1

PROJECT REPORT ON Quality Control Study at Varroc Polymer Pvt. Ltd

UNDER THE GUIDANCE OF PROFESSOR MRS. RAJLAXMI BHOSLE SUBMITTED BY MAHESH YASHVANTRAO GHODAKE Enrollment No -: 4740900388 SUBMITTED TO ANNAMALAI UNIVERSITY IN THE PARTIAL FULFILLMENT OF MASTER OF BUSINESS ADMINISTRATION NIS ACADEMY AURANGABAD

YEAR 2010-11

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 ARROC !OLYMER ! T.LTD IN AURANGA"AD# This project is the result of candidates own work and satisfactory enough to warrant his Presentation for Master of Business Administration first year! "#amination. This project report has not been pre$iously submitted by candidate for the degree of other %ni$ersity. &ead of 'epartment Prof. (anesh Salunke 'AT" *+ P,AC" *+ A%)A-(ABA' Project (uide Prof. )ajla#mi Bhosle

DECLARATION
I hereby Declare that the project report entitled of my own outcome of my own efforts under the guidance of Prof. Rajlaxmi hosle and it is submitted to the THE NIS ACADEMY in the Partial fulfillment of master of business !dministration "#irst year$ %xamination 2&1&'11 I also declare that this project report has not submitted by me to any other (ni)ersity.

*r. *ahesh +ashwantrao ,hoda-e

'AT" *+ P,AC" *+ A%)A-(ABA'

ACKNOWLEDGEMENT
/he completion of any project of always due to efforts from numerous people. I ta-e this opportunity to express my gratitude to all those who ha)e helped me to understanding and completing this project successfully. *y word of than-s should begin by than-ing ,od for being with me at all instances of my life with hea)enly help. 0incere than-s to *anaging Director ,anesh 0alun-e. I express my deep ,ratitude to *r.*ahendra Pujari 1R Person of 2arroc ,roup who ga)e me all information and timely helped me out in Project. #urthermore I owe *y Profound than-fulness to Prof. Rajlaxmi hosle who guided me to furnish my wor- and showed me the direction towards success of this Project #inally my bound ness gratitude lies to my dear Parents without whom could hardly do anything3to my dear friend4 to the staff at /1% 5I0 !6!D%*+ at !urangabad. *!1%01 +!017!5/R!8 ,18D!9%.

INDEX
0r. 5o 1 2 3 . : < > A ? 1& 11 12 13 1. 1: 1< 1> 1A 1? 61!P/%R 2!RR86 ,R8(P *I;%0/85% ! 8(/ 6%8 *R. /!R!5, =!I5 *I00I85 2I0I85 68R% 2!;(0 8# 8R,!5I@!/I85 8RD 8# DIR%6/8R0 2!RR86 PRI8RI/I%0 PR8D(6/ PR8#I;% !7!RD0 *!5(#!6/(RI5, PR86%00 PR8D(6/I85 PR86%00 B(!;I/+ P8;I6+ B(!;I/+ 685/R8; 2!RI8(0 /%6/ 685D(6/%D D%P!R/*%5/ ;!+8(/ 078/ !5!;+0I0 6856;(0I85 I ;I8,R!P1+ 7% ;I8,R!P1+ Page 5o. < > ? 1& 12 1. 1< 1> 21 23 2: 31 3. 3: 3< 3? .1 .2 .2

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Varroc Group Mile !o"e

#$$%&#$$' S!ra!e(ic re !ruc!uri"( o) Varroc (roup
*+ Varroc #+ Varroc

,ol-.er / ,0!+ L!1+ E"(i"eeri"( ,0!+ L!1+ E"2a"ce Capaci!ie 3 A11e1 !ec2"olo(ie !o ca!er !o OEM +

#$$4&#$$%
5ora- i" Europe i" 5or(i"( Space 6- Ac7uiri"( IMES Spa 8 I!al- a"1 ,ola"1+ SO, a! I"!e(ra!e1 Ma"u)ac!uri"( ,la"! i" ,a"!"a(ar9 Nor!2er" Re(io" #$$4&$% I"1u !rial Hu6

#$$:&#$$4
Enhanced Capacities Started Exports to European OEMS Added customers in Northen Region of India

#$$;&#$$<
E"2a"ce1 Capaci!ie )or all ; .a"u)ac!uri"( 1i0i io" E"2a"ce1 pro1uc! por!)olio 6- a11i"( E"(i"e Val0e Tec2"olo(' Ne= ,la"! 3 R3D Ce"!er S!ar!e1 5ocu 8 ,a e"(er Car I"1u !r- 3 W2i!e Goo1 I"1u r-

*>>>&#$$#
SO, a! ; a11i!io"al pla"! Me!allic 3 ,ol-.er 1i0i io" 5ocu 8 Ho"1a9 LG 9 Ya.a2a

*>>:&*>>'
SO, a! ; a11i!io"al pla"! Me!allic 3 Elec!rical 1i0i io" 5ocu 8 Ba?a? Au!o 3 O0er ea Mar@e!

>

*>>$&*>>*
,la !ic Mol1e1 Co.po"e"! )or Au!o.o!i0e a"1 Co" u.er Elec!ro"ic I"1u !r-+ Co..ercial ,ro1uc!io" S!ar!e1 A*>>$B Elec!rical Di0i io" AAura"(a6a1B

A6ou! CEO

Mr+ Tara"( Cai"9 .a"a(i"( 1irec!or+ Varroc Group9 2a1 a" i"!erac!i0e e io" =i!2 MBA !u1e"! )ro. ,IRENS i" !i!u!e o" Tue 1a- !2e >!2 Marc2/*$+ T2e !opic =a C,lobaliDation E its Impact on 0*% 0ectorF. He .e"!io"e1 i" 2i a11re 9 !2e e.er(i"( eco"o.- li@e I"1ia ca" (ro= e7uall- !o o!2er 1e0elope1 cou"!rie pro0i1e1 =e ca" crea!e !2e i.ilar @i"1 o) 6rai"po=er+ T2e I"1ia" co.pa"ie are (ro=i"( !2e ri(2! =a-9 2a0i"( !ro"( )u"1a.e"!al 3 0alue a"1 e0e"!uall- =ill e.er(e =i""er =i!2 a li!!le .ore uppor! )ro. !2e (o0er".e"!+ He po@e a6ou! !2e I"1ia" SME (ro=!2 oppor!u"i!ie 3 al o a6ou! !2e !2rea! )ro. C2i"a+ T2e C2i"e e co.po"e"! upplier 2a0e (o! (oo1 uppor! )ro. !2e C2i"e e Go0!+D =2ere i" a per lai1 1o=" policie !2e Glo6al OEM pu! up .a"u)ac!uri"( )oo! pri"! i" C2i"a 2a !o i"1i(e"ou co.po"e"! =i!2i" !2e !ipula!e1 !i.e perio1+ I" I"1ia" per pec!i0e !2e SME 1o"/! 2a0e !2e i.ilar le0era(e9 "o .a?or uppor! )ro. I"1ia" Go0!+ A uc2 !2e SME are )aci"( !ou(2 !ar! co.pe!i!io" )ro. C2i"e e upplier + Ho=e0er 2e 2are1 !2e a ura"ce o) c2a"(e i" ourci"( ce"ario i" "ear )u!ure i" I"1ia a =ell+ T2e (lo6al OEM .ore o" i"1i(e"ou reco("iEi"( !2e 6rai" po=er a"1 R3D !re"(!2 o) I"1ia" upplier 3 )ocu i"( ouri"( e))or! + T2e SME i" I"1ia are (ra1uall- 1e0elopi"( !2e. el0e .ore o" !ec2"ical )ro"! !o i.pro0e !2eir 0alue c2ai"+ He .e"!io"e19 I"1ia i li@e a" elep2a"! 8 !ro"(9 lo= 3 !ea1- up !o "o= 6u! I !2i"@ i! =ill ru" "o= =i!2 2elp )ro. !2e (o0er".e"!+ A" elep2a"! =i!2 all i!/

Mi io"

I.ple.e"!i"( !2e e core 0alue i"!o e.plo-ee a"1 =or@er !o=ar1 !2eir ?o69 )a.il-9 ocial re po" i6ili!- a"1 "a!io"al re po" i6ili!- )or !2eir 6ri(2! )u!ure !2i i !2e .i io"+

1&

Vi io"
We are co..i!!e1 !o er0e !2e ocie!- 6- a11i"( 0alue !o !2e Cu !o.er 9 E.plo-ee 9 Supplier 9 S2are2ol1er a"1 !2e Co..u"i!- a! lar(e i" !er. o) F G ,ro0i1i"( Cu !o.er Sa!i )ac!io" 6- o))eri"( Relia6le ,ro1uc! a"1 Ser0ice a! Co.pe!i!i0e ,rice G ,ro0i1i"( a" e"0iro".e"! co"1uci0e !o !2e 1e0elop.e"!9 (ro=!2 a"1 a!i )ac!io" o) e.plo-ee =2ile )ul)illi"( !2eir rea o"a6le a pira!io" G ,ro0i1i"( a1e7ua!e re!ur" !o !2e 2are2ol1er =2ile "ur!uri"( 6u i"e (ro=!2 G Co"!ri6u!i"( !o !2e =ell 6ei"( o) !2e ocie!- a"1 co"1uc!i"( our el0e a a re po" i6le corpora!e ci!iEe" @"o=" )or i"!e(ri!a"1 e!2ic +

11

Core Value O) Or(a"iEa!io"

We are co..i!!e1 !o .a@i"( Varroc a lea1er i" !2e i"1u !r- 3 e" uri"( !2a! 0arroc i al=a- !2e )ir ! 3 .o !!ru !e1 c2oice )or i! cu !o.er +We pla" !o ac2ie0e !2i 6- prac!ici"(9 SINCERITYF To (o !2e 1i !a"ce I" carr-i"( ou! role 3 re po" i6ili!ie !ra" pare"!lI" eHpre io" o) !2ou(2! 3 )eeli"( I" co"cer" )or !2e !ea. 3 !2e co.pa"I HUMILITYF To =al@ =i!2 e0er-o"e B- 2o=i"( re pec! )or o!2er B- 2ari"( ucce 3 ac2ie0e.e"! B- 6ei"( ope" 3 po i!i0e I INTEGRITYF To 1o =2a! i ri(2! To i"culca!e a cul!ure o) 2eal!2- co.pe!i!io" To 2a0e "o !olera"ce )or u"e!2ical prac!ice To a12ere !o co..i!.e"! I ,ASSIONF To ac2ie0e a(ai" ! all o11 To proac!i0el- par!icipa!e i" !2e or(a"iEa!io" To 6ri"( a6ou! i""o0a!io" i" all =or@ To re.ai" .o!i0a!e1 a(ai" ! all o11 I

12

SEL5 DISCI,LINEF To .a@e i! 2appe" To !a@e o="er 2ip )or -our ac!io" To 6e co" i !e"! 3 1epe"1a6le a! all !i.e To lear" 3 i.pro0e e0er-1a-

Hi !orical Bac@(rou"1
POLYMER DI I!ION"

*>>$ & E !a6li 2.e"! o) Jpol-.er 1i0i io"/ )ro. Walu?9 Aura"(a6a1+ *>>: & Varroc ucce )ull- i"!ro1uce1 Jru66er .oul1i"( proce +/ *>>: 8 JMoul1cra)! Hi"1u !a" ,0!+ L!1+9/ AMH,LB e! up a ?oi"! 0e"!ure =i!2 Vi1eoco"+ *>>4 8 J5oa. .oul1i"( proce / i"!ro1uce1 6- 0arroc (roup+ *>>' 8 JMoul1cra)! Hi"1u !a" ,0!+ L!1+9/ AMH,LB i"!ro1uce1 J 2ee! eH!ru io" proce +/ *>>> 8 Ne= pla"! e! up a! Ta@0e i" ,u"e pecialiEi"( i" Jpla !ic .oul1i"( proce /+ #$$* 8 JMirror pla"!/ opera!io" !ar!e1 a! Ta@0e i" ,u"e+ #$$# 8 Varroc ,ol-.er ,0!+ L!1+9 Grea!er Noi1a AV,,L&GNB =a e! up =i!2 pecialiEa!io" i" JGa a i !e1 I"?ec!io" .oul1i"( proce / #$$; 8 J,ai"! 2op/ !ar!e1 i! opera!io" )ro. pla"! I+ #$$; 8 JAir clea"er a e.6l-/ pro1uc!io" )or # =2eeler o) Ba?a? Au!o L!1+ #$$< 8 E !a6li 2.e"! o) JTec2"olo(- De0elop.e"! Ce"!er/ ATDCB )or Ba?a? # =2eeler 6u i"e + #$$< 8 V,,L&GN recei0e1 JBe ! ,ar!"er EHcelle"ce A=ar1 A#$$<B/ )ro. LG Elec!ro"ic + #$$< 8 V,,L&GN =o" pre !i(iou JEHcelle"! Ve"1or A=ar1 A#$$<B/ )ro. LG Elec!ro"ic #$$: & Varroc ,ol-.er ,0!+ L!1+9 Bi"ola AV,,L&BNB =a co..i io"e1

13

=i!2 pecialiEa!io" i" KMoul1i"( proce / a! Bi"ola i" Har-a"a+ #$$4 8 S2i)!i"( o) JMirror pla"!/ a! Ra"?a"(ao" i" ,u"e i+e+ ,la"! II+ #$$4 8 I"crea e i" !2e 1o.ai" o) eHper!i e o) JTec2"olo(De0elop.e"! Ce"!er/ ATDCB 6- i"corpora!i"( ac!i0i!ie i"!e(ral !o < =2eeler 6u i"e + #$$% 8 JEHpa" io" o) Varroc ,ol-.er ,0!+ L!1+9 ,la"! II/ AV,,L & IIB a! Ra"?a"(ao" i" ,u"e !o ca!er !2e J)our =2eeler 6u i"e +/ #$$' 8 JHo! a"1 col1 I"?ec!io" proce / i"!ro1uce1 a! V,,L ,la"! II a! Ra"?a"(ao" i" ,u"e+ #$$' & Varroc ,ol-.er ,0!+ L!1+9 Bi"ola AV,,L&BNB =o" Ac2ie0e.e"! A=ar1 A#$$'B )or .ee!i"( 7uali!- a"1 1eli0er- !ar(e! 6- Ho"1a Mo!orc-cle a"1 Scoo!er I"1ia A,B L!1+ #$$' & Varroc ,ol-.er ,0!+ L!1+9 Grea!er Noi1a AV,,L&GNB a11e1 a"o!2er )ea!2er i" i! cap 6- =i""i"( EHcelle"ce A=ar1 A#$$'B i" L9 C9 a"1 D i" Mol1 Ca!e(or- )ro. LG Elec!ro"ic +

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Boar1 o) Direc!or
Chairman Managing Dir !"#r Dir !"#r Dir !"#r : : : : Mr.Naresh Chandra Mr.Tarang Jain Mr.Naren Jain Mr.Rajiv Sahney

E$ !%"i& C#%n!i' M m( r) :

S a"ing *r#m ' *" "# righ": Mr.Ashok Chandak, Prof. Anjani Koomar, Mr. Tarang Jain, Mr. S.N. Patil, Mr. B. Padmanabhan S"an+ing *r#m ' *" "# righ": Mr. Arvind hanna, Mr. M.P.Sharma, Mr.!arsh ohli, Mr. "ineet Tyagi, Mr.Prakash hose, Mr. Naveen Singh

1:

Managing Dir !"#r -r#%. S ni#r /i! Pr )i+ n" B%)in )) D & '#.m n" Chi * Finan!ia' O**i! r -r#%. S ni#r /i! Pr )i+ n" P#'1m r Di&i)i#n -r#%. S ni#r /i! Pr )i+ n" H%man R )#%r! -r#%. A))#!ia" /i! r )i+ n" C#r.#ra" Ma" ria') A))#!ia" /i! .r )i+ n" Pan"nagar O. ra"i#n -r#%. A))#!ia" /i! Pr )i+ n"

: Mr. ,arang Jain : Mr. A)h#0 Chan+a0 : Mr. B. Pa+mana(han : Mr. S.2. Pa"i' : Mr. An3ani 4##mar : Mr. M. P. Sharma : Mr. Har)h 4#h'i : Mr. 2a& n Singh

E' !"ri!a' Di&i)i#n A))#!ia" /i! Pr )i+ n" : Mr. Pra0a)h 4h#) M "a''i! Di&i)i#n -r#%. A))#!ia" /i! Pr )i+ n" : Mr. San3a1 4. Sa!h+ & C#r.. L ga' A**air) 5 -r#%. S !r "ar1 A))#!ia" /i! Pr )i+ n" O. ra"i#n) Chi * S1)" m) A%+i"#r

: Mr. /in

" ,1agi

: Mr. Ar&in+ 4hanna

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Varroc Group ,riori!ie

G Luali!G Cu !o.er 3 I"!er"al ,,M G T,M9 KaiEe" Cul!ure9 G TS *4><> accre1i!e1 G Co ! G I"pu! Co ! M Be"c2.ar@i"( =i!2 Co.pe!i!io" G Re1uc!io" o) Re?ec!io" 3 Wa !e Eli.i"a!io" G Lea" Ma"u)ac!uri"( Tec2"i7ue M Re1uc!io" i" i"0e"!orie G Co"!rol O0er2ea1 EHpe" e G I""o0a!io" G E"2a"ci"( per)or.a"ce o) !2e co.po"e"!M.o1ule uppl-i"( G Co"!i"uou 5ocu o" i"crea i"( Brai" ,o=er G I.pro0e !2e Value C2ai"9 Co.po"e"! !o S- !e.MSu6& - !e. Supplier G Value E"(i"eeri"( ,ropo al G Deli0erG CIT Deli0er- S- !e. G *$$N )la=le 1eli0erie

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,ro1uc! ,ro)ile O) Varroc Group

Varroc 2a0e a !a!e&o)&!2e ar!9 e"0iro".e"! )rie"1l- ,ol- Ure!2a"e 5oa. .ol1i"( )acili!- )or !2e .a"u)ac!ure o) )oa. pa1 a"1 ea! a e.6l- )or !=o9 !2ree a"1 )our =2eeler + Varroc 2a0e ro6o! co"!rol li"e a! Aura"(a6a1 ,la"!+ I" !alle1 ,ro1uc!io" Capaci!- i :$$$ T+ ,er A""u.+ Clie"! i"clu1e uc2 pre !i(iou "a.e a Ba?a? Au!o 9Ta!a .o!or 9A 2o@ Le-la"19Ya.a2a i" !2e 1o.e !ic .ar@e! a"1 Au1i9 5ia! 9GM9a"1 Dai.ler C2r- ler i" !2e i"!er"a!io"al .ar@e!+ Varroc .a"u)ac!ure a"1 uppl- ea! a e.6l- !o au!o.o!i0e cu !o.er 9 po=er !rai" .a"u)ac!urer acro !2e (lo6e+ Varroc Group 2a a1op!e1 !2e T,M - !e. !o e" ure co"!i"uou i.pro0e.e"! a"1 u !e"a"ce o) !2e 7uali!- o) !2e pro1uc! + All 1i0i io" .a"u)ac!ure preci io" 2i(2 7uali!- par! )or !2e au!o.o6ile i"1u !r-+ *+ ,OLYMER DIVISIONF I"!erior ,illar Tri. 9 Door ,a"el 9 5loor Co" ole EH!erior ,ar! 8 Bu.per 9 5e"1er 9 Cla11i"( 9 W2eel Arc2e U"1er6o1-M HVAC par! I"?ec!io" a"1 Co.pre io" Mol1e1 Ru66er ,ar! Mirror A e.6lie a"1 Mirror Ru66er ,ar! Air Clea"er A e.6l,U 5oa. ,a1 a"1 Sea!i"( S- !e. A e.6lMul!ila-er co&eH!ru1e1 T2er.opla !ic S2ee! Mol1e1 par! )or W2i!e Goo1 a"1 Co" u.er Elec!ro"ic ,ar! Serie Mol1 a"1 ,re ,ro1uc!io" Mol1

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#+ METALLIC DIVISIONF E"(i"e Val0e Cra"@ pi" )or .o!orc-cle Ho!9 col1 3 =ar. )or(e1 .ac2i"e1 co.po"e"! Ca!al-!ic co"0er!er )or #9 ; a"1 < =2eeler ;+ ELECTRICAL DIVISIONF A+C+ (e"era!or 3 Ma("e!o Di(i!al CDI9 1i(i!al re(ula!or rec!i)ier u"i! S!ar!er Mo!or9 Wiper Mo!or S=i!c2 A e.6l- a"1 2a"1le 6ar a e.6l- )or .o!orc-cle9 LED Li(2! Elec!ro"ic co"!rol u"i! 9 Elec!ro"ic Clu !er

1?

,ro1uc! I.a(e O) Varroc ,ol-.er

,U )oa. ea! o) Ba?a? ,ul ar*:$+

2&

,er)ec! )i!!i"( o) ,U )oa. ea! !o 6i@e+

S!-li 2 2ape o) ea! )or "e= 6i@e O

21

AWARDS

In 2&&&?'1& 2arroc ,roup has won award of best Performance in product de)elopment 0upplier performance !ward by Dr. Pawan ,oen-a. /his award is gi)en for commodity criteria of plastic and rubber.

22

In 2&1& 2arroc Polymer has won best supplier !ward by /!/! /8+8 R!DI!/8R ;I*I/%D .

In 2&&? 2arroc Polymer P)t ;td has won the best -aiDen !ward in third -aiDen competition.

23

Ma"u)ac!uri"( ,roce
Varroc ,ol-.er i .a"u)ac!urer o) ,U 5oa. ea! =2ic2 i .a1e 6- MiH!ure o) pol-a.i"e a"1 i o -"a!e+ Ma"u)ac!uri"( ,roce o) ,U 5oa. i a u"1er Ma"u)ac!uri"( ,roce *B #B ;B <B :B 4B %B 'B Moul1 Clea"i"(+ Spra- Applica!io" )or relea e+ ,ouri"(+ De.oul1i"(+ S7ueeEi"(+ De)la 2i"(+ I" pec!io" i" ,roce + 5i"al I" pec!io"+

Luali!- I" pec!io" Luali!- a ura"ce a! 0arroc i pa !2rou(2 *% 1i))ere"! 7uali!- eHa.i"a!io" !2e e are a )ollo= + *B 5oa. 2ar1"e Bu $*$$:Re0 %pu&% MG!M*+ #B 5oa. 2ar1"e + ;B Re i !a"ce+ <B Co.pre io" o" e! !e !+ :B Hea! a(ea(i"( !e !+ 4B Wa!er A6 or6!io"+

2.

%B Repea!e1 ,er.e"a"!+ 'B De" i!-+ >B Speci)ic Gra0i!- o) ,U ra= .a!erial+ *$B Drop i.pac! !e !+ **B 5or ReHi"e c1our 6rea@i"( !re"(!2 a"1 Elo" A12e io" !o coa!i"( !e ! !ear !re"(!2 Gelli"( !e !+ *#B )or )oa. !er ile !ear !re"(!2 6rea@ elo"(a!io"+ *;B )or reHi"e )leH !e !+ *<B )or reHi"e re i ! !o col1+ *:B )or reHi"e colour )a !"e !o 1r- o) =e! ru66i"(+ *4B Sur)ace re i !a"ce !o c2e.ical + *%B T2ic@"e a"1 .ea ure.e"!+

2:

,ro1uc!io" ,roce
Varroc 2a a !a!e&o)&!2e ar!9 e"0iro".e"! )rie"1l- ,ol- Ure!2a"e 5oa. .ol1i"( )acili!- )or !2e .a"u)ac!ure o) )oa. pa1 a"1 ea! a e.6l)or !=o9 !2ree a"1 )our =2eeler + Varroc 2a ro6o! co"!rol li"e a! our Aura"(a6a1 ,la"!+ Installed Production 6apacity is :&&& /. Per !nnum.

2<

Raw material reHuired

*+ I oc-a"a!e HD #+ I oc-a"a!e LD ;+ ,ol-ol HD <+ ,ol-ol LD 5or .a"u)ac!uri"( !2e ea! 9 I oc-a"a!e a"1 ,ol-ol ra= .a!erial are .o !l- u e1+ T2e e ra= .a!erial 2a0e !=o 1i))ere"! 1e" i!ie 9 o"e i + H+D+i+ e+ 2i(2 1e" i!- a"1 L+ D+ i+e+ lo= 1e" i!-+

0ystem
Hi(2 ,re ure Reac!io" I"?ec!io" S- !e.+
Lo= ,re ure I"?ec!io" S- !e.+

2arroc has following manufacturing lines.

He""ec@e Mac2i"e9 Ger.a"-& # Li"e+ Hi(2 ,re ure9 A;$ !a!io" B+ G"o i Gree"9 Tai=a"& * Li"e+ Lo= ,re ure+ A#: !a!io" B+

Density of #oam ProcessedI

Lo= De" i!-F <: !o ::+ Hi(2 De" i!-F %: !o ':+

2>

H+D+ i u i"( )or .a"u)ac!uri"( !2e !=o =2eeler/ !2ree =2eeler/ ea! +

ea! a"1 L+D+ i u i"( )or

1ennec-e *achine

2A

T2i i He""ec@e B .ac2i"e u e )or .iH !2e I oc-a"a!e a"1 ,ol-ol c2e.ical !o(e!2er9 a"1 !2e" pour i! i" !2e .oul1 o) !2e par!icular Sea! !2a! =e 2a0e !o .a"u)ac!ure+

Production #lowI'
Raw material from store department

6ollection of raw material in tan-

*ixing of raw material

*ould loading on con)eyor

*ould cleaning and spraying

*achine parameter setting for production

2?

*ixture of Isocyanate and Polyol pouring in mould

! !

*ould closing

*ould passes through o)en for

*ould opening

*ould demoulding and sHueeDing

#oam deflashing

#oam dispatch by B. !.

3&

#oam testing

!ssembly of manufacturing

#oam dispatch for assembly to )endor

#oam assembly ready for dispatch

31

Luali!- ,olicT2e Varroc Group 2a 6ee" a6le !o ac2ie0e !eep (ro=!2 i" !2e la ! 1eca1e i" all i! opera!io" + T2i =a ac2ie0e1 6- .ea" o) a lar(el- !ra1i!io"al 6u i"e .o1el+ I" or1er !o @eep !2e Group a6rea ! o) co" !a"!l- i"crea i"( cu !o.er eHpec!a!io" !2e Ma"a(e.e"! )el! !2e "ee1 )or a - !e.ic approac2 !o all a pec! o) !2e GroupK opera!io" 9 o !2a! !2e (ro=!2 ra!e coul1 co"!i"ue !o 6e ac2ie0e1 o" a u !ai"a6le 6a i + T2e approac2 =a .ul!i)ace!e19 )or a11re i"( .ul!iple i"!er"al a"1 eH!er"al )ac!or 9 uc2 a e.plo-ee @ill le0el9 c2a"(i"( pro1uc! pro)ile9 co.pe!i!io" o" price9 !ri"(e"! pro1uc! peci)ica!io" a"1 cu !o.er eHpec!a!io"+ A )ur!2er !ra!e(ic o6?ec!i0e =a !2e "ee1 !o 6uil1 i"!er"a!io"al 6ra"1 e7ui!-+ T2e Corpora!io" !2ere)ore 1eci1e1 !o a1op! a 2oli !ic approac2 !o .a"u)ac!uri"( a"1 opera!io"al eHcelle"ce9 a"1 1eci1e1 !o a1op! !2e T,M =a- a !2e !ool )or i.ple.e"!i"( !2e c2a"(e+ A ca!c2- lo(a"9 KLe! u .a@e i! 2appe"K9 =a a1op!e1 !o 1ri0e !2e .e a(e 1o=" !o !2e lo=e ! le0el o) !2e or(a"iEa!io"+ Varroc i"i!iall- 6e(a" !2e T,M ac!i0i!ie a a upplier !o Ba?a? Au!o L!1+9 =2o are VarrocK .a?or cu !o.er9 a"1 =2o 2a1 a1op!e1 !2i .e!2o1olo(-+ I" No0e.6er #$$49 Varroc 1eci1e1 !o procee1 alo"( !2i roa1 o" i! o="9 u"1er !2e (ui1a"ce a"1 au pice o) T,M (uru ,ro)+ Ya.a(uc2i a"+ T2e i"i!ia!i0e )or.all- co..e"ce1 =i!2 !2e co"1uc! o) a T,M 1eplo-.e"! e.i"ar )or !2e .i11le a"1 e"ior .a"a(e.e"! o) !2e Varroc (roup+ T2e e.i"ar =a a!!e"1e1 6- a6ou! *;: 1ele(a!e + A T,M polic- =a 1e0elope19 =2ic2 =a ali("e1 =i!2 !2e GroupK 0i io" a"1 .i io" !a!e.e"! I" parallel9 *S&#S ac!i0i!ie =ere al o i"i!ia!e1+ T2i re ul!e1 i" i..e1ia!e !a"(i6le re ul! + Valua6le )loor pace o" !2e 2op )loor 6eca.e a0aila6le9 pla"! =ere loo@i"( 6e!!er9 a"1 a 1a!a6a e =a 1e0elope1 )or u"=a"!e1 .a!erial a"1 e7uip.e"!9 o !2a! o!2er pla"! coul1 loo@ a! !2e li ! )or e7uip.e"! !2e- "ee1e1+ T2i i" !ur" le1 !o capi!al a0i"( + T,M Mo1el Mac2i"eMCell ac!i0i!ie =ere al o i"i!ia!e1 6- .a"a(er !o 1e.o" !ra!e !2e 0ariou ac!i0i!ie i" !2e T,M =a- o" !2e cri!ical .ac2i"e cell+ T-picall-9 a

32

.ac2i"e i" !2e poore ! co"1i!io" =i!2i" a cell =a pic@e1&up a !2e Mo1el Mac2i"e+ T2e Mo1el .ac2i"e pro(ra. =a ai.e1 a! pro0i1i"( .a"a(er

=i!2 2a"1 o" eHperie"ce o" 2o= !o appl- !2e T,M pillar !o e7uip.e"! up@eep9 a"1 al o pro0i1i"( !2e. =i!2 a" apprecia!io" o) !2e !a"(i6le a"1 i"!a"(i6le 6e"e)i! o) T,M+ T2e .a"a(er i" !ur" are eHpec!e1 !o i.par! !2i lear"i"( !o !2eir u6or1i"a!e 9 !2u crea!i"( a ca ca1i"( e))ec! =2ic2 =ill percola!e 1o=" !o !2e lo=e ! le0el o) !2e or(a"iEa!io"+ T2e o6?ec!i0e i !o crea!e a cul!ure o) 1oi"( !2i"( i" !2e T,M )ra.e=or@9 a"1 1ocu.e"!i"( i.pro0e.e"! ac2ie0e1 !2ere6- a a 6a i )or )ur!2er i.pro0e.e"!+ T2e Mo1el Mac2i"e i"i!ia!i0e -iel1e1 pec!acular re ul! + ,ro1uc!i0i!- i"crea e1 6- *:$ !o ;$$N9 Eero cu !o.er re?ec!io" =a ac2ie0e1 6- o.e pla"! 9 !2ere =a a :$N 1ecli"e i" i"&proce 1e)ec! (e"era!io"9 acci1e"! =ere Eero9a"1 !2ere =a a co" e7ue"! #$&:$N re1uc!io" i" .a"u)ac!uri"( co ! + Mo ! i.por!a"!l-9 !2e le0el o) par!icipa!io" 6- all !ea. .e.6er 2o=e1 i("i)ica"! i.pro0e.e"!9 a .ea ure1 6- !2e "u.6er o) u((e !io" !2a! =ere recei0e1+ T2e lear"i"( )ro. !2e Ma"a(erK Mo1el Mac2i"e i"i!ia!i0e i curre"!l- u"1er 2oriEo"!al 1eplo-.e"! acro .o ! o) !2e Varroc pla"! + ,ar!icipa!io" =a )ur!2er e"coura(e1 6- pro.o!i"( .all (roup ac!i0i!ie + To percola!e T,M a=are"e a.o"( all e.plo-ee a .o"!2l- "e= .a(aEi"e calle1 PT,M Ne= le!!erK i pu6li 2e1 e0er- .o"!2+ I! )ea!ure T,M ac!i0i!ie o) !2e pre0iou .o"!29 o6 er0a!io" .a1e 6- !2e co" ul!a"! 9 i.por!a"! e0e"! 9 a"1 a 1e crip!io" o) 6e ! prac!ice i" 0ariou pla"! 9 !o )acili!a!e 2ari"( 6- !2e o!2er + A .a?or )all&ou! e))ec! o) !2e par!icipa!i0e .e!2o1olo(- a10oca!e1 6- !2e T,M 2a 6ee" !2e (e"era!io" o) @aiEe" i" eac2 pla"!+ I! 2a e"coura(e1 !2e Corpora!io" !o !r- a"1 par!icipa!e i" eH!er"al @aiEe" co.pe!i!io" + La ! -ear <* !ea. par!icipa!e1 i" eH!er"al co.pe!i!io" a a(ai" ! : !ea.K par!icipa!i"( i" Year $4&$%+ Ma"- o) !2e. e.er(e1 =i""er i" Re(io"alA4 !ea. B a"1 Na!io"al A; !ea. Ble0el+ I! i =or!2=2ile !o .e"!io" !2a! o"e o) our pla"! 9 DI,LADuro0al0e I"1ia ,0!+ L!1B 6a((e1 !2e co0e!e1 PSo"a KaiEe" A=ar1 a"1 KaiEe" C2a.pio" Trop2- o) !2e Year #$$% A!2e la ! =or1 i" KaiEe" co.pe!i!io" i" I"1iaB alo"( =i!2 a ca 2 a=ar1 o) R o"e lac a! !2e *$!2 T,M Na!io"al Co")ere"ce co"1uc!e1 a! C2e""ai i" Marc2&#$$'+ T2i i all !2e .ore cre1i!=or!2- 6ecau e i! 2a 2appe"e1 i" !2e )ir ! -ear o) our T,M

33

?our"e-9 co.pe!i"( a(ai" !.a"- o) !2e (ia"! o) I"1ia" i"1u !r-+ T2rou(2 !2e e i"i!ia!i0e 9 Varroc al o 6a((e1 .a"- Luali!- A=ar1 la ! -ear+ : BAL Luali!- A=ar1 =ere recei0e1 6- Varroc la ! -ear a(ai" ! a i"(le a=ar1 i" -ear $4Q$%+ T2e Corpora!io" 2a e! i! el) a" a.6i!iou !ar(e! o) *# BAL L a=ar1 )or !2e curre"! )i"a"cial -ear+ Ma"- o!2er Luali!- a=ar1 )ro. cu !o.er li@e Ta!a Co2" o" =ere al o =o" 6- Group co.pa"ie la ! -ear+ Ma"- o) our Group co.pa"ie 2a0e 6ee" opera!i"( =i!2 Rero ,,M Cu !o.er Re?ec!io" )or !2e la ! 4 .o"!2 or .ore+ All (roup co.pa"ie are "o= TS *4><> cer!i)ie1+ I" co"!i"ua!io" =i!2 !2e e i"i!ia!i0e 9 a"1 i" ali(".e"! =i!2 !2e ocial o6?ec!i0e 9 Varroc i co..i!!e1 !o o6!ai" ISO *<$$*MOSHAS *'$$* cer!i)ica!io" )or all i! pla"! + T2i o"l- rei")orce !2e Corpora!e co..i!.e"! !o=ar1 e"0iro".e"!9 2eal!2 a"1 ocie!- =2ic2 i par! o) our Mi io" S!a!e.e"! a"1 Luali!- ,olic-+

3.

Luali!- Co"!rol
Luali!- A ura"ce 1epar!.e"! ac!uall- 1eal =i!2 !2e )i"al pro1uc! !2a! i a uri"( i! 7uali!- or ra!2er .ai"!ai"i"( i! 7uali!- !o !2e 6e !+ T2i a ura"ce o) 7uali!- or ra!2er .ai"!ai"i"( i! 7uali!- 6e !+ T2e a uri"( o) 7uali!- i (i0e" ei!2er i" proce a ura"ce "a.el-+ *+ #+ ;+ I"=ar1 i" pec!io" Li"e 7uali!- a ura"ce 3 Au1i! i" pec!io"+ o) .a"u)ac!uri"( i! el) or a)!er !2e co.ple!io" o) !2e pro1uc!+ T2u 9 !2ere are !2ree .ai" !-pe o) 7uali!-

I57!RD B(!;I/+ !00(R!56%

T2e i"=ar1 i" pec!io" i 1o"e =2e" !2e par! are purc2a e1 )or. !2e 0e"1or 9 !2e par! =2ic2 co.e )ro. 0e"1or are i" pec!e1 properl- 6- !2e i" pec!or or e"(i"eer or !ec2"icia" a"1 !2e" i) i! i o@a- !2e" !2e par! i allo=e1 !o (o !o !2e pro1uc!io" 1ep!+ W2ere i! i .a1e )i! i" !2e appropria!e place+ I) !2e par! i )ou"1 )aul!- i" !2e 0er- )ir ! i" pec!io"9 !2e =2ole 6u"c2 o) !2e par! i e"! 6ac@ !o !2e 0e"1or a"1 i a @e1 )or "e= o"e+ T2e )aul! .a- 6e .i"or9 .a?or or o.e !i.e cri!ical+ T2e .i"or )aul! are o.e !i.e repaire1 =i!2i" !2e Co.pa"- i! el)+

3:

VARIOUS TEST CONDUCTED I

S S S S S S S Har1"e c2ec@i"(

Bur !i"( !a"1 Moi !ure !e !i"( Vi co i!- !e !i"( Sal! pra- !e ! AMe!al !e !B Hu.i1i!- !e ! c2a.6er AMe!al !e !B Cuppi"( 0alue !e !er+

3<

LAYOUT O5 THE DE,ARMENT

/P* Display 8)en *uffle furnace

Drop impact test

7ater absorption test

%ntrance

9aiDan display

1ardness test mJc

Rubbing test ;oad identification mJc

Rac- for fixture Eindenter test mJc

3>

1.DR8P I*P!6/ /%0/I

,urpo eF To 1e!ec! crac@ o" ea! a)!er 1rop i.pac! ScopeF T2i i applica6le !o all ea! 6a e +

2.82%5J68*PR!/I85 0%/ /%0/I

,urpo eF To !e ! co.p ra!io" :$N!2i@"e ScopeF All !-pe o) ,U )oa. ,roce1ureF Cu! !2e peci.e" )oa. la6 =2ic2 2a 6ee" cure1 )or <' 2our roo. !e.pera!ure i" uc2 =a- !2a! loa1 i applie1 i"1irec!io" o) !2e ri e o) !2e )oa. !o (e! !2e peci.e" o) !2e iEe :$T9 #:T ..+ e! !e ! A!2ic@"e lo B a! 1e)lec!io" o)

3.*(##;% #(R5!6% /%0/I

,urpo eF T2i !e ! 2all 6e per)or.e1 !o c2ec@ a 2 co"!e"! o) ru66er par!

..1!RD5%00 /%0/
,urpo eF T2e e !e ! c2ec@e1+ ScopeF !2i i applica6le )or ,U )oa. 2all 6e per)or.e1 )or !2e .ea ure.e"! o) 2ar1"e o) i !2e )oa.+ T2a! .ea" accor1i"( !o !2e cu !o.er re7uire.e"! 2ar1"e

3A

:./%0/ 8# #8!* ;8!D 2!;(%I

PurposeI to chec- the load )alue of the foam ScopeF all )oa. A#3; =2eelerB Re)F STD +BA $*$$: 5oa. 2ei(2! !2ic@"e I"1e"!a!io" Lc $+$: @( 3 loca!io" )ro. 1ra=i"( .ac2i"e loa1

<. 7!/%R ! 08RP/I85 /%0/I

,urpo eF To c2ec@ !2e =a!er a6 orp!io" capaci!- o) !2e ea! A e.6l-+ ScopeF I! i applica6le )or ea! a e.6l-

3?

078/ !5!;+0I0
STRENGHTSF
T2e )ollo=i"( are o.e o) !2e @e- ele.e"! 9 =2ic2 =ill e"a6le !2e Co.pa"!o ac2ie0e (rea!er pro(re *+ 3 .ar@e! 2areF T2e Co.pa"- .a"u)ac!ure .ar@e! or 1i !ri6u!e a 0er- =i1e ra"(e o) .o1el crea!i"( !2e "ee1 o) all ec!or + Eac2 3 e0er- pro1uc! 2a co0er !2e pec!ru. )or. !2e li ! !o .o ! eHpe" i0e )ro. !2e la!e ! !o .o ! eHpe" i0e i" !2ere re pec!i0e ca!e(orie 9 !2u re7uire.e"! o) all cla #+ T2e Co.pa"-K o) cu !o.er + al o e.p2a iEe !2e u6 .ee!i"(

a10er!i i"( pro(ra.

e(.e"! =i!2i" i! pro1uc! li"e + ;+ T2e Co.pa"-K 6- !2e Co.pa"-K <+ ale i! pro1uc! !2rou(2 a =ell & eHpa"1e1 "e!=or@ uppor!e1 !ro"( ale )orce+

o) i"1epe"1e"! 1ealer loca!e1 !2rou(2 ou! I"1ia9 =2ic2 i

T2e Co.pa"- pro0i1e )or. !i.e !o !i.e a 0arie!- o) i"ce"!i0e 3 pro.o!io" !o 1ealer )ro. !i.e !o !i.e9 =2ic2 are o)!e" !ailore1 !o )o !er (oo1 rela!io" 2ip 3 !o i"crea e ale +

.&

WEAKNESS F&
K S S E.plo-ee !re"(!2 i "o! (e! u!iliEe1 properl-+ No e))icie"c- !o i"crea e !2e =or@ pro1uc!i0i!-+ Co.para!i0el- lo= 1e0elop !ec2"olo(ical i""o0a!io" !2a" i! co.pe!i!or

O,,ORTINUTY
S K S S 5i"e & !u"e 3 eHecu!i0e reli(iou l- !2e per)or.a"ce .a"a(e.e"! Re1e i("9 i"1uc!io" 3 orie"!a!io" are i.por!a"! co..u"ica!io" De)i"e a"1 1i pla- per)or.a"ce i"1ica!or )or (ra!er clari!- a! !2e ,er)or.a"ce li"@ re=ar1 - !e. - !e.+ - !e. 2op )loor+

THREATSF&
K S Co"!rac! la6or a"1 !rai"ee e))ec!i0e"e Re!e"!io" o) @e- people i" .a"u)ac!uri"( proce

.1

S S

I"a6ili!- !o 6e"c2 .ar@ S- !e. o6 ole ce

CONCLUSION
I! =a "ice eHperie"ce !o =or@ =i!2 i" Varroc ,ol-.er ,0! +L!1+ a !2e2a0e eHperie"ce a"1 lear"e1 !a)) i" !2eir re pec!i0e )iel1+ E peciall- I o6 er0e1 !2eir .e!2o1 a"1 !-le o) =or@i"(9 !2e- 2a1 (i0e" .e proper a"1 accura!e !rai"i"( a6ou! Ma"a(e.e"! !u1ie + I! =a !2e prac!ical 1a- =2ere real eHperie"ce =i!2 !2e co.pa"- =or@i"( cul!ure+ I" a (ia"! co.pa"- li@e Varroc ,ol-.er ,0!+ L!1 =2ic2 i )a !e ! (ro=i"( i" )iel1 o) au!o.o6ile9 =or@ i carrie1 ou! i" a 0er- - !e.a!ic9 op2i !ica!e1 3 !ec2"ical .a""er+ T2e Ma"a(e.e"! i" Varroc ,ol-.er ,0!+ L!1 2all !ri0e !o e" ure co"!i"ue or(a"iEa!io"al (ro=!2 6- "ur!uri"( !2e !re"(!2 o) i! e.plo-ee a"1 pro0i1i"( !2e e"0iro".e"!al oppor!u"i!- )or e0er- i"1i0i1ual !o ri e !o 2i M 2er )ull po!e"!ial+

.2

7% ;I8,R!P1+

===+0arroce"((+co. ===+=i@ipe1ia+co. ===+(oo(le+co.

I ;I8,R!P1+
2!RR86 P(;0% *!,0I5%.

.3