2022

Assignment on Managing
Projects

MANUFACTURING & DELIVERY OF

BADMINTON RACQUETS FOR
YONEX SPORTS LIMITED

GROUP-4 , PGCBM-40
1. TB21003 - RaviTej Reddy H
2. TB21017 - Bindu Madhavi P
3. TB21033 - Lokesh Pothu
4. TB21063 - Shubham Anand Sahu
5. TB21077 - Gyanendra Kumar Sinha

PROJECT MANAGEMT ASSIGNMENT | PGCBM-40, XLRI

Contents

Sl. No. Description Page No.

1 Introduction 3

2 Scope 3

3 Objective 3

4 Purpose 3

5 General Data 4

6 Background 5

7 Program Charter 8

8 Required Actions 8

9 Risk Assessment & Mitigation 11

10 Approvals 13

Table No. Description Page No.

1 Major Milestones 5

2 Product Specifications 6

3 Program Charter 8

4 Risk Register 12
1 INTRODUCTION

This report looks into the planning, procurement, manufacturing, testing and delivery
process of badminton racquets project. This report will focus on the following areas of the
project that are listed as below:

a. Planning
b. Resource Mapping
c. Project monitoring and evaluation.
d. Risk assessment and mitigation.

The project is about manufacturing and delivery of two variants of badminton racquets by
Bindra Sports Pvt. Ltd., to Yonex Sports Limited. Yonex Sports Limited is the world leader in
Golf, Tennis and Badminton equipment’s. Bindra Sports Pvt. Ltd., a medium scaled company,
hopes to expand its business nationwide by manufacturing and delivering the products on
time to get future offers from Yonex and other key sports entities.

2 SCOPE

Scope of the project is to manufacture and deliver two variants of badminton racquets, one
model suitable for beginners and the other apt for experts by using specialized graphite
material used in producing shaft that flexes and stores energy, delivering explosive force on
impact with the shuttle and designed using ISOMETRICTM technology to improve the
chances of winning a point by the player using such racquet.

3 OBJECTIVE

The objectives of the project include the following:

a. Manufacturing the racquets using materials suitable to deliver explosive energy to
the shuttle on hitting the racket &
b. Design the racket using technology that increases the chance of shuttle hitting the
sweet spot and thereby winning points by the player.
c. Completing project on the deadline as agreed in the purchase order
d. Completing the project within the given budget

4 PURPOSE

This Program directive is to define and disseminate key information and provide
direction to the team with the aim of ensuring faster execution of the Purchase Order
from M/s. Yonex Sports Limited for manufacturing & delivering 10,000 nos. of
 Badminton Racquets. This Program directive is established to initiate the below
activities:

 To initiate all the Procurement activities of raw materials for in-house production
and outsourcing activities including resource mapping.

5 GENERAL DATA

● Program : Manufacture and supply of Yonex Badminton Racquets.

● Customer : Yonex Sports Limited

● Program Duration : 29th June 22 to 26th March 23

(9 months from the Effective date of Contract date)

● Contract No. & Date : YonexBM/DPUR/I/20205035/Contract-5512 Dt: 29th Jun 22

● Facility Affected : Bindra Sports Pvt. Ltd., Bengaluru

● Program Manager : RaviTej

● Deliveries Schedule : 1st lot – 5000 no’s within 6 months and 2nd lot – 5000 no’s
in 9 months from the Effective date of Contract

Badminton Racquets
(Qty.)
Sl. No. Consignee UOM Total

Expert Beginner

1st lot Yonex Sports Limited, New Delhi EA 3000 2000 5000

2nd lot Yonex Sports Limited, New Delhi EA 3000 2000 5000

Total 6000 4000 10000

 ● Major Milestones : The major milestones of the project are listed in the below
table-1
Also, the Integrated Master Schedule (IMS) timeline for the project is detailed in the
attached PDF file:

Link for IMS Plan

Table 1: Major Milestones

Sl.
No Milestones IMS Date ECD Status
.
1 Acquisition of Contract from YONEX Thu 30-06-22 Thu 30-06-22 Closed
2 Bill of Material (BOM) & Routing Wed 13-07-22 Wed 13-07-22 Closed
3 Budget release for Material & Consumables to Supply Chain Management (SCM) Thu 14-07-22 Fri 27-May-22 Closed
4 Submission of QAP to inspection committee for approval Fri 01-07-22 Mon 01-08-22 WIP
5 Release of Purchase Order for Raw material (RM), Consumable & Outsourcing Tue 19-07-22 Tue 02-08-22 WIP
6 Receipt of Material for 1st lot & 2nd lot Production Wed 31-08-22 Wed 31-08-22 WIP
7 Receipt of Outsourced Material for 1st lot Production Fri 19-08-22 Fri 19-08-22 Open
8 Production of 1st lot of 5000 no’s Racquets Thu 01-09-22 Thu 20-10-22 Open
9 Bulk lot sample offering to Yonex for testing. Fri 21-10-22 Mon 31-10-22 Open
10 Sample selection & bonding of stores Tue 01-11-22 Wed 02-11-22 Open
11 Delivery of 1st lot to respective consignee unit Tue 06-12-22 Mon 12-12-22 Open
12 Production of 2nd lot of 5000 no’s Racquets Tue 01-11-22 Tue 20-12-22 Open
13 Bulk lot sample offering to Yonex for testing. Wed 21-12-22 Thu 29-12-22 Open
14 Sample selection & bonding of stores Fri 30-12-22 Wed 04-01-23 Open
15 Delivery of 2nd lot to respective consignee unit Thu 02-02-23 Wed 08-02-23 Open

6 BACKGROUND

Bindra Sports Pvt. Ltd. secured its very first order from Yonex Sports Limited for
manufacturing and delivering by qualifying all the specification and product testing
requirements competing with 7 bidders in this RFQ. This is one of the prestigious
Sports orders which Bindra Sports Pvt. Ltd. has won in recent times and will be a
stepping stone to win more orders from YONEX in future.

a. Product Description: The name of the products are ASTROX 99 PRO for experts &
ASTROX 99 PLAY for beginners. ASTROX is the latest series from Yonex which focuses
on counter weight balance theory. In this theory, to get maximum control on racket,
re-distribution on weight in done. Now weight of the racket is balanced at racket
frame top, Joint & handle end. This theory provides better racket balance and help
player to quickly adjust the racket for next shots.

Further, Yonex ASTROX is all about getting the steep angle of attack. Player who
wants better angle of attack will love ASTROX series as it offers flexibility to hit steep
 angle attack. ASTROX series racquets offer powerful smash with steep angle of
attack by which you can easily get the point.

b. Specifications: The ASTROX series is built with a world-first, new dimension graphite
material, NAMD, greatly improves the adhesion of the graphite fibers and resin by
attaching nanomaterial directly to the graphite fiber. In high performance racquets,
it is common to combine nanomaterials with resin that connects graphite fibers, but
in NAMD, nanomaterials are directly adhered to the graphite fibers and resin is
greatly increased. This major improvement is that it produces a shaft that flexes and
stores energy, delivering explosive force on impact with the shuttle.

Table 2: Product specifications

The material used, size and weight of the racquets will be as mentioned in below table:

Sl.
Type Series Flex Material Weight/Grip Length
No.
4U (Avg.83g) G5,
1 Expert ASTROX 99 PRO Stiff HM Graphite / NAMD 76.4 cm
6/3U
4U (Avg.83g) G5,
2 Beginner ASTROX 99 PLAY Medium Graphite 66.4 cm
6

Below figure shows the Expert & Beginner series Racquets:

ASTROX 99 PRO (Expert) ASTROX 99 PLAY (Beginner)

Also, ISOMETRICTM technology is used in these racquets. Developed over 30 years ago, the
ISOMETRICTM design increases the sweet spot by 7%*. Compared to a conventional round
frame, a square-shaped ISOMETRICTM RACKET generates a larger sweet spot by optimizing
the intersection of the main and cross strings. ISOMETRICTM delivers greater control
without sacrificing power. ISOMETRICTM is a Trademark of Yonex Private Limited.
*Tested by Yonex

The racquets have extra slim shaft which are the thinnest, strongest ever produced.
Cutting edge NANOMETRIC carbon technology is used to produce an ultra-thin, ultra-tough,
aerodynamic shaft, created for a stronger and more intense shot.
 Also, the racquets possess New Built-in T-Joint, which are the lightweight T-Joint increases
stability of the shuttle on the strings, maximizing power and control. An illustration is shown
in the below pic:

7 PROGRAM CHARTER

Table 3: Program Charter

Project Name Manufacturing and delivery of Badminton racquets for Yonex Sports Limited.
Description & Goals Manufacturing & delivery of 10,000 badminton racquets.
Success of this project is key to further orders.
In Procurement of raw materials, machinery.
Scope Delivery of the finished product to the consignee.
Contingencies due to Covid.
Out
Outsourcing for branding.
Business Case Keeping schedule, scope & budget at optimum.
Time To be delivered within 9 months from the date of PO.
Materia
l The on-time availability graphite material due to the ongoing Ukraine war.
Constraints
Budget Any delay in raw material from supplier end or any forced majeure.
Quality The racquets must pass testing at Yonex facility.
Scope First order in this segment.
1st lot - 5000 Racquets by 30-November-2022 06.12.2022
Deliverables
2nd lot - 5000 Racquets by 30-March-2023

Program Manager RaviTej Revenue of Program ₹ 4,50,00,000.00

Program Head Gyanendra Estimated Budget ₹ 3,37,50,000.00
Manpower
Key Resources
Machine for fixing of strings

8 REQUIRED ACTIONS
8.1 All Functions
 a. Nominate Single point of contact (SPOC) from the respective department responsible
for the execution of the program & shall support the Program Manager in execution
of activities.
b. Ensure all the tasks are completed as per Program Rail Tracker to meet the agreed
delivery schedules.
c. Provide required support for internal and customer reviews, as per the program
requirements.

8.2 Program Management

a. Release of Program directive to start procurement and other planning activities.

b. Coordinate with customer on QAP approval.
c. Comply with operating rhythm for program review & highlight the key risks &
actions.
d. Convey the Program plan and activities to the top management.
e. Ensure necessary support from customer during bulk lot inspection and sample
selection.
f. Ensure the tasks are being followed as per Program plan.
g. Coordinate testing of sample racquets at the Yonex Sports Limited facility.
h. Obtain dispatch clearance from Customer

8.3 Legal & Regulatory Compliance

a. Support on contractual obligation, key contractual requirements identification &

implementation plan.

8.4 Process Excellence

a. Since this is a one-time PO, scope of process excellence, if any, will be implemented in
the next PO.

8.5 Facilities, Plant Engineering & Maintenance

a. Ensure uptime of all equipment required for production.

b. Ensuring, processing and reviewing of Production Preparation Process (3P).

8.6 Business Development

a. To share the Business estimate that includes all costs associated with the program.
b. Business Case shall be Established and Financial viability to be realized.
c. Key Program Contractual Obligations to be shared and documented.
d. Key Customer Quality Requirements to be shared and documented.
e. PO received from the customer shared with the Legal Regulatory and Compliance
team for review post change implementation board.
f. All open BD action items to be Closed.

8.7 Admin., Safety & Security

a. Adherence to EHS policy and compliance as per corporate procedures.

 8.8 Finance

a. Approval of PR’s and release of Purchase Orders on suppliers for material procurement
b. Ensure correct SAP cost capturing and MIS reporting.

8.9 Human Resources

8.10 Deployment of required manpower (contract/on-roll) to be provided as per estimation

& requirement.

8.11 Information Technology

a. Ensure correct configuration of SAP, in terms of material movement and transactions.
b. Support on Material Master creation.

8.12 Operations

8.12.1 Production Planning & Control

a. Ensure the readiness for launch of Program Plan.

b. Raise PR for RM and consumables for series production.
c. Conduct & review the LOB with key stake holders.
d. Route card/MIS release to Production on time.
e. Production plan and capacity allocation for series production parts.
f. Track and Publish daily Production Status.
g. Tracking LOB of raw materials & consumables.

8.12.2 Industrial Engineering

a. Plan for production capacity and layouts.

b. To assess the production capacity, learning curves and provide a realistic and
achievable cycle time for series production.

8.12.3 Tooling Design & Manufacturing

c. To provide necessary tooling support for production (as applicable).

d. To have preventive maintenance for available Tools and calibrate (as applicable)
before releasing to production.

8.12.4 Manufacturing Engineering & Configuration

a. Release of PBOM for detail part raw materials, hardware, consumables to SCM.
b. Plan and identify resources for Configuration Implementation Board (CIB).
c. Development and release of MIS to Production for Detail Part production &
assembly.
d. Finalize and publish manufacturing process.
e. Finalize and release of Conditions of Supply.
f. Development of Process document-PD, Manufacturing Instruction Sheets-MIS,
Manufacturing Visual Aid - MVA, photobooks, work instructions for series production
parts.
g. HSPPD (Handling, Storage, Preservation, Packaging and Delivery) requirements to be
documented.
h. Customer special process and material requirements to be realized and documented.
i. All minor, perishable and hand tool requirements to be identified and PR’s to be
generated.
j. Conduct Change Implementation Board (CIB) meeting regularly to ensure the proper
configuration flow down to all departments.
k. Highlight any gap in technical data & technical queries in a timely manner and
resolve shop issue with regard to configuration.
l. To ensure all Travelling log (route card), process documents etc. ready before start of
production.
m. Publish and track closure of all actions captured in CIB.
n. Ensure configuration control.
8.12.5 Production

a. Should adhere to manufacturing process as per process document (PD).

b. Identifying manpower requirement for limited series production.
c. Identify need of training for technicians.
d. Adhere to the timeline of the project.
e. Identify process improvement initiatives and implementation of the same.

8.12.6 Supply Chain Management

a. Release of RFQ’s on supplier for part raw materials on basis PBOM.

b. Release of PO’s for all raw materials and outsourced items.
c. Ensure all the required Raw material, consumables orders are placed & is readily
available for use as per Program plan.

8.13 Quality

8.13.1 Quality Assurance

a. Quality system requirements thoroughly documented.

b. Submission and approval of QAP from customer Quality.
c. Inspection of Racquets as per approved QAP.
d. Plan for pre-dispatch inspection of Racquets.

8.13.2 Quality Control

a. Ensure the proper adherence of the Quality of part manufacturing according to the
drawings, relevant specifications and customer specific requirements.

8.13.3 Supplier Quality Assurance

a. Supplier audit and compliance of all suppliers if required.

8.13.4 Receiving Inspection

a. Receiving inspection of all material to ensure quality adherence.

b. Support on need basis or based on the CIB or any action points to support execution.

9 RISK ASSESMENT & MITIGATION

As is the case in any project management scenario, some risks are inherent in the project It
is possible through good strategic management of the undertake project to minimize the
risk, but it is impossible to completely eliminate all the risks associated. These risk factors
that are likely attached with the project can cause disruption in project quality, cause delay
in completion, and even make the project over-budget (Virine & Trumper, 2017). So, we
need to have a mitigation or a backup plan for any such instances.
As we see, for this project, the below risks have been identified:

a. Raw material availability.

b. Outsourcing of racquets for branding.
c. Breakdown of machinery.
d. Budget Fluctuations.

To account for this situation involving risk that are related to the project, performing
a structured risk management is a recommended operation (Roberts, 2011). Strategic risk
management policy is a management approach in which all the risks that have a possibility
of occurrence are identified beforehand to increase preparedness. After identifying all of the
risks, the next step taken in strategic risk management process is to make efforts to mitigate
the risks and develop a contingency plan to deal with the risk factors (Molenaar, 2010). All of
these processes are performed with the intent to make the project least susceptive of
negative impact of risk factors.

In this project, the process of risk management is performed using the method of risk
registers. Using the risk register, the project manager can keep track of all the major and
noteworthy risks associated with the undertaken project and ensure that none of these risks
impact the project to a significant degree. The objective of implementing the strategic
project risk management process would be to firstly minimize the probably of risk
occurrence and then in a case that a risk does occur, minimize its damage by preparing a
plan to adequately deal with it (Marcelino-Sadaba, et al., 2014).

The table formulated below represents a risk register for this project, which identifies
relevant risks regarding this project while also noting the mitigation strategy and
contingency plan.

Table 4: Risk Register

Pre- Post-
Risk factor Mitigation strategy Contingency plan action action
score score
Supply would be An immediate purchase
Raw material ensured from a reputed order would be placed
4 2
availability supplier with ample with an alternate
stocks. supplier.
Contractor would be
The contractor hired
contracted to resolve
would be checked for
Outsourcing of any issue in quality of
experience, quality of
racquets for material or flaws by 6 3
work and reputation also
branding immediately using
delivery schedule will be
independent inspection
contractual.
approach.
Breakdown of Only brand new and Such tools will get
Tools/Machiner branded tools would be replaced immediately 5 1
y purchased. using warranty.
Budget estimations are A budget monitoring
Budget
kept accurate as per will be adopted in a 6 4
fluctuations
current rates and expert continuous manner to
 quotations avoid over-budgeting

10 APPROVALS

All personnel involved in the subject program are requested to comply with the above
instructions to ensure the completion of the project as per the scheduled timeline.

(RaviTej) (Gyanendra)
___________________ _____________________
Program Manager Head - Program
Management