3. INTRODUCTION
• Marvi plastic factory is manufacturing
company which is located at “Sher Shah area
Lyari” in karachi.
• It was establised in 1982 by two partners.
• The aim was to provide low and high qulaity
shoppers (plastic bags).
• They started with only six workers.
• Now they have around 20-25 workers.
4. Manufacturing Process
The machine operator pours the polyethylene
resin(ingots) into the hopper.
The hopper feeds the resin into the extruder.
Heating elements and the turning of the
extruder screw melts the resin into molten form
and forces it through the extruder.
The molten poly flows evenly up and over the
circular die.
6. As the molten poly emerges from the die, the
machine operator:
a. Grabs it wearing protective gloves.
b. Pinches the molten poly together.
c. Ties a rope to the top of the molten poly. The rope
leads upward to a pulley system.
d. Pulls the other end of the rope to move the molten
poly upwards. At the same time, the air ring blows
cool air upwards, which solidifies the molten poly.
7. • As the tubular shape moves up, the machine
operator inserts an air gun through the poly film to
blow in additional air. This step is repeated until
the diameter of the tubular poly film reaches the
required bag size.
• Along the length of the tower are guides to keep
the tubular poly film from shifting. As the film
reaches the top of the cooling tower, the guides
gradually flatten it into a lay flat(binding) form.
9. At the top of the cooling tower, motorized nip rollers grab
the solidified poly film. The nip rollers now take over the
job of moving the poly film up the cooling tower.
The lay flat film travels over a series of rollers. For simple
bags, such as trash bags or industrial bags, the film is
contained to a single, in-line process.
For poly bags with complex features (for example, multi-
colored printing, )the film is wound on a roll and then
taken out of line for further processing at a converting
facility.
11. Supply Chain Management
• The material is imported from foreign (Iran, China,
etc.) and as well as from Pakistan.
• The material is of high quality and as well as low
quality.
• They use ingots of different colors: Like Blue,
Green, Yellow and Orange.
• The transportation cost is beard by the owner.
• There is always stock in hand around 10M.
• There is unmeet demand, so even demand of Sindh
is not meet.
12. Product
• Plastic bags, also called “poly bags,” are one of
those modern conveniences we take for
granted.
• Their products are usually available at retail
stores.
•
They also provide transport but they charge
on this service.
13. Variety of Product
Low Quality Shopper Rs.160/Kg
Semi Quality Shopper Rs.210/kg
Special Quality Shopper Rs.240/kg
• There is one product whose demand is very high
(MARVI TOMATO SHOPPER).
• This shopper is used for all Vegetable items.
15. Key performance Indicators
• Financial
– Tax Saving, therefore more profit. (5%-8% profit)
– Low Cost due to no wastage.
• Customer
– Lifetime Value
– Satisfaction and retention
• Process
– Percentages of Product defects.
• People
– Employee Turnover
– Employee Satisfaction.
16. Cost Analysis
• The workers are paid monthly on the bases of
hours.
• The normal target is to achieve 800-1200 kg
plastic bags in a 8 hours.
• If the target is achieved before the time than
no bonus is paid for time saved.
• They work continuously.
• The workers are given bonus on the occasions
of Eid and Diwali etc.
17. • The costing of special orders are charged
separately on the bases of material used.
• There is no wastage, because the material
which is wasted is recycled.
• The price charged varies when there is a
change in the price of material.
18. Conclusion
• Very less wastage of resources.
• There is no complaints from customers.
• Customers get what they want.
• The factory is also contributing in the economy.
• The workers are always motivated to complete
their task.
19. Conclusion cont.…
• The workers are provided good working
condition.
• They also use safety tolls, gloves, mask,
separate uniform for working, and fire
extinguisher.
• Emergency exists
20. Recommendations
• They should use forecasting methods
• As there is excess demand, therefore they
should go for expansion
• They should replace the manual record
keeping system into database system
