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R4 D Bvisit
 

R4 D Bvisit

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    R4 D Bvisit R4 D Bvisit Presentation Transcript

    • Ronch Polymers Pvt. Ltd
      • Ronch Polymers Pvt. Ltd. (RPPL) is one of the leading OEM in thermoplastic moulded components for Automobile , White goods Appliances , Furniture and Consumer Durable Industries .
      • It is also one of the leading players in Designing of tooling , development and manufacture of high quality moulds for discerning customers .
      • It has multilocational state of the art manufacturing facilities at
      • at Taloja ( Navi Mumbai ) , Pune , Daman and Nagpur .
      • Ronch is promoted by a team of Technocrats and industrialist with vision to become one of the top three Custom moulders in India with a strong customer base .
    • Corporate commitment
      • Safety and environment
      • Compliance of HUL – 3P Standard
      • Environmental pollution
        • Liquid : None
        • Solid : Waste of plastics reground and reused in other locations.
      • Quality
      • Continuous improvement
      • On the job training
      • Cost
      • Remain always competitive
      • Continuous improvement process / productivity
      • Flexible /Training
    • Major Customers : Group Financials and Clientele 2006-2007 2007-2008 311 140 80 55 36 07-08 161 60 32 45 24 06-07 Total ( in Cr.) Distribution Water ( HUL ) White Goods Auto Fin years
      • Overview :
      • Total area 100, 000 sq ft
      • Moulding 40, 000 sq ft
      • Pureit manufacturing 15,000 sq ft
      • FG and other storage area : 14,000 sq ft
      • Connected load –2200 kW
      • Manpower – 288 ( Assembly -138, Moulding – 150)
      • Capacity : - 3300 devices/day
    • Safety
      • Safety committee formed and review on safety points - once in a month.
      • Compliance to 3P Minimum mandatory standards (MMS)
      • Quarterly Safety training from external agency
      • First Aid training to key personnel
      • Fire fighting training to key personnel
      • Audits by Bhimpore factory safety officers and their recommendations implemented
    • Training
      • Operator refresher course on Product quality
      • Training on Hygiene and how to maintain that
      • OJT on process parameters in the assembly line
    • Moulding
      • Commissioned on 19th April 2007
      • Moulding Capacity : 3300 Devices per day and 5500 battery parts per day.
      • Area : 40,000 sft
      • No of Machines : 32 Injection molding varying from 100 Tons to 650 Tons
      • No. of plastic parts : 35 Nos ; weighing from 1.4 gm to 930 gm
      • Centralized material feeding
      • Pick and place system
      • Managers and Staff : 14
      • Operators : 144
      • Total Capital employed : Rs. 27 Cr
    • Sub Assembly Area
      • Area : 5000 sft
      • Welding :
        • No of Ultrasonic welding Machines : 6 (2 KW to 3.5 KW)
        • No. of Sub Assemblies : 4
        • Manpower : 19
        • All Welded parts are 100% tested for leak
      • Tap Assembly :
        • Capacity : 4,000 /day
        • Manpower : 13
        • Assembly under Hygiene Conditions
      • Top Cover and Cartridge Cover Assembly :
        • Manpower : 8
    • Pureit Assembly . Plastic injection molding Ultrasonic Welding and Sub assy Device assembly PM & Silicon parts Consumables (Cartridge,CCT,BSCV) Plastic RM PPCP, SAN, ABS 4 subassy, 5 Strokes 35 parts in Device lid top chamber pre-filter dwell chamber sediment cloth bottom chamber down comer Bonded scavenger siphon chamber cartridge Tap Assly
    • Pureit Assembly
      • Assembly Capacity : 3300 Devices per day
      • Managers and Staff : 5
      • Operators : 96
      • Capital employed : 2 cr
      • Highlights :
        • Continous conveyorised assembly line with a capacity of 150 per hr.
        • 50 parts , subassemblies being assembled.
        • Strict Hygiene Control
      • Quality Assurance :
        • Compliance of UNILEVER HPC Hygiene Standard.
        • Regular Audit by GTC microbiology team.
        • Traceability of Devices ( Device Sr. No connects to RM batches and all production details )
    •  
    • Cost Break Up- Purifier For 3300 Devices
    • Factory conversion cost- Purifier (stand alone) For 3300 Devices
    • Factory conversion cost-Device for 3300 Devices Tableting Investment Added
    • Moulding Cost - purifier
      • Reduced by Rs 37 ( eqvt~ 3% NPS) through design change, cycle time optimisation and buying scale benefits.
    • Man Hours per Device
      • Man hours per device reduced from 1.57 to 0.5 i.e., by 67% in the last 20 months.
    • Rejection Cost per Device
      • Rejection cost/device reduced from 7.2 to 1.44 i.e., by 80% in the last 35 months.
    • Environment
      • Solid waste-
        • Rejected plastic- Recycling
      • Liquid waste – NA.