Nilkamal Plastics is one of the oldest & longest manufactures of plastics products in India.

It is a well organized & highly trusted organization which has over the years established & proved themselves. It is Asias largest plastic processor of moulded products. They make products that have changed the very nature of the good transportation & furniture industry in this region. Firstly I would like to tell you about the hierarchal structure. CHAIRMAN: Mr. VAMAN PAREKH. MANAGING DIRECTOR: Mr. SHARAD PAREKH EXECUTIVE DIRECTOR: Mr. HITEN PAREKH DIRECTOR: Mr. MANISH PAREKH & Mr. NAYAN PAREKH The DEPUTY GENERAL MANAGER & also the PLANT INCHARGE: Mr. P.B.RAUT The HEAD OFFICE is at: ANDHERI (EAST), MUMBAI-400093 There are 5 plants of Nilkamal plastics:

1. 2. 3. 4. 5.

VASONA WORKS : Mr. P.B. RAUT GREATER NOIDA WORKS : Mr. PIPLANI PONDICHERRY WORKS : Mr. BHATT BARJORA WORKS : Mr. ANIL PATIL SINNAR WORKS : Mr. PANSE

The first plant of Nilkamal plastics is at Nashik i.e. VASONA WORKS & was established in 1985.It also has plants in SRI LANKA & BANGLADESH.

We visited the plant at VASONA. It is a huge plant very well organized & functions with the help of many skilled efficient workers. It is very important for huge organization like Nilkamal to have in efficient management system. Therefore they truly believe that they are committed to total customer satisfaction by establishing, implementing & maintaining quality systems confirming to international standards. They will strive for continuous improvement in their systems processes, products & services by training their people & fostering the climate for teamwork. Now regarding the working of the company Nilkamal plastics has divided the entire working of the organization into various departments.Each

departments has a person incharge & many skilled workers for each of the respective departments making the whole process a successful one. There are in all 150 efficient workers for the Vasona plant & they are divided into these departments. The various types of department in Nilkamal plastics are 1. ADMINISTRATIVE DEPARTMENT 2. ACCOUNTING DEPARTMENT 3. RAW MATERIAL DEPARTMENT 4. GRINDING & BLENDING DEPARTMENT 5. PRODUCTION & MAINTENANCE DEPARTMENT 6. QUALITY ASSURANCE DEPARTMENT 7. FABRICATION DEPARTMENT 8. DESIGN DEPARTMENT 9. ASSEMBLING & PACKING DEPARTMENT 10. DISPATCH DEPARTMENT

1.ADMINISTRATIVE DEPARTMENT:
Nilkamal plastics uses System Application Product (SAP) system for its administration & accounting purposes.

VASONA WORKS

GREATER NOIDA WORKS

PONDICHERRY WORKS

HEAD OFFICE: ANDHERI

BARJORA WORKS

SINNAR WORKS

SAP system is a system whereby records concerning finance, final products & all the various aspects regarding their business strategy are recorded. Every thing is computerized & systematically controlled. The SAP system proves to be an advantage as it is a transparent system where all the various records of all the plants in India can be viewed. Thus this system is very effective as one can see all the work progress & maintain discipline in the industry. Also there is minimum risk of theft.

2.ACCOUNTING DEPARTMENT:
All the accounting work is done through SAP system. The accounts are looked by the head office. This is one of the most efficient systems as all the accounting is taken care by the head office itself. All the accounting like the dispatch of goods, loading of goods, etc

3. RAW MATERIAL DEPARTMENT:

Nilkamal plastics mainly get its supply of raw materials from Reliance. Also, they get supply of raw material from IPCL, Maldia & Gail. The SAP system also has the record of all the quantity of raw materials that are present in the godown & plants. In the raw material department the raw material is sent upward from basement through conveyor. With the help of this raw material the masterbatch is prepared and raw material is prepared. Also in 100% of raw material 98% is of white colour while 2% is the masterbatch. Earlier they used to have powder form of pigment but now they prepare the masterbatch which is the concenterated colour. Also the raw material is dispatched in such a way that it is neither excess nor less it as per the requirements of the goods to be produced.

SENT

FINAL QUALITY TEST

ASSEMBLY & PACKING QUALITY ASSURANCE

LOADING OF PRODUCTION

OVERALL EQUIPMENT EFFICIENCY

PRODUCTION ORDER IS RECEIVED

PLANT ORDER IS RECEIVED

DESPATCH DEPARTMENT DESPATCHES RAW MATERIAL

4. GRINDING & BLENDING DEPARTMENT:

The masterbatch is grinded & the masterbatch is blended with chemicals like polyethelene & polyethylenes forming 30 tonnes per day are blended for 8-10 hours. Then the mixture is then put into the blender 250kg is put at a time & all the ingredients are equally distributed.

5. PRODUCTION & MAINTENANCE DEPARTMENT:

Nilkamal plastic basically deals in the manufacturing & production of tables, chairs & crates. For this purpose they have 9 different mould machines that provides shape to the goods produced. These machines operates for 24hrs & 365days unless ofcourse there is power shortage. This plant gets its supply of electricity from Gujarat Electric Board. The workers work in shifts. 1 shift = 8hrrs. Thus there are 3 shifts They have Overall Equipment Efficiency(OEE)which should be above 70%. Through this system the wear & tear of moulds is taken care of by the process of wielding by which the moulds are rectified. Thus in this manner the moulds are checked. First the purchase of raw material is done at the head office , thereby plant order is converted into production order & according to requirement of the customer, the production starts. They have automatic injection moulding machines which has capacity to hold 660 tonnes. These machines blend the material & the blended material is then put into these various moulds at a temperature of 250-300C & each single product is made in 46seconds (approx) & also the product is at around 70-80C when it comes out of the mould. Each machine is attached to the

cooler where it cools the mould at around 32C. They have around 400-500 crate moulds & 300-400 moulds for chairs. Thus the whole factor is very well managed & time factor is also taken into consideration as we all know that time management is extremely important. Every two hours there is an inspection round as to assure the perfect functioning of the machines & to check the production of the final product. They have set a moulding program which is followed & thus there is perfection in everything. Also, they produce 700 tonnes per month which accounts to 8400 tonnes a year.

6. QUALITY ASSURANCE DEPARTMENT:

After the product is manufactured the following are the methods to check the quality of the products produced: a. Drop tester: Drop tester is used for testing the strength, capability & durability of the finished products. The finished products are dropped from the height of 2.5mts for about 100 times. If the product gets damaged within 50 falls then it is rejected.

b. Cover Impact tester: Cover Impact tester is used for crates of pepsi & coke & all other cold drinks. They check for the

strength of crates. They would fill the bottles with mud while checking. They check the crate & see whether it is able to hold all the bottles. Thus they check whether the crate is able to hold the bottles under any condition. c. Slide Impact test: Slide Impact tester is used to check each & every corner of the crates. The plate is full of pepsi bottles are made to slide on a machine & banged against an iron plate to protect the bottles from any damages & that provides for a greater protection. d. Ball Drop tester: Ball Drop tester is used to check moulding points of the crates. This test is specially carried out for the crates carrying 125kgs. e. Durability test: Inorder to check the durability & capacity of the chairs they place 120kgs on the chair. Thus they are assured that the chair is strong. Also while performing this experiment the positions of the legs of the chairs are made & in this way they notice that if the chair moves from its mark then that chair is weak and the production is rejected. f. Environment Stress Check Resistance(ESCR): In this test the product are put inside a machine & heated upto 80C for 6hrs to test whether the plastic melts or no due to extreme heat in the environment.

7. FABRICATION DEPARTMENT:
Nilkamal plastics believe in maintain their name & thus they want to avoid the complaints of the customers by giving them with proper facility. In this department the size of the crates are altered according to the needs of the customers . For eg. different in size & shape. If longer crate is required then 3 crates are wielded together thus a larger crate is obtained. If smaller crate is required with less height then the upper portion of the crate is sliced off using the appropriate machines The crates needed for pepsi & coke are

8. DESIGN DEPARTMENT:
The entire outlook of the product depends on this interesting department that deals with giving attractive designs, logos & shapes. Also we have screening and printing department. This makes the product look more attractive & also creates an identity of its own. This is one of the most important departments as all the sales are depended on the looks of the product also incrementation in sales is important as it adds to the profit of the company.

9. ASSEMBLING & PACKING DEPARTMENT:

All the products have to finally be packed in a way that is most convenient for the customer as well as the retailer to transport. All the parts from various departments are assembled & then various types of packing techniques are used. One of them is shrink wrapping. This is mainly done for the foldable tables which have many parts. Thus is done to prevent the loss of any parts & also if the product collides with another product then there are very less chances that the product is affected.

10. DISPATCH DEPARTMENT:

Dispatch department looks after the dispatch of goods. The products are finally dispatched & transported to markets. One of the main features about this is that in this industry one can load & unload 17 trucks at a time & also the place where the trucks are loaded the goods just need to be dragged as the level of the truck & floor is constructed in such a way that they have same height. Thus this saves ample of time & it is very easy to load & unload. Every week they export goods with 2 filled trucks. They always have 15002000 tonnes of raw material in stock.

CRISIS FACED BY NILKAMAL PLASTICS

Nilkamal plastics have not yet faced any major loss due to any kind of crisis. But natural calamity as we all know is that kind of calamity about which one cannot do anything about. Last year 3rd August 2004 silvassa had experienced heavy rainfalldue to which floods were caused. This created failure of power supply as around 25 electricity poles were damaged & due to this the factory function for 48hrs & also managed to recover within a short span of 15 days. This is possible only if the management is very well organized or is so much dedicated towards work.

FUTURE TARGETS & COMPETITORS

Nilkamal plastics strongly believe in quality discipline system as they feel that quality is their biggest tool. Nilkamal plastics has won great confidence from their

customers & thus this has resulted in achieving them the export award for quality production With the trust & confidence of the consumers they are launching new products for luxury of the customers. The name of their latest product is NOVA. This chair has cushion & very beautiful looks. Also they are planning to launch revolving chair, desks for school & stool trolleys. This is world competition whereby everyone has only one goal i.e. to be at the pinnacle. Their competitors are: Supreme, Prince, Cello, Prima, etc They export their goods to: Germany, Dubai, Malaysia, Sri Lanka, Indonesia & USA. The exports have shown incrementation since last 2yrs. It was 332.78tonnes in 2004 & 363.44tonnes in2005.