SHANTI BUSINESS SCHOOL

Operation strategies and related policies at Redisson metals and alloys pvt. Ltd.
Operations Management

SUBMITTED TO:

DATE OF SUBMISSION: 25 February, 2013

th

Prof. Dinesh Thapak

SUBMITTED BY:

FINAL REPORT

2012 14

Rohit Mundra Hitesh Bijlani Manoj Patel

Shanti Business School, Ahmedabad

A REPORT ON Strategies and Policies related to Operation Management At Redison Metals and Alloys Pvt. Ltd.

By : Rohit Mundra Hitesh Bijlani Manoj Patel

A report submitted in partial Fulfilment of the requirements of PGDM Program of

Shanti Business School

Date of Submission: 25/02/2013

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ACKNOWLEDGEMENTS
This project would not have been a success without the guidance and motivation of all our mentors. We are thankful to all the persons behind this project. We would like to express our deep gratitude to Mr. Dinesh Thapak, Professor OPM, Shanti Business School, who acted as a mentor throughout our project for providing us valuable information and guidance. We would also like to extend our thanks to Redisson Metals and Alloys Pvt. Ltd. Operations control department to lend us their Valuable Time and Information.

INTODUCTION OF THE INDUSTRY :

Wire Industry

The wire industry in India is heavily dependent on the automotive, telecommunication and construction industries as the main customers. The rapid growth of these industries in the last few years has led to an annual growth of approximately 25 percent in the wire and cable industry. Though the result in financial crisis year 2008 - 09 was not good, but later the growth has increased steadily. Major players of Gujarat: Bhandari Electricals (1500 tons/month) Shakti Insulation (1200 tons/month) Vidhya Wires (500 tons/month) Major players of Ahmedabad: RMAPL(120 tons/month) Dhara conductors (100 tons/month) Elite Conductors (150-180 tons/month)

DESCRIPTION OF COMPANY IN BRIEF

RMAPL is a manufacturing firm which majorly manufactures winding wires and strips. RMAPL is an ISO 9001:2008 company, certified as a quality management system. Company located at kathwada near Ahmedabad. It is conceived as a private limited firm under the name of Redisson metal & alloys pvt. ltd. Started operations in the year April, 2009, Is one of the companies of kakhani group, which was established in the year 1965. In the liberalized environment, the company is poised to witness a remarkable growth. presently, the company is manufacturing different types of wire and strips.

Quality

& Delivery at Right Time

each & every Time.

As by their quality standards they are having a remarkable growth in the very initial phase of the business.

PRODUCT RANGE
RMAPL are into manufacturing of copper and aluminum wires & strips. 1. 2. 3. 4. 5. 6. 7. 8. Bare Copper Wire. Enamel Copper Wire. Bare Aluminum Wire. Enamel Aluminum Wire. Paper Covered Copper Wire. Paper Covered Aluminum Wire. Paper Covered Copper Strip. Paper Covered Aluminum Strip.

Different Processes of the Operation Management:

(only those are discusses which were present at the firm we visited)

Process Strategy - Hybrid Office (Appendix : 1) - Batch Process (Appendix : 2) - Make to Order Strategy Just In Time Inventory System - Layout (Appendix : 3)

Process Design Process Flow Chart for: a) Insulated Strips b) Insulated Wires c) Insulated Super Enamel Wires Total Quality Management Following steps are followed for Quality Assurance:
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Appendix: 4

1. Raw material inspection & testing 2. In process Checking 3. Finished Product Testing 4. Inspection of Packing & Packed Material

Appendix : 1

Service Process Structuring

Appendix : 2

Process Type

Custom

Broad Demand

Low Volume Job Shop Appliance repair Emergency room Commercial bakery Batch Shop Classroom Lecture Automotive assembly Automatic carwash BAD

High Volume BAD

Repetitive Flow

Continuous Flow

Oil refinery Water purification

Appendix : 3

Rest -Room
R.B.D.
(1)

B. B. R.B.D.
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W.F. M(2).

Raw material section

(1)

Office

Quality Control Area

Enameling machine

Storage and cutting Area for Packaging Aluminium

Covering Machine
(4)

(4) Wastag e collectio n area

(4)

Raw material at the start of the cycle:

Procured from: Veddanta, Hindalco, Balco Size : 9.5mm Copper Procurred from: Hindalco, Sterlite Sizes: 8, 11, 12.5 mm

Wire drawing section Two machines Used: R.B.D.(Rod Break Down): two different machines are placed. Separate one for Copper, as copper being high conductivity. Reduces size of raw material to a minimum size of 1.6 mm or as per the requirement of the customer

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 B.B.( Bull Block) : reduces the size of raw material to a minimum Size of 3 mm. In this process various sizes of Dies are used to drawn different size of wire out of basic raw material. And the number of dies used also depend of the required size of final output

Wire Flattening: Machine used is called wire flattening machine and gives a flattened shape to wire as per the requirement of Customer. A specific formula is used to calculate the required size of input wire which is as follows: ((Length + Breadth)*(0.58))

Or

Wire Enamelling: Machine Used is called wire Enameller. Used for coating both aluminium as well as copper with varnish to provide zero conductivity. Raw material used: Varnish Procured from: Reliance chemicals Cost: 160 Rs/kg

Annealing: A softening process where copper or aluminium wires are softened for durability
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In this process aluminium can be processed without vacuum but care has to be taken while softening of copper. Copper is placed in an air tight container and then vacuum is created inside that container and then softening is done to avoid oxidation of copper on completion.

Packaging: A very important process because it affects the conductivity of the product being sold. Careful measures are taken to provide excellent product. Over here in this section they maintain a dust free environment with 65% humidity continuously maintained via an inflow of air to provide required moisture for the purpose of packaging. Raw material used: Paper for packaging: (electro grade) imported Cost: 150 Rs/kg. Various control processes are continuously been taken care of like quality assurance at every stage and son on.

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Appendix: 4

Process Flow Chart for Insulated Strips ( Aluminium And Copper)

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Process Flow Chart for Insulated Wires ( Aluminium And Copper)

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Process Flow Chart For Insulated Super Enamel Wires( Aluminum and Copper)

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