pom project block 4 sem 2
TRANSCRIPT
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 1
Project Report
ON
“Shah Paper Mills Ltd.”
Under The Guidance Of
Dr. Rana Singh
&
Ashok .Z. Shah
(Executive Director- Shah Paper Mills Ltd.)
PREPARED BY:
Priyanka Thakar (0120114)
MBA (2011-2013)
(BLOCK IV – SEMESTER II)
AURO UNIVERSITY OF HOSPITALITY AND MANAGEMENT STUDIES
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 2
Index
Sr.
No.Table of Contents
Page.
No.
1 General Information of Shah Paper Mills Limited 3
2 Size and Form of the Unit 5
3 Product Planning 6
4 Inventory Planning 7
5 Manufacturing Process 8
5.1 Pulp Making 9
5.2 Conversion of pulp paper 10
5.3 Finishing Operations 10
5.4 Flow Chart/ Sheet 11
5.5 Images of production process 13
6 Products of the company
Production Process Steps Pg no: 24
Samples of the product Pg no: 25
Images of product rolls Pg no: 25
24
7 Laboratory Handling Images of the machines in the laboratory for SPC Pg no:30 29
7.1 Supply Chain Management
Chart of SCM
8 Time Keeping 36
9 Contribution of unit to the Industry
Pollution control
37
10 Conclusion 38
11 Appendix (Viper Report) 39
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 3
1. Introduction
Shah Paper Mills Limited is one of the most renowned mills in Paper and it has achieved an
immense success in Industrial Sector.
SPML was certified in 1990 and it commenced its business in 1992. It started with a capital of
1, 00,000 Rs. And now its Turnover is 150 crores.
Shah Paper Mills Limited produces MG (Machine Glazed) Craft Paper. Earlier Craft Paper were
made up of agricultural products such as, Bagas, Rice Straw, Wheat Straw. But production
through these raw materials is very Hazardous to environment also availability of the same is not
in ample amount, on the other hand if paper is produced by such raw material the Production
Cost increases and thus it affects the MRP of the product.
Hence, Shah Paper Mills Ltd has developed new way of producing it, i.e. production with the
help of just one raw material i.e. “WASTE PAPER”.
Waste paper is recycled here, and all the impurities such as Sand, Pins, Plastic, etc. is removed
and from that purified waste paper M.G Craft Paper is made.
Shah Paper Mills Limited is an ecofriendly plant as waste paper is its Raw Material.
Uses of waste paper are as under:- In making
1. Corrugated Boxes.
2. Paper Tube.
3. P.O.Y Tube.
4. Fiber Drum. And
5. Gum Tape.
Major users of this Product are
1. Yarn Industry (Textile)
2. Chemical Industry
3. Consumer Products
Major companies with whom SPML deals are:
1. HUL.
2. Reliance.
3. ITW.
4. Marico Industries Ltd (Manufacturers of Parachute oil).
5. PepsiCo India.
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 4
SPML is also ISO certified. ISO 9001:2008.
Scope of Registration: Manufacturing and Supply of Papers.
Certificate No: 91/Q/5372.
Original Registration: 8th June 2009.
Certificate Expiry date: 7th June 2012.
Some of the General Information of the company is:
1. Incorporation: 1990.
2. Year of Production 1992.
3. Plant: Vapi District, Gujarat.4. General Products: MG Craft Paper.
5. Location of the Unit: Plot No: 5202, III Phase, GIDC Vapi, Tal. Pardi District, Valsad.
Key Executives of Shah Paper Mills Limited
Mr. Mahendra H. Shah
Executive Director
Mr. Girish S. Shetty
Executive Director
Mr. Ashok Z. Shah
Executive Director
Mr. Bhupendra D. Patel
Executive Director
Mrs. Meher C. DeSouza
Company Secretary
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 5
2. Size and Form of the Unit
SPML is a company incorporated under the Indian Companies Act, 1956 and working since last
20 years.
The Firm consists of approximately 405 employees working in the unit (Vapi).
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 6
3. Product Planning
Shah Paper Mills Ltd are manufacturing Machine Glazed (MG) craft paper which is a basic raw
material for manufacturing corrugated boxes, paper tube, fiber drum, gum tape.
The major users of these products are,
Yarn Industry.
Chemical Industry.
Consumer Products.
These products are planned in various sizes and qualities such as 16BF, 18BF, 20BF, 22BF,
24BF, and 28BF (BF Burst Factor) in yellow and green color.
There are two types of machines in SPML which is very important tool in product planning, as
orders exceeding to machines capacity are not undertaken.
Machine Specification:
1. 90 inch and
2. 120 inch
Product is made order wise, hence the CEO takes the orders from the firms in advance, commit
them a delivery date and next day production begins as per schedule given by the CEO.
Priority basis of Bursting Factor and GSM are,
1. Lower to higher Bursting Factor.
&
2. Higher to lower Bursting Factor.
If there are more orders for coming delivery date related to first priority all the machines are
operated on the same, that day second priority orders are not undertaken.
Raw Material is also very important factor in product planning. The basic material is “Waste
Paper” .There is two types of raw materials, Indian and Imported. If order of product is of rich
quality then machine is loaded with 80% Imported material and 20% Indian material.
If the orders are normal, but the client company is producing heavy goods like refrigerators, AC,
T.V, then machine is loaded with 50% of Indian & 50% of Exported material.
Henceforth, Prices also varies according to the order and type of waste paper used to make the
same. If order of Party (client company is urgent then current machine roll is offered to
them. This is how product planning is done; it is completely dependent on customer orders
and the intensity of urgency.
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 7
4. Inventory Planning
Inventory Planning is done in such a way that inventory is bought in the Godown which is
consumed within ½ month. Hence monthly planning is done, till the time present inventory is
utilized; next lot is on the way.
This is how unnecessary storage of inventory and blocking of funds is avoided. Since production
is based on orders of the client company is not able to maintain Just in Time (JIT).
Furthermore, when the inventory/ raw material enter the premises of the company be it
imported material or regular Indian waste paper, they have a policy, where in it is
compulsory for every departmental head to come at the godown and check the quality and
quantity of raw material. When managers give approval only the payment is made to the
vendor
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 8
5. Manufacturing Process
A brief note regarding the manufacturing process converging production , utility& service
department of the product:-
Manufacturing of company is broadly divided into:-
1) Pulp making from waste paper (basic raw materials)
2) Paper making
3) Finishing and packaging
The company is in the manufacturing of mg kraft paper by recycling of the waste paper. The
basic raw materials, which are:-
1) Imported waste paper
2) Indigenous waste paper
3) Chemical used in the process
4) Starch powder, gaur gum power - to increase strength of the paper.
5) Alum, rosin- to maintain water absorbency (COBB).
6) BF deformer- to kill the foam generated in the process.
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 9
5.1 Pulp making from waste paper
Pulp making is the first process in the manufacturing of craft paper. Pulp is made up of the basic
raw materials i.e. recycled waste paper. The waste paper of different quality is fed into high
consistency pulper in the required proportion depending on the quality of the kraft paper to be
manufactured. The waste paper is put on the conveyor belt, which takes the material to the HC
pulper the waste paper is mixed with the black water (effluent treated water) under vigorous
stirring process in the pulper by high consistency operating rotor. After achieving 16 percent of
the consistency of pulper in the HC pulper, It is then fed to the pour unit, the pulp is then further
treated with black water to bring the consistency of the pulp to 2 percent also with the help of
perforate screen plate and rotor impurities like wooden pieces, plastics of big sizes and other
foreign materials is drained out through drain valve automatically with the help of pneumatically
operated valve. The semi cleaned pulp containing little bits of plastic and sand is then pumpedinto the dump with the help of pour pump where this pulp is stored. The semi cleaned pulp is fed
to HD cleaners and turbo separators to remove the finer impurities like sand and small bits of
plastic.
The impure pulp is then sent to cleaning system consisting of HD cleaners and turbo separators
where the foreign particles such as plastics, twine sand, grit, removed from the pulp. Then the
pulp is thickened to desired concentration with the help of thickener. This pulp is treated into
refiners to attain properties into final paper.
Pulp is sent to section known as stock preparation section. The pulp is suitably treated in to two
operations as required for the particulars grade of paper tube made from it.
Firstly beating operation gives the required strength to the paper and
Secondly, chemical treatment to give desirable characteristics such as smoothness
brightness strength. The pulp after beating and mixing with chemical is ready for paper
making known as stock.
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 10
5.2 Conversion of Pulp Paper
The ready pulp is then send to paper machine and where the pulp flows in a highly water diluted
form on to an endless web of woven wire cloth. The wire cloth removes the bulk quantity of
water from the stuff by suction and pressure. Then the wet paper sheet is pressed in press sectionto remove excess water. When the paper sheet comes out of the press, it is passed through the
Rotary cylinders, known as dryers. Therefore, the sheet passes through MG cylinder which gives
glaze to one side of the paper. Then the sheet is passed through post dryer section to dry the
paper to attain required moisture.
5.3 Finishing Operations
The paper sheet formed as above is Fecon calendaring machine for more thickness. The paper
sheet is then wound up to jumbo rolls on Pop Reel. The jumbo rolls are placed in rewinder
machine to bring the paper in the form of reels as per specification of customers. These reelsare packed and dispatched to customer in reel form.
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 11
Conveyor Belt
Pulper
Pump
Chest
Pump
H.D Cleaner Vibrating Screen
Turbo T-500 Turbo T- 400
Thickener
Chest
Pump Rousing Tank Alum Tank
Magnetic Trap
Pump Pump
Refiner
Chest Mixing Chest
5.4 Flow Sheet
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 12
Pump
Machine chest
Pump
Refiner
Regulating Box
Fan Pump
Cleaner
Head Box
Wire Part
Press I
Press II
Pre- Dryer
M.G
After Dryer
Pop Reel
Rewinder
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 13
Step wise Images of entire production process of Shah Paper MillsLimited.
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 14
Step 1: Raw Material
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 15
Step 2: Processing Raw Material
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 16
Ste 3: Removin Im urities from Raw Material
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 17
Step 3: Continued
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 18
Step 3: Continued
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 19
Step 4: Generating machine
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 20
Step 5: Actual production with the pulp
Step 6: Water supply
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 21
Step 7: To shape the product with the help of water.
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 22
Step 7: Continue…..These are Rollers to shape the product
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 23
Step 8: Actual moisture less product
Step 9: Formation of Mother roll.
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 24
6. Products
SPML Produces MG Kraft paper which is produced in different sizes as detailed under:
BF( Bursting Factor) GSM(Grams Per Square Meter) Nature
16 120-150 Natural Shade
18 120-180 Natural Shade
20 120-180 Natural Shade
22 120-200 Natural Shade
24 120-200 Natural Shade
28 120-200 Golden Yellow
28 201-250 Golden Yellow
Production Process is conducted by following steps:
Client Orders
Directors
(Here director fixes price, quality and quantity of product as per order of the customer, delivery
date is also decided at this stage)
Programmer
(Enters Transaction in records)
Production Site
Dispatch
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 25
Samples of Shah Paper Mills Products and Images of Final Product in the
Mill
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 26
Mother Roll
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Manufacturers of KRAFT PAPER & BOARD Page 27
Three sizes offered by SPML from Mother Roll
Products in the odown
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 28
Transportation of the product
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 29
7. Laboratory Handling/ Quality Control
When the product is ready, it is tested in laboratory to see whether product is made exactly
according to customer order or not. Laboratory handling is done by Mr. PM Patel.
There are many types of machines that are used to check the quality of the product, so as to
maintain the quality of the product.
Explanation of various machines:
1. Crush Tester: To check the thickness of the product.
2. Tear Tester: Here the product is place on the machine, and it is torn on it and then on the
basis of Time taken to tear the product calculations is done. GSM is calculated in this stage.
There are different specifications for different types of the product.
3. Cob Testing: In this stage cob is adjusted as per customer requirement, the reading of this
machine helps in determining water absorbency of the product.
4. Oven: To Check the moisture of the product.
5. Brushing strength Machine: After calculating GSM with the help of tear tester BF (Bursting
Factor) is read. Exact checking is done whether it is as per customer’s specifications or not on
this stage.
This is how product is tested before dispatch.
However, if in case any deviations are found in all the stages of testing, then Customer is
informed about the deviations, and if he permits to dispatch the lot then order is dispatch with
some Discount. And if the Customer denies accepting a little deviated product then the whole lot
is sent back to the First stage of production, or that inferior quality product is given to
whomsoever it is useful.
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 30
Images of the Laboratory, and all the machines with the help of which SPC is
carried out at Shah Paper Mills.
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Manufacturers of KRAFT PAPER & BOARD Page 31
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 37
7.1 Supply Chain Management
Supply chain management of Shah Paper Mills is very well managed. There are several
companies which require Kraft paper, and Mills for Kraft paper are very few, they have
oligopoly system, in which they decided that Mills will supply their products only to the Agents,then it is the job of the agent to distribute the orders to the client’s Company, thus entire
transport is in hands of the agents.
In this process the Paper Mills have to handle only few agents, (where agents compile the orders
and order sizes, and then ask the paper mill to produce the same
Process of SCM
Agents take the order from various clients.
They communicate with director of the mill regarding order acceptance, date of delivery,
and pricing.
Production process is carried out.
Once product passes through laboratory/ quality check, it is transported to the Agent.
Agent arranges for trucks & truck drivers which is again totally outsourced.
Goods are loaded in the trucks/ tempo and delivered to the customer or Client Company.
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 38
8. Time Keeping Department
Time keeping department plays a very important role in every business.
Absence of time keeping department, is uncompensated. This department helps in maintaining
regularity of an employee which is very important to increase effectiveness and efficiency of the
organization.
It helps in utilizing human resources fully as to avoid wastage and this result in enrichment the
goal of the company.
In shah mills ltd time keeping is handled by H R department itself by the H R manager Anil
Koli. Strict policy is adopted by the manager so as to maintain discipline in the organization.
In shah mills, employee’s working hours are up to 8 hours a day.
On a day there are three shifts all of 8 hours. Shifts are bifurcated as:-
Shift 1:- 7am to 3pm
Shift 2:- 3pm to 11 pm
Shift 3:- 11pm to 7am
In shah mills time keeping is handled as follows:-
1. Reporting:-
Reporting is done by security at the gate through punch card system (online). Reporting time is
as per shift
2. Late entry:-
Is the employ is late , 10 mins flexibility is available . i.e. is the employee is late for 10 mins
he/she is allowed to enter. After this no employ is allowed to enter even if there is a genuine
reason. In this case the employee have to contact Anil Koli , the manager and if he feels the
reason genuine , only then he can order the gate keeper to give him entry else he is marked as
absent for the day and affects his salary .
3. Punch card system:-
When an employee is allotting for his card to be punched by the gate keeper he is recognized by
the camera which is connected to the HR manager office computer, so managers can know who
entered at what time. This avoids in accidents such as theft and maladjustment etc. This is how
strict time policy is handled by shah paper mills to maintain discipline and avoid conflicts in the
organization.
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Shah Paper Mills Limited 2012
Manufacturers of KRAFT PAPER & BOARD Page 39
9. Contribution of unit to the industry
Shah paper mills have made largest contribution to industry as it is an ecofriendly plant.
A shah paper mill produces paper but not with the help of trees and agricultural residual, it
manufactures its products with the help of waste paper.
In the process of manufacturing water plays a very significant role, it is used in excess, thus to
save water, shah paper mills have recycling technology in the plant itself. So water can be used
again.
This way SPML satisfy its customer by making excellent paper and on time delivery, but not at
the cost of environment deterioration.
Pollution Control
Water can be recycled only up to certain limit, when it becomes impossible to use the same again
then that dirty water is sent to Vapi Waste Control & Management Company. This company
has their own Common Effluent Treatment Plant (CEPT). Here dirty water is sent, for which
SPML have to pay accordingly, which means they have outsourced the pollution control
technique.
SPML has also taken permission from GPCB i.e. (Gujarat pollution control board) for
production purpose and this consent is renewed every 5 years as per the consent of the Company.
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Shah Paper Mills Limited 2012 10. Conclusion
Shah Paper Mills is considered as one of the renowned unit in paper industries. On my visit I was
satisfied with all the information provided regarding the operations of the unit, I had least
knowledge about the unit and now after completion of this project I have learnt a lot.
The company is well versed and is attaining huge turnovers. Furthermore, in this cut throat
competitive world this unit is gaining an overall success, not only in India but also overseas.
Hence according to my view this company is developed in all the aspects and has a great future,
and I am very glad knowing about the industry as a whole via this project.