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Department of Management Science Dr. Babasaheb Ambedkar Marathwada University Aurangabad In-Plant Training Report
Department of Management Science Dr. Babasaheb Ambedkar Marathwada University Aurangabad In-Plant Training Report
AURANGABAD
ON
In Partial fulfilment of
Submitted By
R.K.PRIYA MAM
There is always a sense of gratitude towards the people who have helped me in this
project. I am indebted to all that have directly and indirectly helped me in completing
this project. I am thankful to our university for giving us this marvellous opportunity.
I am also thankful to our Director Sir Prof. Abhijeet Shelke whose encouragement
and moral support has been a source of inspiration to us.
I also wish to thank everyone who helped me directly or indirectly in the preparation of
this In-plant.
1 Introduction 5
2 Company Profile 7
3 Scope and Objective of Study 9
4 Vision and Mission 10
5 Awards 11
6 Management Team 12
7 Research Methodology 15
8 Departments 18
9 SAP 50
10 SWOT Analysis 52
11 Suggestions 54
12 Summary and Findings 55
13 Bibliography 56
Garware polyester is the largest as well as the first reputed company to produce
polyester film in India for the last 33 years. They have grown to be a force to reckon
with within the polyester film industry. They are continuously diversifying to meet new
challenges and reach new horizons.
At Garware polyester they serve the need of diverse industry. Their product range
includes films cater to the solar control industry, packaging industry, reprographic
industry etc.
They have four fully integrated films line that enable us to meet their customs demand.
They are in ISO: 9001:2000 companies with a customer base that spans the globe.
Garware polyester self produced the raw material in their chips plant, and then they
produced the different types of the film, this company never left the waste material.
Company recycled waste material. Garware polyester exports their products in the
global market; their products have very good demand in the international market. The
main offices of the Garware polyester are also available in the foreign country like,
USA, UK, and JAPAN etc. Garware polyester is the India very big and respected
company. This company has two plants at the Aurangabad.
1. Plain film
2. Solar film
3. Sun control film
4. OHP film
YEAR EVENTS 1957 - The Company was incorporated on 6th June, under the name
Garware Motors & Engineers Pvt. Ltd., and was converted into a public limited company
on 26th May 1981. The Company's objects is to manufacture rigid PVC pipes, HIP
sheets, ABS cop sleeves, PVC pipe fittings and industrial mouldings, general mouldings
and extrusion items, metallised film for Sari yarn, electrical insulation film, packaging
laminates, tea wrapping film and bare film.
1979 - The Company obtained an industrial licence to expand the capacity of polyester
film from 600 tonnes to 1,500 tonnes per annum and to set up a captive plant with a
capacity of 2,000 tonnes per annum for the manufacture of polyester chips which was the
raw material for the manufacture of film. The expansion was to be carried out in the
Company's existing unit at Waluj in Aurangabad.
Garware is well reputed listed organization to reckon with in the field of polyester film.
They continuously diversify to meet new horizons and challenges with competence and
dynamism.
With their vertically integrated production plants, four independent manufacturing lines
and skilled manpower, they have built a business that spans the globe.
With an annual turnover in excess of US $100 million, they employ more than 1500
employees in their factories and offices. The Corporate Head Quarter is located in
Mumbai and the company's main production facilities are at Aurangabad and Nasik.
The forties witnessed the birth of Garware, a simple manufacturing unit producing plastic
buttons for the Navy. We later diversified our product base to include knitting needles, pen-
holders and toothbrushes.
In the fifties we lead the race by manufacturing injected, moulded and extruded plastic products
like television casings & fan blades.
The sixties brought new challenges in the form of new technologies. We responded by
expanding our product line to include PVC pipes, fittings and allied products. End sixties saw
the emergence of Polyester film and a whole new world of possibilities opened up for us.
By the seventies we set out to conquer the entire world. Our expansion plans were launched
with exports to the Middle East. To meet growing demands two new plants were set up - the
polyester film plant in Aurangabad and the metallising unit in Nasik.
In the eighties we produced sure winners like Garfilm, Sun Control and X-Ray film - all
polyester based and indigenously developed. We were matching strides with developments
worldwide.
The nineties, the era of high technology, saw us taking on new challenges.
The duration of the In-plant study was 45 days. Working with Garware Polyester Ltd.
under an In-Plant Training is an exciting experience. As part of my In-plant Training, I
got an opportunity to do In-plant Training in an esteemed organization. Along with In
Plant Training, I also got a chance to update myself with the policies followed in the
manufacturing fields, which provided me an invaluable insight in to the working
practiced of the company.
The time spent In Plant Training period provided me rich and memorable experience,
which would always be treasured by me, the improvement and further individual
growth for me.
Since the In Plant Training is to be completed in very short period of time it was not at
all possible to acquire dept knowledge in the overall working of the industry. The scope
was in Plant Training is very much restricted to the area of specialization desire in
future. Accordingly In-Plant Training was carried out with view to absorbed as much as
possible from the relevant department concern i.e. Production, Quality assurance,
Human resource, Account, Purchase and Storage.
Objective of study
The basic objective of the training was to get through the different management
concept through production, finance as well as the marketing department.
Also we had an increase the knowledge of engineering through the managerial
concept.
To apply the theoretical knowledge to learn the various aspects of management.
Initially founded by Mr. B D Garware, the company was furthered by Mr. Shashikant
Garware, who steered the company through four decades of growth, diversification and
changing technologies.
Mission
Promote the use of polyester film, while focusing on sustainable growth and
environmental greenness.
Prompt and efficient service to ensure provides customer satisfaction of their
products.
An ISO 9002 certified company since 1994, they have achieved a number of awards for
innovation and excellence.
S. B. GARWARE
S. S. GARWARE (MRS.)
DILIP J. THAKKAR
N. P. CHAPALGAONKAR
B. MORADIAN
M. S. ADSUL
M. C. AGARWAL
RAMESH P. MAKHIJA
Dena Bank
Bank of India
The company has recently perfected the technology for scratch resistant sun control
with focus an export. The new variety has tremendous export potential particularly to
the US.
The company has already commissioned continuous polyemeriasation plant (CP Plant)
in the year 1994-95. Graware polyester ltd is the well known market leader. It has
already completed substantial expansion of their production in polyester film. Thus it
makes the company a true market leader.
Research is the common refers to a search for knowledge. One can also define research
as a scientific and systematic search for information on a specific topic. In fact research
is an act of scientific investigation.
It is the pursuit truth with the help of study, Observation, Comparison and systematic
method of finding solution to a problem is research. The systematic approach
concerning generalization and the formulation of the theory is also research.
Business firm uses marketing research has grown continuously over the last year.
Systematic records of analysing to helpful for marketing goods and services. Research
always starts with a question and a problem. Its purpose is to question through the
application of the scientific method.
Data was collected through Primary and Secondary data collection methods in primary
data method survey and interviews were taken and secondary data books, internet,
articles, marketing journal etc. With the help of this method I have collected the data.
Primary data:
Data that is collected for a specific purpose at hand is called primary data. The
collection primary data is costly and time consuming. It calls for greater planning and
co-ordination. Collection primary data requires developing more manpower.
1) The questionnaire:
The questionnaire was used as a tool for data collection, which consist
of close ended questions, regarding the performance appraisal system in the
organization and employees opinion about it.
2) By observation:
Finance department
Marketing department
Production department
Purchase department
Store department
Director
Vice President
Safety
HR Policy
Salary
Over time
Accident policy
The company has introduced accident policy to all its workers and
employees. Policy converge includes accident while working at machine.
Communication policy
Working
The working time holidays of the company are as
As per the accounting rules Garware polyester limited maintains all the records in
proper accounts books.
1. General ledger
2. Cash and bank book
3. Journal voucher
4. Purchase book
5. Sales book
6. Loan to staff ledger
7. Supplies ledger
8. Personal ledger
Objective
Overall finance is the backbone of each and every type of industry. Without financial
nothing can’t be done in the business organization and management.
Introduction
Production means to change the raw material into the finished goods, production
department always works to make finished goods and introduce to the market.
Production department in short modified the raw material in the finished goods or
product by using latest technology.
Garware polyester limited is the very large company and it has units at Aurangabad
location, one is at the Chikalthana M.I.D.C. area and second one is at Waluj M.I.D.C.
area. At the Chikalthana complex there is only production plant. And at Waluj there
chips production plant and administration office is also available.
At Waluj M.I.D.C. Garware polyester ltd produce their raw material itself in chips
plant and then after distribute the raw material at Chikalthana plant and Waluj plant.
Then the production department can process for the production in the Garware
polyester ltd has lining production technique and they have four lines including both
plants.
Production Department
Page 27
Inflow and outflow of the production department
Film Process
Recycling
The polyester chips are used as raw material for manufacturing the polyester film.
These chips are received from chips plant by pneumatic conveying. They are then
pneumatically conveyed into the silo located at 30 meter height. The chips are fed
to the crystalliser with the help of screw conveyer for crystallisation. The chips
are heated in a jacketed vessel having a counter flow of hot air. The oil
temperature is about190 deg.C and the air temperature is about200 deg.C. From
the crystalliser the chips fall in the dryer by gravity. In the dryer chips are heated
by a counter flow of hot air at 200 deg.C and having a dew point of 60 deg.C.
2) Extrusion:
From the dryer the chips fall in the extruder by gravity. There are two numbers of
extruders in line 4 and 3 in line 5. One extruder of line 4 is electrically heated and
another is heated by oil. In line 5, all extruder are electrically heated. From
extruder the molten polymer goes in screen changer and from the screen changer
it goes to a pump. It is then filtered in a polymer filter and the filter it passes
through a die for producing film. There is used for casting the polymer. Chilled
water at20 deg.C is circulated to the chill roll.
The film is passed through series of rolls, which are heated by hot oil at 60-80
deg.C. The longitudinal stretching is done by speed difference between the roll.
Transverse direction stretching of the film is done in oven which is oil heated. The
film is passed through the oven with the help of two endless chains. The oven is
distributed into various zones and temperature of the oven is between100 to245
deg.C.
The film is taken out from the oven Transverse direction (TDO) by the take up
and transfer rolls wound in the winder.
The film rolls are then slit on the slitting machine as per customer requirement in
various lengths and widths.
1. Solar Film:
FEATURES:
Saves energy by rejecting up to 40% of heat. This enhances comfort level and reduces
load on air conditioners
Blocks up to 90% of harmful ultra violet radiation and thus prevents damage to skin
and upholstery
Reduces glare substantially and increases driving comfort
In case of accidental breakage the broken glass splinters are held together by film,
limiting the extent of damage and injury
The numerous matching shades available enhance visual appeal
2. Plain Film
In plain film there are different products. These plain films are:
1. Food Packing
2. Cable Insulation
3. Thermal lamination
4. photo sensitive coatings
FEATURES:
BENEFITS:
Garware Tracing and Drafting film is a lacquered polyester film suitable for
manual drawings (on boards) as well as pen plotter drawings.
FEATURES:
BENEFITS:
Purchasing is the procurement of material supplies machines tools and service required
for the equipment maintains and operation of the business. Purchasing must be of the
right in proper quantity for delivery at the correct time and at the most favourable price
from the outside.
The principle of the company for purchase department is the procurement of good of
the right source and the right price. In Gaware polyester ltd purchasing has recently
been centralized. Initially it was decentralized.
As well as after production of the fresh and finish goods means final product so that
time to put that product safe and protected so that time store always become very
useful, so every company needs the store department as well as bigger store room, to
put the inventory safety.
Store department has very important responsibility and this department always
performed their very important role in the company, because store department
always keeps the entries and information of the inventory which has always comes in
the company and goes out from the company.
Store department is plays the very responsible role in the company store department
always keeps the all data and information about company product its quantity quality
etc. These are the some introduction of the store department.
Function:
Stock accuracy
House keeping
Inventory control
Trade Market
1. North America
2. South America
3. Eastern Europe
4. Southeast Asia
Main Market
1. Africa
2. Oceania
3. Mid East
4. Eastern Asia
5. Western Europe
Export Percentage
71%-80%
S.B. Garware further steered the company through five decades of growth,
diversification and changing technological innovations. The house of Garware is
recognised as one of the leading industrial house in India.
The company have been consistently winning the Top Exporter Award from the
Government of India as well as Government of Maharashtra.
Project Report
Organizational Chart
Page 40
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Sales Department
This department is responsible for establishing the sale objective of the film and their
attainment.
This includes:
In Garware polyester ltd the marketing and sales department handles the sales
coordination function. Sales manager controls the department.
Function:
US
UK
FRANCE
HOLLAND
SINGAPORE
HONKONG
THAILAND
TAIWAN
INDONESIA
JAPAN
UAE
KUWAIT
SAUDI AREBIA
MUSCAT
ISERIL
SUDAN
KOREA
AUSTRALIA
ITALY
NEW ZEALAND
Organisation chart
Chikalthana Waluj
Manager Manager
Dr. J.D.Chaudhary D.S.Jadhav
Executive
M.P.Shinde
24 Firemen 24 Firemen
Fire Vehicles
1. Fire Tender- 4500 liters water
2. Fire Jeep
Fire Extinguishers
1. CO2
2. DCP
3. Water
Training
SAP is System Application Programming. The system software is developed for the
processing of data in the company. It is a database program linked on one server and it
is connected to all departments.
1. MM - Marketing Management
2. QM - Quality Management
3. PP - Production Planning
5. FM - Finance Management
7. HR - Human Resource
These are some important field on which S.A.P. works. The every function as
transaction done in company, the respective department how to make entry in the
computer and that entry is visible to all departments. So no one has to go personally
in other then getting any info about department.
So S.A.P. has done the things very easy for every department and save time and
increase the accuracy in functioning of all departments.
SAP SD is the Sales and distribution module of the SAP ERP software package
from SAP.
SD is used for Sales and distribution of products.
Broadly, the various levels that can be defined for a SAP SD implementation
are: Client, Company Code, Plant, Sales organization, distribution channel,
and division.
The main functionality within SD includes Presale activity, sales order
processing, Delivery, Shipping, Billing, Payments.
Production Planning
SAP PP is the production planning module of the SAP ERP software package
from SAP.
Material Management
SAP MM is the Materials Management Module of the SAP ERP software
package from SAP.
Strengths
Opportunity
Additional Serve for customer groups: If they are taking additional server
for their customer then they have opportunity to the more customers are
buying their product.
Expand product line to meet broader range of customer needs: They have
more opportunity to the expand product line to broader range of customer
needs. Their customers are more so that more products sell in national and
international market.
Diversify into related products: More opportunity to diversify into related
products. Different products are produced. By using plain films they are
having a better capacity to produce different products.
Garware Company has more cost waste on marketing strategy compare to other
competitors. And also, Product cost is more than the other competitors. So I want
to suggest that to decrease your product cost and not to more cost waste on
marketing strategy.
Garware polyester ltd has only concentration on international level. They are use
marketing skill in international market. So that local market loses in the some
areas. So I want to suggest, also concentration on local market so that more local
areas to purchased their product and increase their profitability.
In foreign market their product cost is high compare to the other competitors. So I
suggest that to low product cost in foreign as well as local market. Garware
Company has not more cost waste on advertising, waste of production so they
reduce the product cost.
The machineries are more used because it’s continuous production, so it’s not
possible to check every time, and change equipments. I want to suggest that
regularly check machine and reduces the cost.
Garware polyester ltd is having the good Human Resource. The entire employees in
the company are well trained and qualified into the work. All the departments are
well established and fulfil the need of the employee.
Garware Polyester Ltd. is one of the leading multinational companies in India. This
company has the large share of the market. The company Garware have the main
competitors are not Indian they are multinational companies.
The production is done on the basics of marketing requirement. The requirement and
other information is gathered by the marketing department this requirement send to
the P.P.C. Department and this department makes the production plan and gives the
production department and distributed in the market.
www.garwarepoly.com
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