Total Polymer Consumption in Automobile Sector in Pune Region Appl Industries Pune by Mrinal Khajuria Marketing

A Project Report On
Total Consumption Of Polymer In Automobile Sector In Pune Region
With Special Reference To APPL. Industries Limited, Pune
Submitted To Vishwakarma Institute Of Management, Pune
In Partial Fulfillment Of The Requirement For The Award Of Degree Of Master Of Business Administration By Mrinal Khajuria (2004-06)
Under The Guidance Of Mr. Yuvraj Lahoti (Professor, VIM)
CERTIFICATE OF SUMMER TRAINING COMPLETION
This is to certify that Project Report titled Total Consumption Of Polymer in Automobile Sector In Pune Region has been completed satisfactorily in partial fulfillment of Master Of Business Administration course for the academic year 2004-2006 by Mrinal Khajuria, Student of Vishwakarma institute of management pune-37.
Place: Pune Date:
Director, Vim, pune-37
GUIDE CERTIFICATE
This is to certify that Mr. Mrinal Khajuria student of Master of business administration course with specialization in Marketing, for the session August 2004- July 2006 prepared project report entitled Total Consumption Of Polymer in Automobile Sector In Pune Region at Aalekh polymers PVT. Limited. From15th June to 30th July under my guidance and supervision. I wish him all success in life.
Prof. Yuvraj lahoti (Marketing)
TABLE OF CONTENTS
S.No
TOPIC
PAGE No.
1.
INTRODUCTION
10-11
2.
COMPANY PROFILE
13-14
3.
PRODUCT PROFILE
16-20
4.
OBJECTIVES OF THE STUDY
22
5.
RESEARCH METHODOLOGY
24
6.
OBSERVATIONS AND FINDINGS
26-45
7.
CONCLUSIONS & SUGGESTIONS
47-49
8.
ANNEXURES
51-56
ACKNOWLEDGEMENT I take the occasion to thank Aalekh polymers private Limited for giving me the opportunity to work on this project, which has immensely helped in gaining & developing my knowledge & experience. I would like to thank my institute VIM as well as Director sir Dr. Sharad L Joshi to provide me such a wonderful opportunity. I especially thank my project guide Mr.Yuvraj Lahoti (professor, VIM) for his valuable guidance, co-operation & encouragement throughout the project. I am also Grateful to Mr.Arun Sharma (senior head marketing) and Mr.Inder Jain (CEO) for providing their valuable thoughts and inputs throughout the project & kindly accepting the suggestions & recommendations given by me. I am very thankful to god as well as my family who really helped me during the project work without there ally and support it its not possible to study here in a very pleasant atmosphere. Lastly I would like to specially thank the subordinates & their superiors for their co-operation and also would like to thank to all the respondents of the survey, members of the faculty & all my other fellow summer trainees for their co-operation & co-ordination in the project along with me. Place-Pune Mrinal Khajuria
EXECUTIVE SUMMARY
Objectives: 1) To know the total polymer consumption in the automobile sector 2) How many injection moulding companies are using polymers for automobile industry in Pune Region? 3) What are the prices at which injection moulding companies are buying raw materials from other manufacturers 4) To know the availability of substitutes and grade of polymers in Pune region 5) To find out the awareness of the product in the market 6) To know the strengths and weaknesses of the companies 7) To know various parameters whatever the business rivals of APPl. are following: o Marketing strategy o Pricing policy o Credit policies
Findings: Polypropylene is used readily in automobile sector because we can enhance its properties by adding filler for example: glass, mica, talc, etc. as per the requirement of the product. Appl produces PP + Filler as per the customer requirements. Polypropylene is used in bumpers, dashboards, fuel tanks etc. Polypropylene is used frequently because:
1) There is no problem in the availability. 2) Its trends do not vary. 3) It is cheaper then metal. 4) Properties are more or less same as of metals. 5) The weight is lesser then metals which helps in increasing average of the vehicle.
Recommendations: The company should increase sales The company should try to reduce the cost of production Growth opportunities in public transport and commercial sectors Material handling Sourcing of materials Proper inputs from customer Trend analysis
Limitation of the study: Sometimes consumers are not aware of the new product Due to limited sample representation population may not be that much accurate
I, here by declare that this project report entitle Total polymer Consumption In Automobile Sector with special reference to APPL Industries Limited Pune, Which is the outcome of the summer training undergone by me from 15th June 2005 to 30th July 2005. The empirical finding of the study is entirely based on the data collected by myself.
INTRODUCTION
History and significance of polymers Plastics are polymers. What is a polymer? The simplest definition of a polymer is something made of many units. Think of a polymer as a chain. Each link of the chain is the "mer" or basic unit that is made of carbon, hydrogen, oxygen, and/or silicon. To make the chain, many links or "mers" are hooked or polymerized together. Polymerization can be demonstrated by linking strips of construction paper together to make paper garlands or hooking together hundreds of paper clips to form chains. Polymers have been with us since the beginning of time. Natural polymers include such things as tar and shellac, tortoise shell and horns, as well as tree saps that produce amber and latex. These polymers were processed with heat and pressure into useful articles like hair ornaments and jewelry. Natural polymers began to be chemically modified during the 1800s to produce many materials. The most famous of these were vulcanized rubber, gun cotton, and celluloid. The first synthetic polymer produced was Bakelite in 1909 and was soon followed by the first semisynthetic fiber, rayon, which was developed in 1911 Even with these developments, it was not until World War II that significant changes took place in the polymer industry. Prior to World War II, natural substances were generally available; therefore, synthetics that were being developed were not a necessity. Once the world went to war, our natural sources of latex, wool, silk, and other materials were cut off, making the use of synthetics critical. During this time period, we saw the use of nylon, acrylic, neoprene, SBR, polyethylene, and many more polymers take the place of natural materials that were no longer available. Since then, the polymer industry has continued to grow and has evolved into one of the fastest growing industries in the U.S. and in the world. Characteristics of Polymers The two major groups of polymers are thermoplastics and thermosets. Thermoplastic and thermosetting nature is based on the heat response of polymers. The light transmittance of polymers includes the description of materials as being transparent, translucent, or opaque. Transparent polymers are those that you can see through, translucent are those that you cannot see through but allow light to pass through, and opaque polymers are those that you can neither see through nor allow light to pass through. Light penetration qualities are dependent on the degree of crystallization of the polymer and the presence of additives. 10
Every polymer has very distinct characteristics but most polymers have the following general attributes. 1. Polymers can be very resistant to chemicals 2. Polymers can be both thermal and electrical insulators 3. Generally, polymers are very light in mass with varying degrees of strength 4. Polymers can be processed in various ways to produce thin fibers or very intricate parts As a leading manufacturer of engineered thermoplastic compounds having largest capacity in India with multilocational compounding base, thus providing the complete solutions for Automotive and Appliances Industries. Research and Development Manufacturing is fully supported by a team of dedicated Research and Development officers. A laboratory scale Extruder very similar to the production machines has been installed in our R & D department. This ensures that the scale up is smooth from R&D to production. In house R&D also helps us to develop new materials in the shortest time period to meet our customer's new and exacting requirements. R & D department is well dedicated to upgrade our material time to time as per customer's requirements.
11
12
Company Profile
About APPL APPL Industries Limited, which has been formed by the merger of three groups of companies Aalekh Polymers (P) Limited, Aalekh Industries (P) Ltd., and Prateek Enterprises, is one of the leading compounder of engineered thermoplastics in India. We have been providing material solutions to our customer for over 15 years. Today, we offer precoloured compounds based on Polyolefin s and engineering plastics modified with minerals, glass fiber/beads, wood flour, flame retardants etc. We also offer blends and alloys of various plastics, colour concentrates and additive master batches.
Article I.
APPL Facilities
Production units at multiple sites - strategically located to meet customer's requirements. Latest fully Computer controlled state-of-the-art compounding systems from Germany, Japan offer Advanced Materials Technologies. International standard Quality Control Laboratory. APPL has established highly sophisticated Polymer Compounding units at IMT Manesar near Delhi and at Pune in Maharashtra with a total installed capacity of 30,000 MTA, and by the end of 2006, APPL will set up its third compounding unit at Hosur, Tamil Nadu with additional 10,000 MTA capacities. APPL PROCESS Twin Screw Super Compounders Co-rotating and counter-rotating type
Gravimetric Loss-in-Weight feeders from Brabender Technologies, K-Tron Automation of material handling Our production equipment and its variety allow us to match each product to the right process, highest and consistent product quality in shortest lead-time. VISION To be a multilocation company engaged in production of Engineered Thermoplastic Compounds based on Polyolefin s and Engineering Plastics, thereby attaining a top-performing compounding industry dealing in multiple products and developing new applications close to customers.
13
MISSION To provide materials based on advanced technology to our esteemed customers, which meet challenging demands. To respect the strength and capability of all our employees, customers and associates. To honour all commitments we undertake. ACHIEVEMENTS 1990: - The Company was established at New Delhi to manufacture Color Concentrate. 1995: -Manufacturing Plant dedicated for Black Masterbatch was set up at Rajasthan. 1998: - Two compounding line from Japan were installed at Delhi for PPAM compounds. 2001: - Two state-of-the-art compounding line from Theysohn Maschinenbau, Germany were installed at pune.
2002: - Commissioned IMT - Manesar plant with two lines from Japan and two more Compounding Lines from Theysohn, Germany. 2003: - Obtained ISO - 9001:2000 accreditation. 2003: - Automated Feeding system was installed at IMT Manesar Plant.
2004: - Appointed as consignment agent of Ciba Speciality chemicals for plastics additives for Eastern India. 2005: - Accelerated Weather meter instrument was set up at Pune plant. 2005: - Two state-of-the-art compounding lines from Coperion were installed at Pune and IMT Manesar plant. 2005: - Two Research & Development purpose compounding lines from Coperion were installed at Pune and IMT Manesar plant. 2006: - One Counter Rotating Twin screw extruder from Japan was installed at Pune
14
15
SEGMENT
DESCRIPTION
TRADE NAME
Advanced Polypropylene Compounds Engineered Plastics based on Commodity Resins
APPCOM
Advanced Styrenic Compounds Advanced Colour Masterbatches Speciality Additive Masterbatches
APPSTRON APPCOL APPLENE
Polycarbonate Compounds Engineered Plastics based on Advanced Plastic Resins Alloys PBT Compounds Nylon Compounds
APPNATE
APPLOY APPET APPLON
16
Engineered Plastics based on Commodity Resins

A product may start with homopolymer, copolymer, TPO (rubber-modified alloys). The application may require UL recognition, special stabilizers for improved weatherability, and extra heat stabilizers for under the hood applications. The type, particle size and amount of filler can be adjusted as per requirement for their aesthetics and mechanicals. For improved impact, impact modifier can be incorporated. We can provide pre-colored materials as well as natural colour materials. A complete product listing, incorporating all would be too long to list.
Our ABS and HIPS compounds have been developed specifically to meet the requirements of major customers. These grades are the cost-effective answer for purchasers. These grades are available as per customer-specific colours. Our ABS compounds offer excellent processability, good heat resistance and show good balance between impact resistance and rigidity.
APPL also offer SAN compounds, which have high heat resistance and chemical resistance. It has a wide range of applications in electrical/electronic parts, automotive parts, office consumables and so on.
17
An engineered plastic based on commodity resins includes: ADVANCED POLYPROPYLENE COMPOUNDS: These compounds are used in manufacturing bumpers, instrumental panel, door trims, speedometer housing,
speedometer body cover, seat side balance, household items, case heater of air conditioner, automotive filters, refrigerator body parts, foot rest paddles etc. ADVANCED COLOUR MASTERBATCH GRADES: These resins are used in
manufacturing Cover Inner of Two Wheeler Sector, Washing Machine Body Part, Tray for Washing Machines, Hood Meter Cluster. ADVANCED ADDITIVE MASTERBATCH GRADES: manufacturing Blown Film. ADVANCED STYRENIC COMPOUNDS: These resins are used in manufacturing Washing Machine Body Parts, Hood Meter Cluster, UPS Body Parts, Blower for AirConditioner, Two Wheeler Front Cover, Seat and Door Handle, UPS Housing. These resins are used in
18
Engineered Plastics based on Advanced Plastic Resins
We at APPL are offering various grades of mineral filled, glass reinforced, fire retardant polycarbonate compounds, and their alloys, compounds of PBT and nylon. Our R & D department is constantly working in this wide spread Engineering Plastics field. Polycarbonate and its alloys e.g. PC/ABS, PC/PBT, PS/ASA characterized by their unique balance of impact strength, heat resistance and high mechanical properties are the right choice for a multitude of applications including automobile, medical equipment, optical, electrical and electronics, home appliances and various other sectors. Polybutylene Terephthalate (PBT) resin with its combination of heat, chemical resistance, and outstanding electrical properties deliver unique design advantages with exceptionally good processability & surface appearance. PBT compounds find application in electrical/electronic connectors, automotive components, telecommunication enclosures & so on. Nylon is the most versatile plastics-easy to process; easy to modify to meet specific needs, environmentally responsible in production. Due to their outstanding properties these materials have become indispensable in almost all fields of engineering for the wide variety of components and machine parts, as high-quality electrical insulating materials and for many special applications. Nylon grades are exceptional for their high mechanical strength, rigidity & thermal stability.
19
Engineered Plastics based on Advanced Plastic Resins includes: POLYCARBONATE COMPOUNDS: These resins are used in manufacturing Head Lamp Reflector, Door Handle, Electrical/Electronic Body Parts. ALLOYS: These resins are used in manufacturing Wheel Cover, Inverter Housing, Cub Panel & Exterior Automotive Body Parts, Exterior Automotive Body Parts, Tail Light Housing. PBT COMPOUNDS: These resins are used in manufacturing Garnish, Louvers, CFL Housing NYLON COMPOUNDS: These resins are used in manufacturing Chain Cover, Heater Cover, Handle Window Regulator, Roof Clip, Radiator Fan, Handle, Ash Tray
20
21
OBJECTIVES OF THE STUDY 1. To know the total polymer consumption in the automobile sector 2. How many injection moulding companies are using polymers for automobile industry in Pune Region? 3. What are the prices at which injection moulding companies are buying raw materials from other manufacturers 4. To know the availability of substitutes and grade of polymers in Pune region 5. To find out the awareness of the product in the market 6. To know the strengths and weaknesses of the companies One more important aspect is transportation related issues: - incidents like chemicals get contaminated during transportation process due to: -
o Delays in transporting o Exposure to air o Leakages in tanks To know various parameters whatever the business rivals of APPl. are following: o Marketing strategy o Pricing policy o Credit policies
22
23
Research Methodology
RESEARCH APPROACH 1) Observation and survey a) In this research report survey method is used. Survey is the method of gathering of primary data by asking the questions to the customers about their usage and requirements. 2) Contact method a) Telephone b) Personal interviews c) E-mails 3) Target respondents Here personal interviews of all the respondents are taken; Proprietors of all injection moulding companies are interviewed personally at their specific place where they are standing RESEARCH DESIGN The research has been done for the market of polymer consumption in automobile sector so the research design for this survey is exploratory research For the presentation and preparation of this report I have covered following things: 1) Study of theory 2) Market research 3) Sample questionnaire 4) Graphical presentation 5) Analysis of data 6) Company visit 7) Internet information, books, magazines
24
25
NAME: DESIGNATION: ORGANISATION: PRODUCT NAME:
Yuvraj Sadashiv Marath Owner PLAST O MECH Exide Container Caps, Bajaj Pulsar Lights, Wireless handsets for Bharat Electronics
OEM: ADDRESS: TEL NO: EMAIL: MOBILE:
Tata Johnson, Exide, Bharat Electronics, Bajaj Auto 55-77/1, MIDC Bhosari 020-27120618 plastomech@bsnl.net 9850062653
ABS+ FILLER
NYLON6
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
AC RY LIC
HD PE
1.5
1.5
25
0% 18% 0% 18% 3% 3% 2% 0%
56%
ABS+ FILLER NYLON6 NYLON66+ FILLER POLYCARBONATE PBT PP + FILLER HI PS PCABS PCPBT GPPS NY+ 30% GF ACRYLIC HDPE
From the above information we come to know that the plastomech company use 56% of polypropylene + filler as compare to other polymers the company use the polymer in manufacturing wireless handsets and Bajaj Pulsar lights
26
NAME: DESIGNATION: ORGANISATION: PRODUCT NAME: OEM: ADDRESS: TEL NO: EMAIL: MOBILE:
Muley A.S. G.M. (Operations) SPS Plastics Pvt. Ltd. Pulsar mud guard, Caliber mud guard Bajaj Auto Sector C, 7/10&11, Ranjangaon, MIDC
9890600382
ABS+ FILLER
NYLON6
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
AC RY LIC
HD PE
10
0.5
4%
0%
16% 0%
80%
From the above information we come to know that SPS plastics use 80% of polypropylene + filler as compare to other polymers. The company is using the polymers in manufacturing the products like mudguards for two wheelers.
27
Ashok G. Chavan Asst. Engg. Sermo PM (I) Ltd. White Goods Bajaj Auto, Honda 5/4, Nagar Road, Pune - 14 020-27013840
9822647158
ABS+ FILLER
NYLON6
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
AC RY LIC
HD PE
20
10
0%
33%
0% 0%
67%
From the above information we come to know that sermo pm uses 67% high impact polystyrene as compare to other polymers. It is engaged in manufacturing white goods.
28
Sandesh Kumar Proprietor Vinayak Polymer Industries Fuel Tank, Brake Fluid Container Kinetic Motors 2, Vighnahar Chambers, Erandawane, Karve Road, Pune - 4 020-25459218 sandk@rediffmail.com 9822192885
ABS+ FILLER
NYLON6
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
AC RY LIC
HD PE
11
13% 0% 13% 0% 0% 0% 74% 0% 0% 0%
From the above information we come to know that vinayak polymers uses 74% of HDPE as compare to other polymers. The company is engaged in manufacturing fuel tanks
29
Nitin Mulay Partner Niky Engineers Intricate Shape Precision Components Bajaj Auto, Piaggio, Mahindra & Mahindra B26&27, Satyam Estate, Erandwane, Pune - 38 020-25467976 nikyengg@vsnl.net 9822063868
ABS+ FILLER
NYLON6
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
AC RY LIC
HD PE
1.5
0.5
10
0% 0% 0% 0% 14% 0% 11% 4% 0% 0% ABS+ FILLER NYLON6 NYLON66+ FILLER POLYCARBONATE PBT PP + FILLER HI PS PCABS PCPBT GPPS NY+ 30% GF ACRYLIC HDPE
71%
From the above information we come to know that niky engineers uses 71% of polypropylene + filler as compare to other polymers. It is engaged in manufacturing intricate shape precision components.
30
Rathi Lalit Director Nitiraj Plastics & Engineering Car Tanks, Reservoir Tanks Maruti Udyog Ltd., Tata Motors Plot No. 41, Sinhgad Road, Manik Baug, Pune 020-243654040 nitiplast@vsnl.net 9371003914
ABS+ FILLER
NYLON6
NYLON66 + FILLER
POLYC ARBON ATE
PB T
PP + FILLE R
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
AC RY LIC
HD PE
2.5
7.5
0.5
29
3% 6% 0% 19%
0%
72%
From the above information we come to know that the company uses 72% of HDPE and is engaged in manufacturing car reservoir tanks
31
M.S.R.CH. Murty Proprietor Apex Engineers Electical Items for two wheelrs Bajaj Auto S. No. 27, Wadgaon Bk., Sinhgad Road, Pune - 51 020-24353307 murtymsp@vsnl.com 9850954087
ABS+ FILLER
NYLON6
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLE R
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
LD PE
HDPE
0.5
0.3
0.65
0% 0% 34% 45%
0% 21%
ABS+ FILLER NYLON6 NYLON66+ FILLER POLYCARBONATE PBT PP + FILLER HI PS PCABS PCPBT GPPS NY+ 30% GF LDPE HDPE
From the above information we come to know that Apex engineers uses 45% of HDPE, 21% of LDPE, 34% nylon 66 + filler. It is manufacturing electrical items for two wheelers.
32
Hemant R. Lasaris Partner Shrimani Industries Tool Box, Fender, Cowling, Fan Cover, Battery containers Bajaj Auto, Exide D-3, Plot No. 59, MIDC, Chinchwad, Pune 020-27472449 shrimanii@eth.net 9422324936 19
ABS+ FILLER
NYLON6
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
AC RY LIC
HD PE
3.5
35
18
5% 30%
6% 0%
0%
59%
From the above information we come to know that shrimani industries uses 59% of polypropylene, 30% of HDPE, 5% of abs + filler and 6% of nylon 6. it is engaged in manufacturing tool box etc.
33
Borate Sadashiv Rambhau MD (Proprietor) Elite Plastic Industries Battery Containers, Electrical Items Exide, Bharat Electricals Sector 65, MIDC, Bhosari, Pune - 26 020-27120619/24113772 elite_plastic@vsnl.net 9822015531
ABS+ FILLER
NYLON6
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
LD PE
NY+ 30% GF
AC RY LIC
HD PE
12
18%
7%
11% 0% 0% 0%
21%
0%
43%
ABS+ FILLER NYLON6 NYLON66+ FILLER POLYCARBONATE PBT PP + FILLER HI PS PCABS PCPBT LDPE NY+ 30% GF ACRYLIC HDPE
From the above information we come to know that ELITE plastic industry uses almost all kind of polymers but it uses more of PP + filler about 42% and rest are all other polymers. It is manufacturing electrical items and battery containers.
34
ABS+ FILLER NYLON6
Nilesh S. Sawant Production Incharge Rantnadeep Enterprises Fuel Filter, Backup Rings Bajaj Auto Talawadi Road, Sahayognagar, Pune - 1 020-251305000000000 plasticprd@vsnl.net
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
LD PE
NY+ 30% GF
AC RY LIC
HD PE
0.7
0.3
0% 0% 23% 33% 0% 0%
0% 10% 0% 34%
From the above information we come to know that Ratnadeep enterprises uses 34 % of EP + filler, 33& HDPE, 23 % of nylon 66 + filler and 10 % of LDPE. It manufactures fuel tanks and backup rings.
35
NAME: DESIGNATION: ORGANISATION: PRODUCT NAME: OEM: Brakes ADDRESS: TEL NO: EMAIL: MOBILE:
R.M. Agrawal CEO Shree Plastics Brake Oil Container Maruti Udyog Ltd., Tata Motors, Mahindra & Mahindra, Kalyani
29/9, D-2 Block, MIDC, Chinchwad, Pune 020-27477285, 56111870
9822294440
ABS+ FILLER
NYLON6
NYLON 66+ FILLER
POLYC ARBON ATE
PB T
PP + FILLER
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
AC RY LIC
HD PE
1.5
0.5
0%
13% 8% 0% 4%
75%
From the above information we come to know that Shree plastics are using 75 % of PP + filler, 13 % of Nylon 6, 8 % of nylon 66 + filler + 4 % of PBT. It is manufacturing brake oil containers
36
Nadeem S. Kazi Commercial Manager Trimurti Plastics Industries Dash Board, Facia for Speedometer, Battery lids and Containers Exide, Minda Instruments 20, D III Block, MIDC, Chinchwad, Pune 020-27470805 trimurtiplastics@rediffmail.com 9422317847 19
ABS+ FILLER
NYLON6
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
AC RY LIC
HD PE
2.5
10
2.5
5%0% 11% 27% 0% 0%
0% 11% 0% 46%
From the above information we come to know that TRIMURTI plastics uses 46 & of pp + filler, 27 % of HDPE, 11% of nylon 66 + filler and 11 % of nylon + 30 % glass fields. It is manufacturing Dashboards etc.
37
Pankaj Kumar Incharge (Quality Control) Prima Paper & Engineering Pvt. Ltd. Cowling, Dash Board Fender Force Motors, TATA Motors, Mahindra & Mahindra, Piaggio T-73, MIDC Bhosari, Pune - 26 020-27129353
9822086496
ABS+ FILLER
NYLON6
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
LD PE
NY+ 30% GF
AC RY LIC
HD PE
20
55
10
20
10
8% 0% 16%
16% 4% 0% 1%
0% 2% 0% 0% 8% 45%
From the above information we come to know that Prima paper is using 45 % of EP + filler, 16% of nylon 6 and 16 % of polycarbonate, 8 % HIPS & HDPE, 4 % of nylon 66 + filler, 2% of LDPE & 1 % PBT. It uses in manufacturing in cowling & dashboard.
38
B.V. Poptani Incharge (Moulding Shop) Tek Component Pvt. Ltd. Automobile connetors Tata Yazaki EL 32/15 J Block, MIDC Bhosari, Pune 020-30680300/19 bhupendra_poptani@tekcomponents.com 9850880352
ABS+ FILLER
NYLON6
NYLON 66+ FILLER
POLYC ARBON ATE
PB T
PP + FILLER
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
AC RY LIC
HD PE
0.5
0.5
5% 0%
0% 18%
27%
5% 9%
36%
From the above information we come to know that Tek is using 36 % of nylon 66 + filler, 27 % of PP + filler, 18 % of Nylon 6,9 % of PC, 5 % of HDPE & ABS + filler. It is manufacturing automobile connectors
39
T.S. Virdi Partner Tej Plastics Autoswitches Minda Industries J 362, MIDC, Bhosari, Pune - 26 020-27120976 tej@pm3.vsnl.net.in 9890006928
ABS+ FILLER
NYLON6
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
LD PE
NY+ 30% GF
AC RY LIC
HD PE
2.5
0.5
0%
40% 50%
0% 0% 10% 0%
From the above information we come to know that TEJ plastics is using 50 % of nylon 6, 40 % 0f HDPE and 10 % of LDPE. It is manufacturing auto switches for two wheelers.
40
Hemant Joshi Purchase Incharge Emdet Engineers Pvt. Ltd. Steering, Bumpers, Shrouds Tata Motors, Mahindra & Mahindra, Larson & Tubro J-146, MIDC, Bhosari, Pune - 26 020-27122004/1528 emdet@p2.vsnl.net.in 9823070075
ABS+ FILLER
NYLON6
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
AC RY LIC
HD PE
41
15
0% 7% 0% 25%
0% 0% 0% 0% 68%
From the above information we come to know that Emdet is using 68 % of PP + filler, 25 % of nylon + 30 % glass fields and 7 % ABS + filler. It is manufacturing bumpers + fillers
41
ABS+ FILLER NYLON6
Ashwin Garg MD Argee Plastics Pvt. Ltd. Battery Handle, Radiator Fan, Radiator Housing Piaggio, Exide MIDC Bhosari, Pune
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
LD PE
NY+ 30% GF
AC RY LIC
HD PE
6.5
16
15
10% 30% 13%
0%
10% 2% 4% 31%
From the above information we come to know that Argee plastics is using 31 % of PP + filler, 30 % of HDPE & 13 % nylon 6 and 10 % of ABS + filler & 6% of other polymers. It is manufacturing battery handles.
42
ABS+ FILLER NYLON6
V. Sugathan Proprietor Jaihind Enterprises Inner and Outer Handles Tata Motors J 132, Opp. Quality Ice Cream, MIDC, Bhosari, Pune - 26
020-27122044 jaihindent@vsnl.com
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
AC RY LIC
HD PE
0.5
7.5
0%
10% 10% 5% 0% 0%
75%
From the above information we come to know that Jaihind industries is using 75 % of PP + filler, 10 % of ABS + filler, 10 % nylon 6 and 5 % nylon 66 + filler. It is manufacturing inner and outer handles for four wheelers and other automobile components
43
ABS+ FILLER NYLON6
Ravindra Bhorpe GM (Operations) Renata Plastics Automotive components Tata Motors J 526, MIDC, Bhosari, Pune - 26
020-27121285 renata@vsnl.com
NYLON66 + FILLER
POLYC ARBON ATE
P B T
PP + FILLER
HI PS
PC AB S
PC PB T
GP PS
NY+ 30% GF
AC RY LIC
HD PE
0.5
0.5
0% 25% 24%
13% 25% 13%
From the above information we come to know that Renata plastics is using 25 % of nylon 6 & PBT, 24 % of ABS + filler and 13 % polycarbonate and nylon 66 + filler.
44
Total Polymer Consumption in Automobile Sector

LDPE ABS + (FILLER) NYLON 6 NYLON 66 POLYCARBONATE PBT PP + (FILLER) H.I.P.S PCABS PCPBT GPPS NYLON + 30% GF ACRYLIC HDPE
6 72.65
26.9 43.5
17 21.5 10 1 1.2 10.5 99.3
21.25 6 6.7
Abs Ny Ny Poly +(fil lon lon carb ler) 6 66 onat e
PBT PP+ Fille r
H. PC PC G I.P A PB PP .S BS T S
26.9 43. 21. 6% % 5% 2%
6.7 %
99.3 %
10. 1.2 1% 10 5% % %
Ny lon +3 0 % G F 21. 5%
Ac ryl ic
H Ny Pol DP lon yca E 66 rbo nat e
17 %
72. 21. 6% 65 25 % %
45
46
CONCLUSION
Actually the main function of the company was to find out the consumption of polymers in automobile sector in pune region so as to find out the potential in the market. From the total polymer consumption chart mentioned earlier we come to the conclusion that polypropylene is used readily in automobile sector because we can enhance its properties by adding filler for example: glass, mica, talc, etc. as per the requirement of the product. Appl produces PP + Filler as per the customer requirements. Polypropylene is used in bumpers, dashboards, fuel tanks etc. Polypropylene is used frequently because:
There is no problem in the availability. Its trends do not vary. It is cheaper then metal. Properties are more or less same as of metals. The weight is lesser then metals which helps in increasing average of the vehicle.
As a student I have got a wonderful opportunity to work with such a good company as from this study I have learnt a lot, I have given the work of research throughout the whole Pune region that what are the steps company should follow in regard with their competitors, that was indeed to be the best phase of my project when the recommendations given by me were accepted and the company is following some steps which they think the most important among all of the suggestions given by me. As well as I am thankful to all my subordinates and my project guide Mr. Arun Sharma, as without their support and ally it was difficult to work or attain something.
47
SUGGESTIONS
After studying all the aspects of the company I have certain suggestions, which are as follows:
The company should increase sales in such areas where it is lacking in sales in other words company have to first take care of its marketing strategy that whether the company is meeting as per the demands of the customers or not because a customer accepts what he expects.
The company should try to reduce the cost of production by way of automation, if this would be taken in consideration then the supply of the company automatically meets the ordered quantity and it saves time too which is very important as money spended on idle time would be saved and cost of production must be low.
Growth opportunities in public transport and commercial sectors o As being a polymer industry a company have a wide scope in public as well as commercial sector because still these transport companies are using metals other then polymer
Material handling o Proper utilization of resources so that there should not be any wastage o Take care of the rejected lot o Transportation issue is the biggest or considered to be the most vital because of the expectation of the consumer V/S the delivery of the product.
Sourcing of materials o Analysis of the market trends as demand changes as per the trend therefore company have to adopt a policy of trend analysis because with the help of this a company can change its standardization of the product which plays a very big or essential role to attract consumers towards their own product.
Proper inputs from customer o A company have to produce as per the specifications lead by the customer what are their actual wants and desires what are the things which they are looking in their purchasing behaviour 48
Market study must be done time to time as to know the behaviourial aspect of the customer and to become aware about their wants and desires
Meetings must be done separately with each and every customer to add some new inputs to the product, this is considered to be the best way to retain a customer for a long time, as customer has become a part of production in this process.
Dealing with customer on several aspects such as o Credit policies o Complaints and customer care issues o Salesmanship (personal interaction with the customer)
Personal visit must be done by a marketing head by presenting seminars on monthly basis and each and every customer must be given a sense of participation so that they can raise their issues regarding anything
49
50
ANNEXURES Our Original Equipment Manufacturers:

MARUTI UDYOG LIMITED
Our Major Customers:
TATA AUTO PLASTICS SYSTEMS LIMITED VARROC ENGINEERING PRIVATE LIMITED VARROC LIGHTING PRIVATE LIMITED BRIGHT BROTHERS LIMITED PARADISE PLASTICS ENTERPRISES LIMITED SUBROS LIMITED SUN VACUUM FORMERS LIMITED
TATA MOTORS LIMITED BAJAJ AUTO LIMITED HONDA MOTORCYCLES INDIA LIMITED HERO HONDA MOTORS LIMITED GAS AUTHORITY INDIA LIMITED PREMIERE INSTRUMENTS AND CONTROLS LIMITED SAMSUNG INDIA ELECTRONICS LIMITED LG ELECTRONICS INDIA PRIVATE LIMITED VDO INDIA LIMITED AMERICAL POWER CONSERVATION COMPANY INDIA LIMITED GODREJ LIMITED PHILIPS INDIA LIMITED
TATA FICOSA LIMITED
LUMAX GROUP OF COMPANIES MOTHERSON GROUP OF COMPANIES THE SUPREME INDUSTRIES LIMITED DYNAMIC INDUSTRIES DURALINE INDIA PRIVATE LIMITED
51
QUESTIONNAIRE NAME:
DESIGNATION:
ORGANISATION:
ADDRESS:
TELEPHONE NO:
FAX NO:
E-MAIL:
1. Nature of your business? 2. Which polymers you use? 3. What are the sources of purchasing raw material? 4. Are you using blends? 5. If you are willing to use it in future? 6. What is your approval base? 7. What is the time framing of testing? 8. Which part of the automobile you mould, for which company and for which model? 9. What is the weight of the part you mould? 10. What are the critical requirements? 11. What are the credit terms? 12. What is the price range? 13. What is your total requirement?
What are your suggestions or comments which u likes to make regarding the service of the product
52
Total Polymer Consumption of Automobile Sector In Pune Region

OTH ER EQUI PME NT MAN UFA CTU RER AB S + (FI LL ER ) PO LY CA RB ON AT E A C R Y L I C
CUST OME R NAM E
PRO DUC T NAM E
L D P E
NY LO N6
NY LO N6 6
PP+ P (FIL B LER T )
H.I.P. S
P C A B S
P C P B T
GP PS
NY LO N+ 30 % GF
HD PE
TOT AL IN (MT)
PLAS TO MEC H
Exide Batter y Caps, Bajaj Pulsor Lights ,Wirel ess Hands et For Bharat Electr onics
Tata Johns on Exide Bharat Electr onics Bajaj Auto
1.5
1.5
25
45
SPS Plastic s Sermo PM Vinay ak Polym er Indust ries White goods Fuel Tank Brake Fluid conain er Intrica te Shape Precis ion Comp onents
Bajaj Auto Bajaj Auto, Honda
10
0.5
12.5
10 + (10)
10
30
Kineti c Motor Bajaj Auto, Piaggi o, Mahin dra & Mahin dra
0.3
0.2
1.5
10
15
Niky Engin eers
1.5
0.5
(10)
14
53
CUST OME R NAM E
PRO DUC T NA ME
OTHE R EQUI PMEN T MAN UFAC TURE R
L D P E
A BS + (F IL L E R)
NY LO N6
NY LO N6 6
PO LY C A RB O N AT E
PB T
PP + (FI LL ER )
H . I PCA . BS P . S
PC PB T
G P P S
N Y L O N + 30 % G F
A C R Y LI C
HDPE
TOT AL IN (MT )
Car Nitiraj Tank Plastics s, and Rese Engineeri rvoir ng Tank s Elect rical Apex Items for Enginee rs two Whe elers Tool Box, Fend Shrim er, ani Cowl industr ing, ies Batte ry Cont ainer
Telco, Maruti Udyog
0.8
0.2
7.3
0.2
0. 5
29
40
Bajaj Auto Ltd.
0.3
0.0 5
0.65
Bajaj Auto, Exide Batteri es
0.5
18 + (3. 5)
28
Elite Plastics
Batte ry Conta iners, Electi cal Items , Headl ights Conta iner
Exid e Batte ries, Bhar at Elect ronic s, Varr oc Light ing, HiTech Plast Bajaj Auto
0.5
1.5
0.5
0.5
10 + (2)
28
Fuel Ratnadeep Filter, Enterp Back rises up Ring
0.5
(0.5)
54
CUS TO MER NA ME
PR OD UC T NA ME
OTH ER EQUI PME NT MAN UFA CTU RER Maruti Udyog , Tata Motor s, Mahin dra & Mahin dra, Kalya ni Brake s
LD PE
AB S + (FI LL ER )
NY LO N6
NY LO N6 6
PO LY CA RB ON AT E
PB T
PP + (FI LL ER )
H.I .P. S
PC AB S
PC PB T
GP PS
NY LO N+ 30 % GF
A C R Y L I C
HD PE
TOT AL IN (MT)
Shree Plasti cs
Brak e Oil Cont aine r
1.5
0.5
12
Trim urti Plasti c Indus tries
Das h Boar d, Faci a For Spee dom eter, Batt ery Lids & cont aine rs
Minda Instru ments, Exide Batteri es
2.2
0.3
10 + (6)
2.5
22
Prim a Paper & Engg . (P) Ltd.
Cow ling, Das h Boar d, Fen der
Force Motor s, Tata Motor s, Mahin dra & Mahin dra, Piaggi o
20
25 + (50 )
10
10
124
Tek Com pone nts (P) Ltd. Tej Plasti cs
Aut omb ile Con nect ors Aut o Swit ches
Tata Yazak i
0.5
0.5
10
Minda Indust ries
0.5
2.5
55
CUS TOM ER NAM E
PRO DUC T NA ME
OTHE R EQUIP MENT MANU FACT URER
L D P E
AB S + (FI LL ER )
NYL ON 6
NY LO N6 6
POL YCA RBO NAT E
PB T
PP + (FI LL ER )
H.I.P .S
PC AB S
P C P B T
N Y L G O P N P +3 S 0 % G F
A C R Y L I C
HD PE
TOT AL IN (MT)
Emde t Engin eers
Steeri ng Whee ls, Bum pers, Shro uds
Tata Motors, Mahind ra & Mahind ra, Larson & Tubro
30
15
49
Arge e Plasti cs
Batte ry Hand les, Radia tor Hous ing, Radia tor Fans Inner and Outer Hand les
Exide Batterie s
0 . 5
5.5
0.5
15
0.5
15
50
Jai Hind Enter prises Renat a Plasti cs
Tata Motors
0.5
5+ (2. 5)
10
0.5
0.5
56
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Total Polymer Consumption in Automobile Sector in Pune Region Appl Industries Pune by Mrinal Khajuria Marketing

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A Project Report On

Total Consumption Of Polymer In Automobile Sector In Pune Region

With Special Reference To APPL. Industries Limited, Pune

Submitted To Vishwakarma Institute Of Management, Pune

Under The Guidance Of Mr. Yuvraj Lahoti (Professor, VIM)

CERTIFICATE OF SUMMER TRAINING COMPLETION

Place: Pune Date:

Director, Vim, pune-37

Prof. Yuvraj lahoti (Marketing)

OBJECTIVES OF THE STUDY

OBSERVATIONS AND FINDINGS

CONCLUSIONS & SUGGESTIONS

Advanced Polypropylene Compounds Engineered Plastics based on Commodity Resins

Advanced Styrenic Compounds Advanced Colour Masterbatches Speciality Additive Masterbatches

APPSTRON APPCOL APPLENE

APPLOY APPET APPLON

Engineered Plastics based on Commodity Resins

Engineered Plastics based on Advanced Plastic Resins

NAME: DESIGNATION: ORGANISATION: PRODUCT NAME:

OEM: ADDRESS: TEL NO: EMAIL: MOBILE:

POLYC ARBON ATE

POLYC ARBON ATE

POLYC ARBON ATE

POLYC ARBON ATE

13% 0% 13% 0% 0% 0% 74% 0% 0% 0%

POLYC ARBON ATE

POLYC ARBON ATE

POLYC ARBON ATE

POLYC ARBON ATE

POLYC ARBON ATE

POLYC ARBON ATE

29/9, D-2 Block, MIDC, Chinchwad, Pune 020-27477285, 56111870

NYLON 66+ FILLER

POLYC ARBON ATE

POLYC ARBON ATE

5%0% 11% 27% 0% 0%

POLYC ARBON ATE

NYLON 66+ FILLER

POLYC ARBON ATE

POLYC ARBON ATE

POLYC ARBON ATE

POLYC ARBON ATE

10% 30% 13%

POLYC ARBON ATE

POLYC ARBON ATE

13% 25% 13%

Total Polymer Consumption in Automobile Sector

17 21.5 10 1 1.2 10.5 99.3

Abs Ny Ny Poly +(fil lon lon carb ler) 6 66 onat e

PBT PP+ Fille r

26.9 43. 21. 6% % 5% 2%

H Ny Pol DP lon yca E 66 rbo nat e

ANNEXURES Our Original Equipment Manufacturers:

Our Major Customers:

TATA FICOSA LIMITED

Total Polymer Consumption of Automobile Sector In Pune Region

CUST OME R NAM E

PRO DUC T NAM E

PP+ P (FIL B LER T )

Tata Johns on Exide Bharat Electr onics Bajaj Auto

Bajaj Auto Bajaj Auto, Honda

Niky Engin eers

CUST OME R NAM E