Varroc Final Report
Varroc Final Report
A
PROJECT REPORT ON
Quality Control Study at
Varroc Polymer Pvt. Ltd
UNDER THE GUIDANCE OF
SUBMITTED BY
ANNAMALAI UNIVERSITY
YEAR 2010-11
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CERTIFICATE
This is to certify that
Mr. Mahesh Yashwantrao Ghodake
is bonafied student of THE NIS ACADEMY Aurangabad.
Studying in Master of Business Administration Course.
The candidate has satisfactorily prepared the project
report on
“QUALITY CONTROL AT VARROC POLYMER PVT.LTD
IN AURANGABAD”
DATE :-
PLACE :- AURANGABAD
3
DECLARATION
I also declare that this project report has not submitted by me to any other
University.
DATE :-
PLACE :- AURANGABAD
4
ACKNOWLEDGEMENT
INDEX
Sr. No CHAPTER Page No.
2006-2007
Foray in Europe in Forgings Space by Acquiring
IMES Spa – Italy and Poland.
SOP at Integrated Manufacturing Plant in
Pantnagar, Northern Region 2006-07 Industrial Hub
2005-2006
Enhanced Capacities
Started Exports to European OEMS
Added customers in Northen Region of India
2003-2004
Enhanced Capacities for all 3 manufacturing divisions
Enhanced product portfolio by adding Engine Valve Technology
8 New Plants & R&D Center Started
Focus – Passenger Car Industry & White Goods Indusry
1999-2002
SOPs at 3 additional plants
Metallic & Polymer divisions
Focus – Honda, LG , Yamaha
1995-1998
SOPs at 3 additional plants
Metallic & Electrical divisions
Focus – Bajaj Auto & Overseas Market
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1990-1991
Plastic Molded Components for Automotive and Consumer
Electronics Industry. Commercial Production Started (1990)
Electrical Division (Aurangabad)
About CEO
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Mission
Implementing these core values into employee and worker towards their job,
family, social responsibility and national responsibility for their bright future
this is the mission.
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Vision
We are committed to serve the society by adding value to the
Customers, Employees, Suppliers, Shareholders and the
Community at large in terms of :
SINCERITY:
To go the distance
In carrying out roles & responsibilities transparently
In expression of thoughts & feelings
In concern for the team & the company
· HUMILITY:
To walk with everyone
By showing respect for others
By sharing success & achievements
By being open & positive
·
INTEGRITY:
To do what is right
To inculcate a culture of healthy competition
To have no tolerance for unethical practices
To adhere to commitments
·
PASSION:
To achieve against all odds
To proactively participate in the organization
To bring about innovation in all work
To remain motivated against all odds
·
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SELF DISCIPLINE:
To make it happen
To take ownership for your actions
To be consistent & dependable at all times
To learn & improve everyday
Historical Background
“POLYMER DIVISION”
2002 – Varroc Polymer Pvt. Ltd., Greater Noida (VPPL-GN) was set up
with specialization in ‘Gas assisted Injection moulding process’
2003 – ‘Paint shop’ started its operation from plant I.
2003 – ‘Air cleaner assembly’ production for 2 wheeler of Bajaj Auto Ltd.
Board of Directors
Chairman : Mr.Naresh Chandra
Managing Director : Mr.Tarang Jain
Director : Mr.Naren Jain
Director : Mr.Rajiv Sahney
Executive Council Members :
Electrical Division
Associate Vice President : Mr. Prakash Khose
Metallic Division
Group Associate Vice President : Mr. Sanjay K. Sachdev
1. POLYMER DIVISION:
Interior Pillar Trims, Door Panels, Floor Console
Exterior Parts – Bumpers, Fenders, Claddings, Wheel Arches
Underbody/ HVAC parts
Injection and Compression Molded Rubber Parts
Mirror Assemblies and Mirror Rubber Parts
Air Cleaner Assembly
PU Foam Pad and Seating System Assembly
Multilayer co-extruded Thermoplastic Sheets
Molded parts for White Goods and Consumer Electronic Parts
Series Molds and Pre Production Molds
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2. METALLIC DIVISION:
Engine Valves
Crank pins for motorcycle
Hot, cold & warm forged machined components
Catalytic converters for 2, 3 and 4 wheelers
3. ELECTRICAL DIVISION:
A.C. generator & Magneto
Digital CDI, digital regulator rectifier units
Starter Motor, Wiper Motor
Switch Assembly and handle bar assembly for motorcycle, LED Lights
Electronic control units, Electronic Clusters
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AWARDS
In 2010 Varroc Polymer has won best supplier Award by TATA TOYO
RADIATOR LIMITED .
In 2009 Varroc Polymer Pvt Ltd has won the best kaizen Award in third kaizen
competition.
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Manufacturing Process
Varroc Polymer is manufacturer of PU Foam seat which is made by Mixture
of polyamines and isosynate. Manufacturing Process of PU Foam is as under
Manufacturing Process
1) Mould Cleaning.
2) Spray Application for release.
3) Pouring.
4) Demoulding.
5) Squeezing.
6) Deflashing.
7) Inspection in Process.
8) Final Inspection.
Quality Inspection
7) Repeated Permenant.
8) Density.
9) Specific Gravity of PU raw material.
10) Drop impact test.
11) For Rexine cdour breaking strength and Elon Adhesion to coating test
tear strength Gelling test.
12) for foam tersile tear strength break elongation.
13) for rexine flex test.
14) for rexine resist to cold.
15) for rexine colour fastness to dry of wet rubbing.
16) Surface resistance to chemicals.
17) Thickness and measurement.
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Production Process
Varroc has a state-of-the art, environment friendly Poly Urethane Foam
molding facility for the manufacture of foam pads and seat assembly for two,
three and four wheelers. Varroc has robot control line at our Aurangabad
Plant.
Installed Production Capacity is 5000 T. Per Annum.
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System
High Pressure Reaction Injection System.
H.D. is using for manufacturing the two wheeler’s seats and L.D. is using for
three wheeler’s seats.
Hennecke Machine
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This is Hennecke B machine uses for mix the Isocyanate and Polyol
chemicals together, and then pours it in the mould of the particular Seat that
we have to manufacture.
Production Flow:-
Mould closing
Mould opening
Foam deflashing
Foam dispatch by Q. A.
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Foam testing
Assembly of manufacturing
Quality Policy
The Varroc Group has been able to achieve steep growth in the last decade in
all its operations. This was achieved by means of a largely traditional business
model. In order to keep the Group abreast of constantly increasing customer
expectations the Management felt the need for a systemic approach to all
aspects of the Group's operations, so that the growth rate could continue to be
achieved on a sustainable basis. The approach was multifaceted, for
addressing multiple internal and external factors, such as employee skill level,
changing product profile, competition on price, stringent product
specification and customer expectation. A further strategic objective was the
need to build international brand equity. The Corporation therefore decided
to adopt a holistic approach to
manufacturing and operational excellence, and decided to adopt the TPM
way as the tool for implementing the change. A catchy slogan, 'Let us make it
happen', was adopted to drive the message down to the lowest levels of the
organization.
Varroc initially began the TPM activities as a supplier to Bajaj
Auto Ltd., who are Varroc's major customer, and who had adopted this
methodology. In November 2006,
Varroc decided to proceed along this road on its own, under the guidance and
auspices of TPM guru
Prof. Yamaguchi san. The initiative formally commenced with the conduct of
a TPM deployment seminar for the middle and senior management of the
Varroc group. The seminar was attended by about 135 delegates. A TPM
policy was developed, which was aligned with the Group's vision and mission
statements In parallel, 1S-2S activities were also initiated. This resulted in
immediate tangible results. Valuable floor space on the shop floors became
available, plants were looking better, and a database was developed for
unwanted materials and equipment, so that other plants could look at the list
for equipment they needed. This in turn led to capital savings. TPM Model
Machine/Cell activities were also initiated by managers to demonstrate the
various activities in the TPM way on the critical machine cell. Typically, a
machine in the poorest condition within a cell was picked-up as the Model
Machine. The Model machine program was aimed at providing managers
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year 06~07. The Corporation has set itself an ambitious target of 12 BAL Q
awards for the current financial year. Many other Quality awards from
customers like Tata Johnson were also won by Group companies last year.
Many of our Group companies have been operating with Zero PPM
Customer Rejection for the last 6 months or more. All group companies are
now TS 16949 certified. In continuation with these initiatives, and in
alignment with the social objectives, Varroc is committed to obtain ISO
14001/OSHAS 18001 certification for all its plants. This only reinforces the
Corporate commitment towards environment, health and society which is
part of our Mission Statement and Quality Policy.
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Quality Control
Quality Assurance department actually deals with the final
product that is assuring its quality or rather maintaining its quality to the
best. This assurance of quality or rather maintaining its quality best. The
assuring of quality is given either in process of manufacturing it self or after
the completion of the product. Thus, there are three main types of quality
assurance namely.
1. Inward inspection
3. Audit inspection.
► Hardness checking
► Bursting stand
► Moisture testing
► Viscosity testing
Entrance
Hardness
test m/c
Kaizan
display
Load
identification m/c
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4.HARDNESS TEST
Purpose: These tests shall be performed for the measurement of hardness of
the foam. That means according to the customer requirement hardness is
checked.
Scope: this is applicable for PU foam
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SWOT ANALYSIS
STRENGHTS:
The following are some of the key elements, which will enable the Company to
achieve greater progress & market share:
1. The Company manufactures markets or distributes a very wide range
of models creating the needs of all sectors. Each & every product has
covers the spectrum form the list to most expensive from the latest to
most expensive in there respective categories, thus meeting
requirement of all class of customers.
WEAKNESS :-
OPPORTINUTY
► Fine - tune & executive religiously the performance management
system.
► Redesign, induction & orientation are important communication system
► Define and display performance indicators for grater clarity at the shop
floor.
► Performance link reward system
THREATS:-
► Contract labors and trainees effectiveness in manufacturing process
► Retention of key people
► Inability to bench mark
► System obsolesce
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CONCLUSION
It was nice experience to work with in Varroc Polymer Pvt .Ltd. as they
have experience and learned staff in their respective field.
WEBLIOGRAPHY
www.varrocengg.com
www.wikipedia.com
www.google.com
BIBLIOGRAPHY
VARROC PULSE MAGSINE.
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