder : late, Sri C Govindan

General Manager : Sri, Srinivasan

Managing partner : Sri, K Ramesh Kumar

Main products : Buckets, Basins, Container Mug, Jug, Cycle

Raw material : HDPE, LDPE, pp, Master Batch colour

Type of Layout : Process Lay out

Brand Name : Gemplast

Wage payment : Time Rate System

Trade Mark : Picture of Baby in a Bucket

Number of Employee : 58

5
 CHAPTER 5

ORGANIZATIONAL PROFILE

MANAGING PARTNER

MANAGER

MARKETING DIVISION FINANCE DIVISION MANUFACTURING DIVISION

SALES EXECUTIVE ACCOUNTATNTS

CLERK

STORE KEEPER SUPERVISOR

WORKER WORKER

6
 CHAPTER 6

DEPARTMENTATION OF GEMPLAST INDUSTRY

DEPARTMENTATION can be defined as process of grouping of activities in to unit &

sub unit for the purpose of administration. The administrative units & sub units many be
designated as the division, units branches, section, etc the process of DEPARTEMENTATION is
done in all section of the organization. The top level executive or manager of the organization
groups the entire activities into major division such as production sales, finance, IIRM, etc A
senior executive of the organization administers these divisions. They are reporting the important
information related to this DEPARTEMENT to chief executive. Senior executive assigns duties
to their juniors. So DEPATEMENTATION is done on the basis of level of management.

6.1 METHODS OF DEPARTMENTATION

There are five methods of DEPARTMENTATION within an organization structure:

 By function
 By products or services
 By project team
 By location
 By customers

6.2 MAIN DEPARTMENTS

 Production
 Stores &dispatch
 Accounts &finance
 Administration

7
 CHAPTER 7

FUNCTIONS OF DEPARTMENT

7.1 PRODUCTION

Production, planning, stock of raw materials is looked after by this department. Production
is done in three shifts.

7.2 STORES & DISPATCH

Receipt of material at the factory, arranging for clearing the same from transport, etc.
storing & keeping records of the some is the responsibility of this department. Stock of
finished products & raw materials is taken periodically & recorded. Stock is planed
&monitored for ordering of raw materials & other activities in time for uninterrupted
running of the factory. Order from distributers own vehicles sales bills are raised in the
computer accounting system.

7.3 ACCOUNTS &FINANCE

Day to day accounting & financing matters are handled in this department. Scrutiny of sales
bills. Purchase bill for raw material etc from various suppliers is checked & put up for
payment in time. Financial planning is done with regarding to purchase of raw materials in
various government departments are done by this departments.

7.4 ADMINISTRATIVE SALES MARKETING

The firm has about 20 distributors all over Kerala. Our sales representative visits each area
periodically & meets these distributors. Also he meets dealers in the area of distributor &
orders are collected & handled over the distributor concerned for supply of goods. Goods are
supplied to these distributors supply to wholesalers in their area. Tour plan for sales
representative, interaction with distributors, etc are handled by this department.

8
 CHAPTER 8

PRODUCTION PROCESS

The main part of production plant consists of injection molding machine which mainly uses high
density polyethylene as raw material it is in the granule state. These granules are hydraulically
injected to deferent moulds. As a result, plastic house hold of different shape is returned. The
firm uses only virgin material, no other substances are added. So the product obtained is of high
quality 40% of the retailers are of the opinion that quality of Gemplast is good compared to its
competitors.

The production part is fully modernized. three machines are used in manufacturing plastic
product. They are injection molding machine, color mixing motor & grinder motor. The crucial
function of manufacturing is done by injection molding machine. In the vessel like part of the
machine, raw materials are put, then the raw material then passed through a passage where
temperature pressure & timing are automatically adjusted. Enough injection pressure is required
to inject raw materials through nozzles into cavity of the mould. Mould clamping force is
required to hold the mould together. Then the melted raw materials, the actual plastic are injected
to different moulds which give different products. Before putting the raw material in injection
molding machine, suitable color are mixed by using color mixing motor. Defective products are
used as raw materials, in manufacturing mug or any small items.

Production process time varies from 23 to25 seconds depending on the size of the product.
Gemini plastic industries uses pure & high quality raw materials for manufacturing. So the
product arc of high quality, 60% of the consumer's opinion that the quality of Gemplast is
excellent.

Production process of Gemini plastic passes through following stages:

Stage 2 : Grinding

Stage 2 : Mixing

9
Stage 3 : Mould closing

Stage 4 : Mould locking

Stage 5 : Injection

Stage 6 : Injection holding

Stage 7 : Refill

Stage 8 : Finished products

Stage 9 : Mould opening

Stage 10 : Labeling

10
 CHAPTER 9

INJECTION MOULDING

Injection molding is a manufacturing process for producing parts by injecting material into
a mould. Injection molding can be performed with a host of materials mainly including metals,
(for which the process is called die-casting), glasses, elastomers, confections, and most
commonly thermoplastic and thermosetting polymers. Material for the part is fed into a heated
barrel, mixed, and forced into a mould cavity, where it cools and hardens to the configuration of
the cavity.

The first step to the injection molding process is the clamping of the mold. This clamping unit is
one of three standard parts of the injection machine. They are the mold, the clamping unit and
the injection unit. The clamp is what actually holds the mold while the melted plastic is being
injected, the mold is held under pressure while the injected plastic is cooling.

Next is the actual injection of the melted plastic. The plastic usually begins this process as pellets
that are put into a large hopper. The pellets are then fed to a cylinder; here they are heated until
they become molten plastic that is easily forced into the mold. The plastic stays in the mold,
where it is being clamped under pressure until it cools.

The next couple of steps consist of the dwelling phase, which is basically making sure that all of
the cavities of the mold are filled with the melted plastic. After the dwelling phase, the cooling
process begins and continues until the plastic becomes solid inside the form. Finally, the mold is
opened and the newly formed plastic part is ejected from its mold. The part is cleaned of any
extra plastic from the mold.

11
 Figure 9.1 Injection molding machine

Figure 9.2 Thermoplastic resin pellets for injection molding

12
 CHAPTER 10

PRODUCT PROFILE

The GEMPLAST products are the messengers of strength, durability & faith .Each product
is made out of imported virgin raw materials which with sudden destruction with fully
atomized injection MOULDING machines of internationally control system.

They have a term of highly skilled technicians, LABOUR forced & a newly setup fully
equipped tool room. It strengthens the quality of their products.

10.1 FEATURES OF THE PRODUCT

DURABILITY

Gemini products are made from high quality raw comparatively more durable than
others.

CHOICE

Gemini products come in different colors, design, shape, etc

HYGIENE

Gemini product are highly heat resistant & fashionable. maintain hygienically.

QUALITY

Gemini products are of high quality because they are produced from high quality raw
materials.

13
10.2 MAIN PRODUCTS

BUCKET

Bucket is a highly durable product. Family set handles, well designed lids ,etc. are the
main features of GEMPLAST buckets. Buckets are available in attractive colors. The size
of bucket varies from 5 LITRES to 22 litres.

STORE WELLS

Store wells are the best by construction & convenience. Store well are of the super
quality & appearance. They are available in different shades.

CYCLE BASKETS

Built to last, firmly set handles & beautiful design. They are also available in different
shades.

UTILITY TRAY

They have wide range of uses, from office table to kitchen. They are also available in
different colors.

BASIN

Wideness is varied as per the purpose. It is available in different sizes. They are also
manufactured in attractive colors.

MUGS

Mugs are of high quality. They are also available in different sizes & shapes.

WASTE PAPER BASKET

Waste paper baskets are like a knitted cloth, net design in superb. They are able to
survive in every situation. It is available in attractive shapes.

14
ROUND COMBS

Round combs bristles are strong & not malleable can be used for long. They are
available in attractive colors.

WATER JUGS

Jugs are strongly built with a cute design. They are also available in various colors &
sizes.

OFFICE TRAYS

They are easy to handle & simple in designs

15
 CHAPTER 11

SALES DEPARTMENT

In a business firm marketing generates the revenues that are engaged by financial people and
used by the production people in creating products series. The challenge of marketing to generate
that revenue by satisfying consumers wants at profit and in socially responsible manner.
Marketing is not limited to business. Whenever you try to persuade somebody to do something
you're engaging in marketing. Thus marketing has a broad social meaning. In fact, the societal
view is more truly descriptive of marketing today.

The essence of marketing is a transaction and exchange untended to satisfy human needs or
wants. Consequently, marketing occurs any time on societal limits strives to exchange something
of value another social unit.

Marketing is the process of planning and executing the conception, pricing promoting and
distribution (4Ps) of ideas, goods and services to create exchange (with customers) that satisfy
individual and organizational objectives. Satisfying customer needs (creating utility) through the
exchange process.

A customer is a person who brings us his wants. A marketer must identify that are his customers,
that their needs and what must be do the win their preferences.

A retailer is the middleman who sells to ultimate customer. He may sell to institution but most of
his sales are made to industrial or house hold customers. He usually sells in small quantities.

16
 CHAPTER 12

PRICE OF THE PRODUCTS

The price of the product affected the Gemini Plastic industries marketing programmed. In product
planning management may decide to improve the quality of its products or odd differentiating
features. This decision can be implemented by if the marked will accept high enough to cover the
cost of these changes. Studies have consistently shown that consumers perceptions of quality very
directly with price thus the higher price, the better quality is perceived to be consumers make this
judgment particularly when no other dues as to product quality are available. Fixation of the
Gemini Plastic Industry products prices based on:

(1) Labour cost plus raw material prices. Plus other expenses plus profit of the company.

(2) Price is based in two balances between estimate of market demand and supply of
products.

(3) Prices are based on competitive market condition.

TABLE 12.1 PRICE LIST OF PRODUCTS WITH EFFECT FROM 10-07-2011

SL NO. ITEM NUMBER PCS RATE DZ RATE

1 Bucket 51 20.50 246
2 Bucket 71 25.27 303.24
3 Bucket 91 30.00 360.00
4 Bucket 101 34.74 416.88
5 Bucket 111 36.75 441.00
6 Bucket 113 43.5 552.00
7 Bucket 115 46.75 561.00

17
8 Bucket 117 53 636.00
9 Bucket 120 62 744.00
10 Bucket 122 69.25 831.00
11 Bucket 251 78 936.00
12 Bucket + LID 98 1176.00
13 Bucket Super 131 47 564.00
14 Bucket Super 131 55.25 663.00
15 Bucket Super 181 62.75 753.00
16 Bucket Super 201 66.5 798.00
17 Bucket Super 251 32 984.00
18 Bucket (clear) 131 49 588.00
19 Bucket (clear) 161 57.25 687.00
20 Bucket (clear) 131 64 768.00
21 Bucket (clear) 201 67.5 810.00
22 Bucket (clear) 202 69 828
23 Basin 111 14.25 171.00
24 Basin 114 23 276.00
25 Basin 116 28 336.00
26 Basin 118 57 423.00
27 Mug 100 7.5 684.00
28 Mug 150 10 90.00
29 Mug 100 clear 8 120.00
30 Dust pan deluxe 12 96.00
31 Cycle Basket 55 144.00
32 Cycle Basket Lid 18 660.00
33 Square Tray 42 216.00

18
34 Water Jug small 21 504.00
35 Water Jug big 23.25 252.00
36 Water Jug small 17 204.00
37 LID 51 7.5 90.00
38 LID 71 8.75 105.00
39 LID 91 12.25 147.00
40 LID 111 13 156.00
41 LID 113 13.5 152.00
42 LID 115 15.5 186.00
43 LID 120 17 204.00
44 LID 251 18.5 222.00
45 Super LID 131 24.5 294.00
46 Super LID 161 17.5 210.00
47 Super LID 181 19.5 234.00
48 Super LID 201 22.5 270.00
49 Super LID131 clear 21 252.00
50 Super LID 161 clear 19 228.00
51 Super LID 181 clear 20 240.00
52 Super LID 201 clear 22 264.00
53 Stone Wed 21.5 258.00
54 Fan 14 168.00
55 Strainer 19 228.00
56 Fruit Tray 28 336.00
57 Office Tray 38 456.00

19
 CHAPTER 13

SALES FIGURE OF GEMPLAST

YEAR SALES
1995-1996 1.27
1996-1997 1.65
1997-1998 1.76
1998-1999 1.46
1999-2000 1.22
2000-2001 1.20
2001-2002 1.15
2002-2003 1.22
2003-2004 1.06
2004-2005 1.05
2005-2006 1.22
2006-2007 2.04
2007-2008 2.22
2008-2009 2.25
2009-2010 2.30
2010-2011 2.47
2011-2012 2.90

Table 13.1 Sales Figure Of Gemplast

20
 CHAPTER 14

PLANT MAINTENANCE

A system of frequent inspection should be established to prevent break down & keep working under
observation. Following are the preventive maintenance carried out by Gemini plastics.

14.1 DAILYMAINTENANCE

 To clean the machinery externally.

 Greasing the guide bars on the injection side as well as bars on locking side.
 Checking the oil level of the tank & top if necessary.
 Checking that lock plates on tail stock are fully tightened.
 Checking the oil temperature.
 Checking toggle setting.

14.2 WEEKLY MAINTENANCE

 To check whether grease nipples are working correcting.

 To check oil tank cover in properly fixed.
 To check to find a loose connections.
 To check water cooling at hopper block.

14.3 FORTNIGHTLY MAINTENANCE

 Checking the bolts under head stock mould plate.

 Checking the setting of relief valve.
 Checking the machine for correct machining.

14.4 MONTHLY MAINTENANCE

 Contact points of contractors should be checked.

 Checking the heater circuit.

21
  Checking the temperature controllers for correct functioning.
 Checking the function of limit switches.

14.5 QUARTERLY MAINTENANCE

 Check hydraulic oil for Contamination.

 Check loss in oil level.
 Take oil samples from oil tank for analysis.

22
 CHAPTER 15

CONCLUSION

The GEMPLAST products are the messengers of strength, Durability and faith. GEMPLAST
industry is showing excellent performance in sales from time it was started. Each product is made
out of fully automatic injection molding machine of internationally famous Kolkner windsom with
high quality standards.

GEMPLAST occupies the top most position in Kannur, Kuthuparamba and Thalassery areas in the
market of plastic products. They are very strict in advertisements. All the department function is
controlled and coordinated under the supervision of their dynamic Managing Director
Mr.Sreenivasan, GEMINI PLASTIC INDUSTRY PALAYAD. There is a harmonious relation
between the management and staff in this industry. In the coming years we can see GEMPLAST
industry as a more widened and more profitable firm.

23