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Ronch Polymers Pvt. Ltd <ul><li>Ronch Polymers Pvt. Ltd. (RPPL) is one of the leading OEM in thermoplastic moulded compone...
Corporate commitment  <ul><li>Safety and environment  </li></ul><ul><li>Compliance of HUL – 3P Standard </li></ul><ul><li>...
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  ...
<ul><li>Overview :   </li></ul><ul><li>Total area 100, 000 sq ft </li></ul><ul><li>Moulding 40, 000 sq ft </li></ul><ul><l...
Safety <ul><li>Safety committee formed and review on safety points - once in a month. </li></ul><ul><li>Compliance to 3P M...
Training <ul><li>Operator refresher course on Product quality  </li></ul><ul><li>Training on Hygiene and how to maintain t...
Moulding  <ul><li>Commissioned on 19th April 2007 </li></ul><ul><li>Moulding Capacity : 3300 Devices per day and 5500 batt...
Sub Assembly Area  <ul><li>Area : 5000 sft </li></ul><ul><li>Welding : </li></ul><ul><ul><li>No of Ultrasonic welding Mach...
Pureit Assembly . Plastic injection molding Ultrasonic Welding and Sub assy Device assembly PM & Silicon parts Consumables...
Pureit Assembly <ul><li>Assembly Capacity : 3300 Devices per day  </li></ul><ul><li>Managers and Staff : 5 </li></ul><ul><...
 
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 <ul><li>Reduced by Rs 37 ( eqvt~ 3% NPS) through design change, cycle time optimisation and buyin...
Man Hours per Device <ul><li>Man hours per device reduced from 1.57 to 0.5 i.e., by  67% in the last 20 months. </li></ul>
Rejection Cost per Device <ul><li>Rejection cost/device reduced from 7.2 to 1.44 i.e., by  80% in the last 35 months. </li...
Environment <ul><li>Solid waste-  </li></ul><ul><ul><li>Rejected plastic- Recycling  </li></ul></ul><ul><li>Liquid waste –...
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R4 D Bvisit

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R4 D Bvisit

  1. 1. Ronch Polymers Pvt. Ltd <ul><li>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 . </li></ul><ul><li>It is also one of the leading players in Designing of tooling , development and manufacture of high quality moulds for discerning customers . </li></ul><ul><li>It has multilocational state of the art manufacturing facilities at </li></ul><ul><li>at Taloja ( Navi Mumbai ) , Pune , Daman and Nagpur . </li></ul><ul><li>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 . </li></ul>
  2. 2. Corporate commitment <ul><li>Safety and environment </li></ul><ul><li>Compliance of HUL – 3P Standard </li></ul><ul><li>Environmental pollution </li></ul><ul><ul><li>Liquid : None </li></ul></ul><ul><ul><li>Solid : Waste of plastics reground and reused in other locations. </li></ul></ul><ul><li>Quality </li></ul><ul><li>Continuous improvement </li></ul><ul><li>On the job training </li></ul><ul><li>Cost </li></ul><ul><li>Remain always competitive </li></ul><ul><li>Continuous improvement process / productivity </li></ul><ul><li>Flexible /Training </li></ul>
  3. 3. 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
  4. 4. <ul><li>Overview : </li></ul><ul><li>Total area 100, 000 sq ft </li></ul><ul><li>Moulding 40, 000 sq ft </li></ul><ul><li>Pureit manufacturing 15,000 sq ft </li></ul><ul><li>FG and other storage area : 14,000 sq ft </li></ul><ul><li>Connected load –2200 kW </li></ul><ul><li>Manpower – 288 ( Assembly -138, Moulding – 150) </li></ul><ul><li>Capacity : - 3300 devices/day </li></ul>
  5. 5. Safety <ul><li>Safety committee formed and review on safety points - once in a month. </li></ul><ul><li>Compliance to 3P Minimum mandatory standards (MMS) </li></ul><ul><li>Quarterly Safety training from external agency </li></ul><ul><li>First Aid training to key personnel </li></ul><ul><li>Fire fighting training to key personnel </li></ul><ul><li>Audits by Bhimpore factory safety officers and their recommendations implemented </li></ul>
  6. 6. Training <ul><li>Operator refresher course on Product quality </li></ul><ul><li>Training on Hygiene and how to maintain that </li></ul><ul><li>OJT on process parameters in the assembly line </li></ul>
  7. 7. Moulding <ul><li>Commissioned on 19th April 2007 </li></ul><ul><li>Moulding Capacity : 3300 Devices per day and 5500 battery parts per day. </li></ul><ul><li>Area : 40,000 sft </li></ul><ul><li>No of Machines : 32 Injection molding varying from 100 Tons to 650 Tons </li></ul><ul><li>No. of plastic parts : 35 Nos ; weighing from 1.4 gm to 930 gm </li></ul><ul><li>Centralized material feeding </li></ul><ul><li>Pick and place system </li></ul><ul><li>Managers and Staff : 14 </li></ul><ul><li>Operators : 144 </li></ul><ul><li>Total Capital employed : Rs. 27 Cr </li></ul>
  8. 8. Sub Assembly Area <ul><li>Area : 5000 sft </li></ul><ul><li>Welding : </li></ul><ul><ul><li>No of Ultrasonic welding Machines : 6 (2 KW to 3.5 KW) </li></ul></ul><ul><ul><li>No. of Sub Assemblies : 4 </li></ul></ul><ul><ul><li>Manpower : 19 </li></ul></ul><ul><ul><li>All Welded parts are 100% tested for leak </li></ul></ul><ul><li>Tap Assembly : </li></ul><ul><ul><li>Capacity : 4,000 /day </li></ul></ul><ul><ul><li>Manpower : 13 </li></ul></ul><ul><ul><li>Assembly under Hygiene Conditions </li></ul></ul><ul><li>Top Cover and Cartridge Cover Assembly : </li></ul><ul><ul><li>Manpower : 8 </li></ul></ul>
  9. 9. 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
  10. 10. Pureit Assembly <ul><li>Assembly Capacity : 3300 Devices per day </li></ul><ul><li>Managers and Staff : 5 </li></ul><ul><li>Operators : 96 </li></ul><ul><li>Capital employed : 2 cr </li></ul><ul><li>Highlights : </li></ul><ul><ul><li>Continous conveyorised assembly line with a capacity of 150 per hr. </li></ul></ul><ul><ul><li>50 parts , subassemblies being assembled. </li></ul></ul><ul><ul><li>Strict Hygiene Control </li></ul></ul><ul><li>Quality Assurance : </li></ul><ul><ul><li>Compliance of UNILEVER HPC Hygiene Standard. </li></ul></ul><ul><ul><li>Regular Audit by GTC microbiology team. </li></ul></ul><ul><ul><li>Traceability of Devices ( Device Sr. No connects to RM batches and all production details ) </li></ul></ul>
  11. 12. Cost Break Up- Purifier For 3300 Devices
  12. 13. Factory conversion cost- Purifier (stand alone) For 3300 Devices
  13. 14. Factory conversion cost-Device for 3300 Devices Tableting Investment Added
  14. 15. Moulding Cost - purifier <ul><li>Reduced by Rs 37 ( eqvt~ 3% NPS) through design change, cycle time optimisation and buying scale benefits. </li></ul>
  15. 16. Man Hours per Device <ul><li>Man hours per device reduced from 1.57 to 0.5 i.e., by 67% in the last 20 months. </li></ul>
  16. 17. Rejection Cost per Device <ul><li>Rejection cost/device reduced from 7.2 to 1.44 i.e., by 80% in the last 35 months. </li></ul>
  17. 18. Environment <ul><li>Solid waste- </li></ul><ul><ul><li>Rejected plastic- Recycling </li></ul></ul><ul><li>Liquid waste – NA. </li></ul>

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