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Apollo Tyres is one of the largest tyre manufacturing companies in India. The company was incorporated industry. The company can be traced back to the 70’s when hard-nosed MNC’s and Indian tyre major dominated the tyre industry. Apollo set up its very first manufacturing unit in Perambra, Kerala in 1977, with a very huge production capacity of 185 tonnes. It was in 1982, that Apollo formulated and put into action a series of pragmatic project generating policies that led towards a turn around. A dynamic new management team under the leadership of Vice-Chairman and MD, Mr. Onkar S Kanwar took over the helm of the company affairs. Objectives were redefined and service aggressive market penetration and expense containment became order of the day. Apollo Tyres Ltd. is the leading Indian tyre manufacturing with annual revenues of over US $ 1 billion. In fact it is the first Indian tyre company to reach this milestone. In 2006, Apollo acquired Dunlop Tyres of South Africa. The company has its operations in India, South Africa and Zimbabwe with a network of over 4,000 dealerships in India alone. Sometime in January, the company also announced its plans to start its operations in Hungary. My project at Apollo tyres ltd. Perambra in Thrissur is a humble effort to understand and comprehend its organization. The project is intended to access and to acquire the knowledge regarding the functional as well as the management aspect of the firm. in 1972 and commenced its production in 1977. It was the first company to receive ISO9001 accreditation in Indian tyre

The organization study is to familiarize ourselves with the working of various departments for a particular period, so that one can have an exposure to the practical side. The objectives include: 1. To understand the organizational structure of Apollo tyres 2. To understand the various key functional areas of the company Page 2


3. To get an idea about existing business operations at Apollo tyres 4. To interact with managers at various levels of the organization hierarchy 5. To analyze the practical aspect in relation to the theoretical aspect of the organization 6. To gain a clear picture about the challenges and activities faced by the organization 7. To observe the work culture existing in the organization 8. To identify the strength and weakness of the organization 9. To analyse competition within the industry.

Apollo Tyres, Perambra has all those function areas such as production, finance, personal, and marketing etc. The study is focused on the functioning of each department of the organization giving emphasis to their working.

To conduct the study, different methodologies have been adopted. The study was undertaken by visiting the plant. Both Primary and Secondary data are used.

DATA COLLECTION 1. Primary Sources
o Direct interview with the department heads o Discussion with the divisional heads o Interaction with workers in the company o Data collected by observing the function of the organization

2. Secondary Sources
• • • • Annual reports of the company Department manuals Periodicals, books, etc. published materials by the company Internet websites (,

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Banks of the company. GOODYEAR INDIA Chapter 4 Organisational Structure – Organisational chart Chapter 5 Analysis of functional departments Chapter 6 SWOT Analysis – Company’s Strength. APOLLO TYRES. Methodology. Passenger car radials. CEAT. Light commercial vehicles. corporate social responsibility. Weakness. Company’s Mission. Limitation of the study. Chapter 7 Porter’s five force in Apollo Chapter 8 Findings. JK industries. chapterisation Chapter 2 Industry Profile – History of tyre industry – World scenario. History of company. conclusion & suggestions Page 4 . Scope of the study. State Scenario. Product Profile – Truck. Achievements. Market Profile – MRF. Objectives of company.APOLLO TYRES LTD LIMITATIONS OF THE STUDY • • The time period available for the study was limited The study was conducted only during the day shift and hence the working conditions of those employees working during the evening and night shifts could not be examined CHAPTERISATION Chapter 1 Introduction – Objectives. Company’s vision. Indian Scenario. Global position of Apollo Tyres. Farm. Opportunities & Threats are explained. Chapter 3 Company Profile – Organisational goal. Sources of data.


WORLD RUBBER & TYRE FORECASTS FOR 2011 & 2016 The world tyre industry is worth around US $ 70 billion. Therefore. Countries like the US. It consumes 3 lakh tones of natural rubber annually to produce 68 different types of tyres. following more than a decade of strong growth in motor vehicle production and industrial goods manufacturing. which is heavier than air to prevent inflation loss. The global demand is to rise 4% annually through 2011. the automobile industry is the single largest consumer of natural rubber in the form of auto tyres and tubes certain other parts and accessories.0 percent annually to 26. The industry is marked by the presence of around half a dozen major players who together occupy to 70% of the world market share. Italy’s Pirelli SpA consumes 120000 tonnes of natural rubber in the production of tyres. China and Japan dominate global rubber consumption. collectively accounting for more than half of the market in 2011. as well as a strong global economy.APOLLO TYRES LTD WORLD SCENARIO Worldwide. Gains will directly benefit from solid growth in world motor vehicle production. The engineers forecast that tomorrow’s tyres will have possibly have inflation with gases. the world price of rubber goes through a cycle o few years of busts with the state of world economy. Economic recession anywhere first hits this industry before any other industry. The country overtook Japan as the second largest rubber market in the late 1990’s and by 2001 had Page 6 . The advent of computer has revolutionized the tyre technology and tyre industry. China has become the leading consumer of rubber worldwide. For instance. The tyre industry was grown to one of the largest industries in the world. World rubber consumption is forecast to increase 4. Japan’s Bridgestone Corporation is the world’s third largest producer of tyres.5 million metric tonnes in 2011. and will continue to do so.

4 19.6 7. West European and Japanese markets will all see gains below the global average. MARKET SHARE OF VARIOUS COMPANIES COMPANY Michelin Bridgestone Goodyear Continental Sumitomo Pirelli Yokohama Kumho Others MARKET SHARE (%) 19. Page 7 .1 4. CEAT. Goodyear Tyres and Premier Tyres. the US and Japan will remain leading markets worldwide.7 23.9 3. excluding Japan. though still solid. which will benefit from strong economic growth and rising motor vehicle production. The first generation industries viz.9 3. though the double digit annual gains that characterized China’s rubber market from 2001 to 2006 are forecast to slow significantly as its domestic market matures and motor vehicle production decelerates. Above average gains also are forecast for most of the Asia/Pacific region.5 1. While China will continue to extend that lead.The second generation companies came up in 60’s are MRF Tyres. because of their extensive motor vehicle and tyre industries.1) The tyre industries were classified under three heads.5 (Table No : 2. Each of these regions will suffer from a weak outlook for the regional motor vehicle industry and competition from nations with lower labour or raw material costs. belts and gaskets. Dunlop and Firestone (new Bombay Tyre International Ltd) were set up in the last 30’s and early 40’s. the large North American.APOLLO TYRES LTD essentially caught up with the US as the world’s leading consumer. offsetting slower. The strongest gains are forecast for China. Among the major developed regions. growth for tyre rubber.4 16. In addition the growing tyre industries in these nations will support demand for rubber. The Chinese market will be sustained primarily by expanding demand for industrial rubber products such as hoses.

Indian tyre industry comprises 12 major companies. MARKET SHARE OF LEADING TYRE COMPANIES COMPANY MRF JK Tyres Apollo CEAT Dunlop Goodyear Others Tyres are basically two types: • • Cross ply Radial MARKET SHARE (%) 21.2 14. Apollo Tyres and Modi Rubber. India is still in the in the cross play age when developed countries are into radial and tubeless tyres. Vikrant Tyres.0 (Table No 2. There are threats from global players who enjoy Page 8 . There are top players in this field having 69% of market share. Ever since the first Indian company Dunlop Rubber Company was incorporated in 1926 the tyre industry is growing rapidly and today its turnover is 100000 million and earning an income of Rs. Analysis by Experts reveals that the ratio of natural rubber usage to synthetic rubber is 80:20 in Indian tyre and 30:70 in worldwide. In radial tyres. They are long lasting and have lower incidence of flats. The tyre industry in India is predominantly dependent on natural rubber as against synthetic rubber. nylon. 1000 crore per annum for exports. such as small tyres.2 17.1 16. Indian tyre industry even though in its infant stage has been striving hard to establish itself in the global market. tubes and flaps. fibre glass or steel cords are arranged perpendicular to the circumstances.APOLLO TYRES LTD The third generation companies that were set up in 70’s are JK Tyres. polyester. 13 minor ones and 34 minor plants manufacturing low technology products. Radial technology is an improvement over cross ply and radial tyres are priced at (of 25-30%) premium. nylon or rayon tyre cords are arranged diagonally across.5 7. In domestic industry market demand for cross ply tyre is more because of rough conditions and also it is cheaper than radial.0 6.2) In cross ply tyres. The industry had a growth rate of 11% over last decade.0 18.

which has to adopt itself to a highly volatile environment. in the Indian industry commercial vehicle tyres take the lead and account for approximately 70% of the industry’s turnover. prevailing interest rates and financing options.. and CEAT Ltd. MRF Ltd. with a focus only on one or two categories of tyres. Hence. tubes and flaps primarily for the replacement market. These companies have a presence in all the major segments of the tyre industry – the replacement market. Led by replacement market growth of over 10%. Although the automotive sector in India saw negative growth in the medium and heavy commercial vehicle segments. As a result. industrial production. The Indian tyre industry is mainly dominated by the organized sector and consists of four major players who together account for approximately 85% of the industry’s turnover –Apollo Tyres Ltd. growth in vehicle demand and secondary factors like infrastructural development. The tyre industry is Page 9 . Unlike the international tyre industry where passenger car radials dominate the market. For the last 10 years. some in the unorganized sector and mostly smaller in size. The fortune of the tyre industry depends on the agricultural and industrial performance of the economy. this downward trend was in contrast to the strong demand witnessed by the tyre industry. Transportation industry has experienced 10% growth rate year after year with an absolute level of 870 billion ton freight. offer the consumer a well diversified product mix. this is a very sensitive industry. Original Equipment Manufacturers (OEMs) as well as exports and consequently. overall GDP growth. the tyre industry registered a high single digit growth. the growth of the entire tyre industry depends on primary factors like agricultural growth. road accounts for over 85% of all freight movement in India. Transportation industry and tyre industry go hand in hand as the two are independent.2 million km. There are many other companies. the Indian tyre industry has grown rapidly. JK Tyre & Industries Ltd. Since then. MRF followed suit in 1946.APOLLO TYRES LTD substantial economies of scale dominant market. Apollo Tyres has maintained its leadership position in the commercial vehicle tyres segment. INDIAN SCENARIO The origin of the Indian Tyre Industry dates back to 1926 when Dunlop Rubber Limited set up the first tyre company in West Bengal. With an extensive road network of 3. The transportation needs tyres and vehicles.

The comparatively stable raw material prices in the first half of FY 2007-08.linked raw material basket. This was after tour consecutive years of raw material cost-push.APOLLO TYRES LTD highly raw material intensive and a major consumer of rubber. margins are once again under pressure. As a result. both for natural rubber and crude oil. coupled with price increases undertaken by the industry in FY 2006-07. With raw material costs accounting for 70 % of the cost of production. Salient features of Indian tyre industry • • • • • • • Adaptability and absorption Exports Innovation Indigenous and ready availability Technology progression Wide product range for diverse use Self sufficiency and vibrant marketing setup INDIAN TYRE INDUSTRY HIGHLIGHTS • • The Indian tyre industry is a 9000 crore industry The fortune of this industry depends on agricultural and industrial performance of the economy. in Indian tyres the ratio of natural rubber to synthetic rubber is 30:70. even while the demand-supply situation continues to be in favour of the industry. DEMAND AND SUPPLY FACTORS Page 10 . resulted in all the major players reporting improved operating profit margins. the unorganized sector holds away in the bicycle tyres The ratio of natural rubber content to synthetic rubber content is 80:20. the transportation needs and the production of vehicles • • The tyre industry is mainly dominated by the organized sector. any change in the price of rubber or the crude basket has a direct impact on the cost of production. The second half of FY 2007-08 again saw an upward trend for all major raw material prices and the same is anticipated for the year ahead.

is the leading Indian tyre manufacturer. Apollo holds the fifth position with 10% of the market shares in Kerala.” has been a pioneer in the implementation of “Six Sigma” among all the tyre companies in India. two in South Africa and two in Zimbabwe. Good Year follow JK with 17 and 12% respectively. of which 190 are Dunlop Accredited Dealers. In 2006 the company acquired Dunlop Tyres International of South Africa. It was founded in 1975. CEAT. This is followed by JK with 24% of the Kerala state shares. In early 2008. it has over 900 dealerships. the company announced plans to open a manufacturing plant in Hungary.2 billion (2007-08). services and stock points  19 state offices  4000 + business partners  2100 + Apollo tyre world  190 + Apollo Radial world  160 + Tubeless service points  60 + Apollo Paragati Kendras STATE SCENARIO Apollo had secured Fifth place in the state of Kerala. Apollo Tyres Ltd. In the state of Kerala MRF has secured the first position with 30% o the market shares under its control. and is in the list of top 15 manufacturers of the world in terms of Revenues. The company now has four manufacturing units in India.APOLLO TYRES LTD The drivers of demand in the Tyre industry are    Industrial and freight activities Personal purchasing power Economic activity APOLLO (in the Indian scenario) Apollo Tyres Ltd. In South Africa.  120 sales. of which over 2500 are exclusive outlets. with annual revenues of over US$ 1. Its first plant was commissioned in Perambra in Kerala state. It has a network of over 4000 dealerships in India. Page 11 .


Mathew T Marattukalam. It is one of the flagships companies of Raunaq group. Company began to earn profits and accumulated losses of 26 crores were wiped out within a short span of time. owned by Raunaq group of industries plays an important role in the world tyre industry. Their second plant was installed at Limda village at Baroda in Gujarat. Jacob Thomas and his associates. Page 13 . quality and objectives were re-defined when Mr. nor can you stop the people behind it’. At the starting time the production capacity was 54 tonnes per day. This is the most modern plant. The emphasis is given on growth. HISTORY OF THE COMPANY Named after the Greek Sun God. The products include tyres. Raunaq Singh and associates in 1974. S Kanwar took over the company’s affairs. tubes and flaps for all kinds of vehicles. “PEOPLE DELIVER INNOVATION INNOVATIONS DELIVER SUCCESS A FEW OF THE DIFFERENCES OUR PEOPLE MADE” The history of the company dates back to the early 70’s. The company was taken over by Dr. After three decades of consisted growth. The R&D centre is also functioning at this location.5 lakh tyre per annum. today it is the premier tyre manufacturing company of India. the company Apollo Tyres has created a niche for itself in the Indian tyre market. Apollo. The main marketing activities are concentrated in New Delhi and 2400 exclusive dealers for Apollo cover the entire area of India.APOLLO TYRES LTD ORGANIZATION GOAL ‘You can’t stop the power of thought. The capacity utilization was only 40 to 50 percentages. During 1977 to 1981 the company was under a heavy loss. In 1972. Total area covered was 97 acres which was bought from the people who stayed there at a cheaper rate. Onkar. The head office of the company is at New Delhi and the registered office is at Cochin. which started production 1991 having capacity of 6. The plant is situated at Perambra 50kms north of Cochin. license was obtained by Mr. The Apollo Tyres Ltd.

In truck tyres it has more than 30 percentage market share.500 SQ.1) APOLLO TYRES OUTLOOK Business Activity: Manufacturers and sale of tyres Allied Businesses: Tread rubber for commercial vehicle tyres and distribution of alloy wheels for passenger cars. AcelereWheelz: Premium alloy wheels. Passenger & ADV Tyres (Table no 3. dedicated retreading plant which is launched in May 2007. it was a sick unit. Rear Tractor. APOLLO TYRES PERAMBRA YEAR OF INCEPTION LAND AREA BUILDING AREA PRESENT CAPACITY PRODUCT RANGE 1976 97 ACRES 69.MTS 300 MT/DAY Truck. Page 14 . The brand XT7 became the largest selling truck tyre in the country. Apollo Dura Treads: India’s best pre-cured tread rubber. The entire requirement of tubes for all plants of Apollo is done from here. The fourth plant was commissioned in 1996 at Pune for manufacturing tubes. Apollo Dura Tyre: India’s first branded re-treaded tyre. first from a tyre company in India. Farm Radial. LCV. While taking over this plant. After the take over Apollo spent a large amount in modernizing the plant and now it is a profit earning unit.APOLLO TYRES LTD The third plant at Kalamassery was taken over by Apollo Tyres from Premier Tyres. The vision of the company is to be a leader in the Indian tyre industry and a significant global player.

Passenger Car Radial. Off. 7 Institutional Areas.Ply. No. of employees: 10000+ Corporate Headquarters: Apollo House. Earthmover Industrial Overall Capacity: 314000 tonnes/ year Key Brands: Apollo. Financial Year: April 1 to March 31 India Net Sales Turnover FY 2005-06: Rs. Farm Radial and Cross. Master Steel. Shanmugham Road. Regal Tyres Other Brands Manufactured: Novex. Sector 32. KwaZulu Natal. Two (South Africa). Phone: +91. Dunlop. APOLLO TYRES LTD-PERAMBRA PLANT IN FOCUS • • • • • • • • ATL Perambra Unit is the mother plant of Apollo family It is the single largest truck tyre plant in India Fastest growing plant in Apollo Family 7th fastest growing tyre company in the world First tyre company to obtain ISO 9001 certification Present production capacity of 307 MT/ day It has nearly 2700 employees Four different trade unions Page 15 . One (Zimbabwe) Product Range: Truck. Bus.2 billion or US$ 332 million. Light Truck Radial and Cross. Gurgaon. South Africa CY 2005: Rand 1339 million or US$ 210 million. and Velocity. Cherupushpam Building. Cochin. South Africa The Registered Office: 6th Floor. India. India Tyres. Rs 15. 26.3) or US$ 503 million (495). Durban 4001.Ply. Kerala 682031. Kaizen. India.484-2381902.APOLLO TYRES LTD South Africa: Distribution of Cooper Tyres and steel wheels for commercial vehicles.124-2383021/ 17 South Africa Office: 265 Sydney Road. Rand 792 million or US$ 117 million. Milestone.3 billion (22. 2381903 Manufacturing Facilities: Three (India). Phone: +91-124-2383002 to 10.The –Road. Fax: +91. TYfoon. Haryana122001.

Indian passenger car radial tyres have also been gaining acceptance in the developed markets. Indore. Africa. Pune Bangalore. Apollo tyres recently acquired Dunlop tyres South Africa and started its operation over there. Ichapuram.Jaipur. In recent years. Jaipur & Mumbai Redistribution centre : Baroda. Kolkata. The key export markets include South America. Delhi. exports have been a growth area for Apollo Tyres. Cochin (2).APOLLO TYRES LTD Growth of the Organization Apollo Tyres Ltd. Coimbatore. Head Quarter Plants Zonal Offices : : : Gurgaon Baroda. light truck bias and passenger car radial. Guahati and Patna. have 4 manufacturing plants in India is having a market all over the country. Middle East and South East Asia. the large and growing domestic market has meant that the export portfolio has always contributed a smaller portion of revenues. This is more so given that realizations are better in the domestic market. Products exported primarily include truck bias.Hubs in Kolkotha. However. India is leveraging its cost competitiveness to emerge as a major player in the segment of industrial tyres. even though it comprises only 8% of overall revenue. Inroads are now being made into Europe and Australia with high performance passenger car radial tyres. Delhi. DREAM OF APOLLO To become a 9000 crore company by the year 2010 COMPANY VISION “A significant player in the global tyre industry and a brand of choice providing customer delight and continuously enhancing stakeholder value” COMPANY MISSION “To become a USD 2010 million company by the year 2010” Page 16 .

Achievements of customer delight through benchmarking global practices.APOLLO TYRES LTD “To create the first Indian Singles Grand Slam Champion by the year 2018” OBJECTIVES OF THE COMPANY • • • • • • • • High volume. high market share. technically superior products. of people 213 1924 113 453 2703 (Table no: 3. High quality. Operating margin improvements. Employee satisfaction. cost effectiveness in all segments. Strengthen supply chain management. HUMAN CAPITAL Labour Management staff Permanent staff Workmen trainees Contract workmen Total No. Revenue growth. Consistent production through harmonious industrial relations.2) GOAL OF APOLLO          Learning and Development Employee safety Family Focus Hygienic Factor Employee Involvement and Cultural Building Employee satisfaction Customer delight Revenue growth Operating margin requirements Page 17 .

It is our policy to design. KALAMASSERY. manufacture and services our products to provide the level of quality and valve that meet every customer’s need.APOLLO TYRES LTD QUALITY PLEDGE “We the people of Apollo Tyres Ltd will create an enterprise committed to quality. BARODA GUJARAT APOLLO TYRES LTD. CHENNAI TAMIL NADU (Table no 3. We will aim to generate customer enthusiasm through continuous improvement in our products and services”.3) Page 18 . PERAMBRA KERALA APOLLO TYRES LTD . APOLLO ONE FAMILY       Arts Day Sports Day Factory Day Safety Day Onam Celebration Summer Camps APOLLO -A RESPONSIBLE CORPORATE Indirect -5000 persons Direct -2703 persons (1500 are locals) PLANTS IN INDIA Sl.No 1 2 3 4 5 PLANTS APOLLOTYRESLTD. PUNE MAHARASTRA APOLLO TYRES LTD. KERALA APOLLO TYRES LTD .

The principles of sustainability are inherent in our vision statement focusing on ‘continuously enhancing stakeholder value. Apollo Tyres believe true sustainability is only ensured by the positive impact of business practices.5) APOLLO’S CORPORATE SOCIAL RESPONSIBILITY By giving back to society in every way possible. leading to a sustainable effort. one builds synergies with the core business.No 1 PLANTS APOLLO TYRES . DURBAN SOUTH AFRICA (Table no 3.’ Page 19 . The company has invested in efforts to build awareness about AIDS and has undertaken to bring solutions to the problems of the community at large. our initiatives in Corporate Social Responsibility are an integral part of the business activities and not outside them.APOLLO TYRES LTD PLANTS ABROAD Sl. but also promotes a feeling of well being.4) GLOBAL POSITION OF APOLLO TYRES LTD YEAR 2004 2005 2006 2007 2008 POSITION 17 16 15 14 14 (Table no 3. 2 ZIMBABWE APOLLO TYRES. BULAWAYA. Recognizing that an optimistic and progressive environment not only enhances productivity. LADYMITH SOUTH 3 AFRICA APOLLO TYRES. all around.

Apollo Tyres Health Care Clinics (for customer’s i. at the onset.e.the trucking community. The current and planned CSR programs are primarily focusing on health and education. Maharashtra. the CSR activities have expanded to include women. health & safety and social aspect. and other large transportation hubs in India. Run by qualified doctors. Sample • surveys were also carried out to record the knowledge. and outreach workers. • HIV-AIDS initiative is the biggest an most comprehensive programs at Apollo. The organization is conscious of the triple bottom line concept and is working towards putting advanced and integrated management system on environment. Emergency Medical Services (EMS) around our manufacturing locations in India. Training and leveraging supply chain in taking the message forward in line with Apollo Tyre’s commitment to capacity building. pharmacists. Established highway rescue project in Gujarat and city EMS in Page 20 . behaviour and practices.Workplace programs (employee) in India and SA. attitude. CSR programs will be undertaken after due needs assessment of the location.APOLLO TYRES LTD CSR is recognized as a key strategy to manage the business and operational challenges. As the geographies of operations expand. except HIV-AIDS. the Clinics focus on diagnosis and treatment of sexually transmitted diseases. From then on. New Delhi. The organization’s strategy is to build key partnerships and linkages to optimize the existing resources in reaching out to more people. Being a people centric business. in collaboration with NGO’s and other external agencies. Some of the planned activities will require local NGO support. All programs. TamilNadu. children and the disadvantaged. Apollo Tyres undertook to bring awareness and solutions to the problems effecting those members of the public that are in closest contact with the company. counsellors. Rajasthan. The organization recognizes it as a development and workplace issue and has a detailed action plan covering key stakeholders. are currently in the domestic market. truckers) have been established in and around cities like Uttar Pradesh. in broad alignment with Millennium Development Programs of UNDP. condom promotion and effective communication to promote behavioural change.

• • • Provision of artificial limbs to war wounded soldiers. • • • Maintenance of school building in the villages. Page 21 . Tailoring classes are arranged on an ongoing basis and an Anganwadi (crèche) was also provided to take care of the children from economically underprivileged families. Customer promotion on safe drive environment Conducting Safe Drive Campaign on the national expressways. Twenty more are planned. Malaria. 20 such Safe Drive campaigns have already taken place across the country this year. TB. • • • Opportunity of self employment / entrepreneurships to war wounded soldiers resulting in revenue generation for them and the organization. etc. Health camps on HIV/AIDS. Perambra. Skill development for women in villages with a view to making them self sustained members of the community. • Health Camps & Medical assistance in the villages surrounding the manufacturing location generate awareness about deadly diseases like HIV/AIDS. which included checking the tyres for damages or wear patterns to ensure that they were safe for an expressway journey. Provision of computers to the schools in the villages.APOLLO TYRES LTD Vadodara Plan to launch in Kerala. TB and Malaria are panned for truckers in the Highway regions as well as in the remote villages. • Primary education in keeping with Millennium Development Goal in the villages involved awarding scholarships to support bright students from economically backward sections of society. Provision of water tank for the village as well as laying a pipe line to bring supply of drinking water for the 500 students of the Government Girls High School. • • Customers were also given Safe Drive booklets. Kodakara. Chickengunia. Adult Literacy classes for villages.

APOLLO TYRES LTD • Wind Energy project initiated six months back along with Suzlon. in an effective and environment friendly manner. • • Technology Up gradation along with waste heat recovery has resulted in approximately 39. with an expected generation of approximately 1. has enabled tapping in to a 8 Megawatt Capacity of wind power. Currently the production capacity is 245 tonnes a day. The plant is having following certifications: • • • • • • QS -9000: 1998.000 tonnes of CO per 2 annum. USA) ECE Certification In-Metro (Brazil) Certification SASO (Saudi Arabia) Certification Page 22 . is conceived as a Clean Development Mechanism (CDM) project under Kyoto Protocol. educational institutions. based on Waste Heat Recovery System from GAIL’s Gas Turbines exhaust. Activities are continuously redesigned and shaped to suit the dynamic requirement of various programs. Dunlop. • Steam energy to replace use of RLNG under an agreement with GAIL. Some activities will need to be managed through expert NGO’s. tractor tyres. This initiative would enable Apollo Tyres to generate 4 MW of power and allow the two companies to save around 935 Million Kilo Calories of energy in producing process steam. The project. a company –wide initiative to responsibly dispose all waste generated in factories and offices.2004 certifications for Quality Management Systems Registered with DGS&D and Defence (CQAV) Registered with DOT (Department of Transportation. It is manufacturing truck. South Africa has launched the ‘War on Waste’ campaign.000 CERs being granted by UNFCCC.70 million units of power every year. LCV. Apollo Tyres aims to further develop its alliances with the business community. Infrastructural Facilities Perambra Plant (Kochi) Apollo Tyres’ first manufacturing unit located in Perambra in Kerala and began its commercial production in 1977 with a capacity of 54 tonnes. thereby also avoiding formation of 55. For the future. social organizations and community gatherings to spread awareness and take action.

Perambra unit was ranked the first among large scale industries for productivity and energy conservation in the year 2002-2003 by Kerala state in year 2005 & 2007 at productivity council • • • • • • • • • Apollo Tyres received the pollution control award by the central government during the year 2003-2004 Apollo tyres received the National Safety Council Award in the year 2005 & 2007 Apollo Tyres acquired the Energy Conservation Award in the year 2006 Apollo Tyres received the award for Road Safety in 2006 Apollo Tyres acquired the Quality Circle Award in 2006 First tyre company to get ISO 9001 CERTIIATION (Octo1 1995) One of the few tyre manufacturers with QS 9000 certification (March 2001) Consistently rated as excellent in quality audit by collaboration M/S continental AG Manufacturing facility and tyre testing laboratory certified by ‘Inmetro’ of Brazil BANKS OF THE COMPANY          State Bank of India Bank of India Bank of Baroda Punjab National Bank State Bank of Mysore State Bank of Patiala State Bank of Travancore ICICI Bank Ltd Union Bank of India Page 23 .APOLLO TYRES LTD • ISO 9001 Certification Initial capacity of the Plant : 49 tonnes per day Existing capacity of the Plant: 300 tonnes per day Number of People :2416(including contract employees) GOLDEN ACHIEVEMENTS OF THE COMPANY • Apollo Tyres Ltd.

6) Page 24 . MILESTONES OF APOLLO TYRES 1972 1974 1975 1976 1977 1982 1991 1995 2000 2003 2004 2005 2006 2007 2007 2007 2008 2009 The company's license was obtained by Mr Mathew T Marattukalam. November 17. Apollo Tyre Ltd. Exclusive Radial capacity established at Baroda. in Kerala. JointVenture with Michelin. Perambra Plant completes 30 Years. Plant commissioned in Kerala with 49 TPD capacity. Manufacturing of Passenger Car Radial Tyre in Kerala. April 13. Perambra Plant Foundation stone was laid down. Netherlands (Table no 3.APOLLO TYRES LTD Apollo key differentiation to other firms          Superior product quality Strong brand equity Committed marketing team High consumer loyalty Product segmentation in truck tyres Benched marked for planning efficiency parameters Power consumption Quick response to market needs Least scrap generation. Acquired Premier Tyre Ltd. April 13. Launch Dura Tyre (Retarded Tyre) for the first time in India Launch Regal truck and bus radial tyres Launch “Apollo Tennis Initiative & Mission 2018 Announce public Greenfield plant to be ready by 2010 for the European markets Announce the acquisition of VBBV Tyres . Dunlop South Africa is acquired. The company was taken over by Dr. Launch of Apollo Acelere. was registered. January 30. The second plant commissioned in Baroda. Raunaq Singh and his associates. Radial Capacity expanded to 6600 tyre per day. Jacob Thomas and his associates.'H' Speed Rated Car Radials.

7) LIGHT COMMERCIAL VEHICLES Load and mileage Technology Overload Technology Premium Mileage Technology • • • • • • • • Mile Star Load Super Star Amar Delux Amar Gold Rib XT9 XT9 Gold Duramile(radial) Champion Regular Mileage (Table no 3.8) Page 25 .APOLLO TYRES LTD PRODUCT PROFILE TRUCK Overload Technology • • • • Load & Mileage Technology • • • • • • • • • • • • • Loadstar Super Loadstar Super Hercules Loadstar Super Gold Kaizen 50L XT 7 XT 7 Haulug XT7 Gold Amar Amar Deluxe Commando Kaizen 36L Kaisen 99 plus Kaisen 77R XT-9 XT9 Gold Amar Gold Kaizen XTD Champion Champion DXL Champion Gold Amar AT Rib Kaizen 27L Premium Mileage Technology Mileage Technology Segment • • • • • ( Table no 3.

APOLLO TYRES LTD PASSENGER CAR RADIALS Tubeless Radial passenger Car Tubeless Radial MUV & SUV Tube Type Radials For Passenger Car • • • Acelere Amazer Lx Hawks • Amar • Amazer XL • Quantum Tube Tyre Radial For • Amar MUV & SUV • Amazer XL • Storm • Hawks Passenger Car & Jeep Bias • Armour • Panther • Gripper Maha Trooper (Table no 3.9) FARM Cultivation Haulage Multipurpose Tractor Trailer Type • Krishak Super • Sarpanch • Power Haul • Farm King (Radial) • Krishak Premium (Bias) • Dhruv • Hunter (Table no. with a 24% share in terms of revenues. the largest segment of the tyre industry. Page 26 . Its leadership position coupled with its strong brand recall and high quality. MRF commands the price – maker status. It is the leader in the 2/3 wheeler segment (including motorcycles) and tractor front tyres and holds second place in the passenger cars and tractor – rear tyres. MRF has a strong presence in the T & B segment. and commands around 19% market share in the segment.10) MARKET PROFILE 1. 3. MRF MRF is the market leader among tyre manufactures in India.

Page 27 . Its leading brands in the T & B segment are Lug XL. 3. The company has a distribution network of 2500 outlets within India and exports within India and exports to over 75 countries worldwide. 5. It derives 45% of the product mix from the MHCV segment and 31% from the tractor tyres segment. with around 22% market share and 82% of its product mix coming from this segment. It also enjoys a strong brand recall.68% of its product mix comes from MHCV segment. CEAT has lower margins compared to its peers. In terms of profitability. The company ranks first in the MHCV and Passenger Car Tyre segments with 79% and 7% of its product mix coming from these segments respectively. and largest player in the T & B segment. It has a significant market share in the tractor tyres segment. Mile XL and Rub XL. Secure in two wheelers and Formula – 1 in passenger radials. with a market share of 22% in terms of revenues. with just 2% of sales coming from exports. Goodyear India Goodyear India with its presence across the globe has a market share of 6% in the Indian Tyre Industry in terms of revenues. Exports account for approximately 17% of its gross sales. in spite of deriving 60% of its revenues from the replacement market. ATL is a strong player in the domestic market. with 22% in tractor – front tyres and a 30% share in tractor – rear tyres. in terms of revenue making it the third largest player in the industry. CEAT CEAT has a 14% market share in terms of revenue and is an average player.APOLLO TYRES LTD Exports accounts for around 12% of the gross sales in the MRF. 2. JK Industries JK industries have a 17% market share. Apollo Tyres (ATL) Apollo tyres is the second largest in the Indian tyre industry. 4. ATL derives 80% of its revenues from the replacement market.




MANAGER ASSO. This department is headed by senior manager and under him there are a number of officers and staff.MANAGER EXECUTIVES EXECUTIVES (Chart no 5. The main items of purchase are: • • • • • Engineering spares Consumables Furnace oil Diesel Chemicals Page 31 . The department is provided with the latest communication facilities and computers.MANAGER ASSO. It covers procurement of indigenous Engineering and miscellaneous items other than raw materials. PURCHASE DEPARTMENT The main function of purchase department is to provide right material at right time in right place at right quantity.1) EXECUTIVES This department is concerned with the purchase of both indigenous and imported materials.APOLLO TYRES LTD 1. STRUCTURE OF PURCHASE DEPARTMENT GROUP MANAGER ASSO.

3. Stock items are purchased for regular use. reorder quantity. 1. They are purchased after considering the reordering level. oils and lubricants. Receiving and inspecting of materials. Under corporate purchase the raw material is purchased after considering what the market require for the month. Develop good supplier relation. Ensuring sources of supply and choosing suppliers. Receiving purchases requirement. Purchase requisition is formed    What required Where required How much required 2.APOLLO TYRES LTD • • Lubricants Some raw materials The purchase may be corporate purchase or plant purchase. For non stock items there is no regular purchase. 2. Make purchase at most economic price. Objectives:     To ensure continuous availability of material. local raw materials. 4. Under plant purchase. Vendor analysis based on    Quality Price Time of delivery Purchase Process:1. lead time etc. import of spares etc. Preparation and execution of purchase order. purchase may be of stock item or of non stock item. The items purchased are engineering items. Ensure alternate source of supply Ensure quality products to reduce wastage and material loss. Different departments have to prepare purchase requisitions. They are having material codes. Page 32 .

attempts are made to identify the manufacturer and source the items directly from them so as to get quality products or services at optimum cost.e by the corporate office situated at New Delhi. Firms offering various services Manufactures are divided into two 1. Page 33 . catalogs. Manufactures 2. Each item of the engineering stores will have a serial number along with code number. OCM (Original Component Manufactures): For all spares. The products to be purchased are automatically generated by the help of computer and this process id called MRP (Material Requisition Plan). spares. Vendors are generally identified as 1. Dealers 3. The purchase order will be placed for the total quantity i. e 12 as above situation. 2. Checking and passing of bill of payments. out of which 8 were taken to the plant then the order will be placed for entire 10 items and not balance 8 items. components etc. At this stage the stock will be above the actual stock i. OME(Original Equipment Manufacture The OME shall be identified as a vendor for the supply of equipment. The capital purchases and raw material purchase is done through centralised purchasing i.APOLLO TYRES LTD 5.A reorder level will be fixed for each and every item (spares) and whenever the stock is below the reorder level the MRP will be run and the order is placed to the vendor (supplier). Information available on supplier’s manuals. They are identified with that number. components and consumables. details available on the nameplates of machines etc shall be used for the purpose. e if the stock is 10 and the reorder level is 4. Vendor selection This includes a list of steps involved in selecting the right vendor for stack items identified as critical by the department to enable a smooth functioning of the plant.

e items with product code will be unloaded at respective departments). On receipt of the goods the respective department will have to prepare a goods receipt (GR) and should be send to purchase department. PURCHASING RECORDS Purchase Order Records Vendor Records Blueprint and Specification Record Drawing Contract Files Record pf all materials purchased List of all vendors. and other details. The purchase department will take decision on such purchase order by calling a meeting. The lowest rate quoted will be fixed. The products so purchased will have to be collected by respective departments manually from the factory gate (other purchase items i. Many items are purchased by blueprint specification and are kept in separate files with index showing their location and where the copies have to be send. Table no 5. In such cases the purchase department must maintain a record of such contracts. And if the decision is taken regarding the order then a tender will be issued for the purchase of goods.APOLLO TYRES LTD When the goods for purchase are without product code then these items are purchased when the required departments will have to place the order manually. Certain goods may be bought under a term contract. their mailing address.1 Page 34 .

I – Input = Raw materials.2 excise and OE customers. preservation & issue of raw materials.APOLLO TYRES LTD 2. packaging. Page 35 . Officer Table no 5. P – Process = Receipt handling. stores. SIPOC S – Supplier = Corporate purchase. storage and issue of raw materials and to the customer. handling. Receipts and related documentation of incoming materials Despatch documentation and account keeping RAW MATERIAL STORES Process:-Receipt handling. Despatch and receipts of in and out various materials. 3 4 5 Sr. Coordinate with transporters supply chain management of Delhi depot. mixing centres other unit of ATL & internal customers. Scope:-Receipt. STORES FLOW OF AUTHORITY RANK 1 2 DESIGNATION Manager Associate Manager Stores DUTY TO BE PERFORMED Managerial functions Coordinate all activities of various stores like RMS. C – Customer = Manufacturing. storage & delivery. O – Output = Confirming RM receipt. forwarding and delivery of material to internal and external customers with proper documentation to meet their requirements. storage. FGS AND EMS. Officer stores Jr. Officer Jr. Purpose:-To supply right material in right time to produce right quality product without any interruption.

Natural rubber. sales tax papers. Weightment of the truck is taken after passing the gate. excise papers. wax etc stored in 1st floor. Each caged pallet will carry a maximum of 1500kg of materials. Preservation – The various raw materials are preserved as follows: • • • • Carbon black and chemical are stored in 2nd floor. 6. bead wire. Materials received in tankers will be pumped in storage tanks. 7. Testing – The various raw materials are tested at the lab and only then the raw materials will be unloaded on the plant store or in the tanks. Verification of documents at the Raw Materials Stores – Various documents submitted at RMS will be examined and verified. Verification of documents at security gate – The security officers will check the various documents like • • • • • • Serial number Suppliers name Description of item Truck registration number Date and time of arrival Date and time of departure 2. Those items in the tankers will be directly unloaded to respective tanks. Page 36 . Rejection – If the items are tested are displayed with a rejected tag by the technical department then if the item is small quantity then it will be kept in rejection area and if the quantity is large it will be kept in the same area till the disposal. packing list. which includes delivery Chelan. A computerized weighment machine is maintained. duplicate copy for transporters of invoice for availing modvat credit. 4.APOLLO TYRES LTD RAW MATERIAL HANDLING PROCESS 1. Fabric. 5. 3. Caged pallets or platform pallets are use for storing of raw materials. Handling and storage – All materials except materials in tankers will be unloaded manually. latex etc stored in ground floor.

Resources: Mixing Centres.APOLLO TYRES LTD VARIOUS RAW MATERIAL USED IN THE MANUFACTURE OF TYRES • • • • • • • • • • • • • • • POLYMERS – Natural rubber. colour. Scope: All operation regarding outside mixing to be carried out by stores department are consolidated in the Procedure. Page 37 . arranging for transportation and maintenance of records. Procedure for handling outside mixing operations Purpose: To define a procedure for identifying sources of executing contracts. reinforcing clays Fillers Curing agent Process oil Curing agents / sculpture Accelerators / activators Antioxidants / antiozonents (waxes) Ret ardors Pepticers for natural rubber mastication Ret order Bead wire Fabrics spools Solvent for cement and solutions Miscellaneous items like paints. crayon. Responsibility: Head of the Department. Technical production planning control and production. scrap flakes etc. carbon black. Stores Departments. synthetic rubber.

description of material code and weight of the material. challan quantity. If any discrepancy is found the same shall be orally reported to the officer concerned before unloading. Challan quantity. description of item. WEIGHMENT (BY THE COMPUTERISED WEIGH BRIDGE) Security shall inform raw material stores about the arrival of the vehicles at the gate. suppliers name. gross weight with materials. He in turn will take decision suitably. packing list and duplicate copy for transporters of invoice for availing MODVAT credit. After recording the above details in the computerised weighting balance the vehicles shall be directed to the respective unloading bay. suppliers name. The security guard and a representative from RMS shall record weighment of truck jointly. date and time departure. time and date of receipt. truck reg no. Both security and RMS personnel shall sign on the computerised weighment slip. SIR no and date. VERIFICATION OF DOCUMENTS AT RMS The receipt in charge shall verify the documents to ascertain the no of packages. In case of non receipt of any of the above documents the consignment will not be unloaded unless and otherwise instructed by Page 38 . date and time arrival. The weighment slip shall indicate the following: Serial no. One copy of the weighment slip will be filed in RMS along with concerned delivery challan and the second copy will be returned by security department. challan no and date or LR no and date.APOLLO TYRES LTD RECEIPT OF RAW MATERIALS VERIFICATION OF DOCUMENTS AT SECURITY GATE The security inspector at main gate shall verify all documents pertaining to the consignments brought to the factory before allowing entry in to factory premises and note the following details. Serial no. sales tax papers. In ATL weighment will be done in a weighbridge closer to the factory under the supervision of security and RMS personnel after ensuring that the weigh bridge posses a valid certificate from weight and measure department. The dispatch documents include: Delivery challan/ invoice.

On receipt of indent from production department. natural rubber/ SBR. while small quantities will be removed and stored in the rejection area duly displayed with the rejection tag. A buffer stock is always maintained in the store. In case of rejection of voluminous quantities the materials are kept in respective areas till disposal. the materials may be kept in the ground floor and other places as directed by the storage in charge.APOLLO TYRES LTD the competent authorised after compliance of all conditions stated above. Materials received in tankers. the engineering stores arrange for its release. latex etc in the ground floor. ENGINEERING STORES DEPARTMENT Engineering goods stores is responsible for storing the necessary spare parts. PRESERVATION Carbon black and chemicals are stored in the 2nd floor. wax etc in the 1st floor and fabrics. Rejection items are identified by displaying a rejection tag by technical department. the respective floors. bead wire. Almost all the activities of this department are computerized. the materials will be unloaded as instructed by the receipt in charge and lead to the respective area. The inventory management technique used is VED Analysis. after checking the seal and dip reading and sample test by QA will be directly pumped into the storage tank. In case of space constrains in the respective floors. HANDLING STORAGE AND PRESERVATION All the incoming materials except the materials coming in tankers will be unloaded manually or with the help of forklift as instructed by the receipt in charge. Another system Page 39 . Caged pallets will be stacked one over the other. Each caged pallets will carry a maximum of 1500 kg of materials. components required for smooth functioning of the plant. The purchase department is initiated whenever reorder level is reached. Caged pallets or platform pallets are used for storing of materials so far as possible to facilitate easy handling at the time of issue. Before unloading the receipt in charge will make sure the availability in the storage tank.

If there is any shortage then it is also informed to the purchase department. ENGINEERING MATERIALS The total number of item codes in engineering stores is 38500 approximately. 2. glows. It is decided to   Identify common equipment by same make and model.APOLLO TYRES LTD followed in the engineering stores is VMI – Vendor Maintain Inventory. which is common across plants. The actual stock and item list are maintained by the computer. Assign uniform code to equipment make and model wise. Equipments are varying from plant to plant by make and model. out of which 23500 are spares and 15000 are consumables.The purchase department will see to it and place s the order to the regular suppliers. It is decided to identify common codification scheme for all consumable items. In this the vendor supply the raw material in large quantities and payment is made only for consumed items. All the items shall be brought under this codification scheme. The various types of items in the engineering store are tools. If new suppliers enter the market the best quoted price will be taken. The materials to the engineering department will be sealed by the security at the gate and the actual stock and order will be verified.  Assign representative plant spares with code of equipment. 1. The engineering store keeps record and stock of engineering materials and consumables. mask etc which are required for the work to progress. Spares Spares are parts of equipments. Page 40 . Consumables (General stores items) Consumables (General stores items) are standard engineering items (bearing. A reorder level is maintained for each item and when the stock is either equal or less than the re order level the computer will automatically place the purchase order by running the MRP (material requisition program). belt etc). If the materials received is correct the goods received receipt is prepared and sent to the purchase department.

8 for RT and 12 for LT/passenger. duplicate will be given back to the production as their file copy and triplicate will be issued the production planning. Material code Description Quantity The original copy of the transfer note will be issued to central excise wing after entering the details in stock statement. ply rating Removal: The finished goods required for dispatch kept at the transferring area. The staff of final finishing will prepare a finished goods transfer note in triplicate which will be countersigned by the staff of FGS/ TTF. will be removed to the loading bay and balance will be removed to stores for storage. size. Page 41 . Each stack with maximum of ten for truck tyres. After verification finished goods transfer note will be serially numbered and have the following details. The various processes to be performed for handling. Material classification in SAP will be used to trace the spares to common machines. All finished goods after final inspections are kept at the transferring area in each shift. Material master codification will follow the external numbering FINISHED GOODS STORES Finished goods stores (FGS) is the place where the final goods are stored from where these are taken away from the plant. preservation and storage are listed below: a) Application for Non – OR (Non Original Equipment)  Finished goods stores is fully covered and protected from sunlight and rain water. after completing packing for required item. after preparing the transferring notes.APOLLO TYRES LTD In general the item code for consumables will be common across all plants and item codes for spares will be plant specific with respect to common equipment code.  Tyres are rolled from transferring area to the stores and stored on size wise. One staff each from production and FGS/ TTF will separately verify quantity.

 Stock levels of FGS are controlled by supply chain management at head office level. Bottom most tyre will be stacked with tube value facing upwards and for others with tube value facing downwards (same practice is followed while loading the tyre in truck also). Supply chain management department give the despatch schedule day to day basis. temporary sheds will be restored for storing those tyres.  Load slips are prepared as per the plan made.  Flaps are bundled and transferred using trolley. b) Application for OE (Original Equipment)  Truck OE tyre if not despatched within 24 hrs should be stacked in the warehouse.  After preparing the stock statement the finished goods transfer note is transferred over to factory excise wing for recording and filling.  In case of higher inventory levels it is not possible to store all the tyres in the godown. DISTRIBUTION OF FINISHED GOODS   Main responsibility is for the head of department. Page 42 .  A stock statement is made as on the closing of the day.  FIFO system is followed  Truck inspection is carried out before loading the tyres. This is made based on the receipt and despatch.APOLLO TYRES LTD  All tubes are packed in HDPE bags and bought to the storage area directly by tube production.  All seconds tyres stored in FGS are identified using a white band and tyre using a red band.  Destination to which trucks are required is arranged day in advance.

Invoice distribution a) Original – Buyers b) Duplicate – Transporter c) Triplicate – Assesse d) Quatriplicate – Extra copy List of serial number of tyres being despatched will be provided when ever necessary. After checking the load. slip will be signed by the staff and given for preparing transport documents and goods will be loaded on to the Lorries. Sales tax. All documents required for transportation are prepared and handed over to the transporters after getting paper acknowledgement and lorry receipt from him. All trucks are despatched to outstation are covered using tarpaulin and tied safely before leaving the factory premises Despatch documentation is made. road permit are handed over to the transporters.APOLLO TYRES LTD  Stores men will keep the loads as per the load slips at the loading bag. security and representative of transported will check the loads.         All finished goods after final inspection are kept at the transferring area in each shift. Staff of FGS. After verification finished goods transfer note will be serially numbered and have the following details: ♦ Receipt ♦ Material Code ♦ Description ♦ Quantity Page 43 . The lorries will be inspected for cleanliness of the platform to ensure that there are no items which will damage or dirty the tyres. The staff of final finishing will prepare a finished goods transfer note in triplicate which will be countersigned by the staff of FSG.

The finished goods required for dispatch kept at the transferring area. One staff each from production and FSG will separately verify the quantity. Heads of each section are in direct contact with the department head. will be removed to the loading bay and balance will be removed to stores for storage. HUMAN RESORCE DEPARTMENT Human Resource and Administration department is one. after preparing the transferring notes. after completing packing for required items.APOLLO TYRES LTD ♦ Removal The original copy of the transfer note will be issued to central excise wing after entering the details in stock statement. ply rating of the finished goods and compare against the entry in the transfer note. size. 3. which facilitates smooth working of the organisation by looking into the human resource side and also the overall administration of organisation. Among the three sections Industrial Relations is the biggest section having four subsections looking into Personnel Page 44 . duplicate will be given back to production as their file copy and triplicate will be issued to production planning. Security and Administration. HR department is divided into three sections namely Industrial and Personal Relations.

 To encourage transparency and teamwork.  To built a culture which is warm forthcoming and professional with a sense of ownership and pride. VISION OF HR DEPARTMENT Our HR vision is to be a strategic partner to the business and create value for the organisation by developing the human capital. Health and Safety. Employees Arrival and Departure. MISSION OF HR DEPARTMENT  To create HR policies and process which are employee friendly.APOLLO TYRES LTD and Industrial Relations. STRUCTURE OF HR DEPARTMANT Page 45 EXECUTIVE .  To create HR brand.  To work towards a attaining and sustaining the best the best employer status.  To develop competencies and skills through training and development.  To create a learning organisation.  To develop leaders at all levels with general marketing skills.  To constantly raise levels of employee productivity. Time .  To encourage innovate thinking.


7 days. 15 days to 1 month. • • • • • Three year production apprentice. 2. Minimum qualification -8th standard. Graduate Engineer trainee.Indction Plan. Non technical – CA/ICWA/MSW/MBA/MA (PM): Executive Trainee. c. Management staff. Personal interview. b. Criteria include. This increases family loyalty towards the company. • • Group discussion. Tech. they are absorbed as officer. Physical fitness (height-168Cm. • • • Workers Associate managers Management staff 2 days induction training. • Consistency in academic performance. After training. Page 47 . Employee children skill development scheme. They are call for the interview and the Chief executive takes the final decision. Technical – B. weight-50Kg) . Dependant of employees. One year training in production.APOLLO TYRES LTD Recruitment is done through advertisement and a good opportunity is given to the child of worker.SELECTION a.

APOLLO TYRES LTD 3. The training system includes. A three dimensional skill frame work is used to identify the training needs of workers as conceptual skills. Cross-functional. Setting objectives.TRAINING The organisation provides training for both managers and workers. Training program for managers consist of both internal and external program. Training evaluation.  For workers. • • • • • • Need identification. Page 48 . Work culture. Behaviour. Technical aspects. functional skills and human skills. • • • • Conceptual. Specialised training for trade unions. Areas covered include:  For management staff. Training impact assessment. Functional. Training design. • • • • Systems. Training implementation.

In order to consolidate and mention various training programme conducted. functional and behaviour skills those are necessary to perform the job at hand.  To provide a nature for the work is to down of an individual where in he/she can explore and optimally use his/her innate and talent potentialities leading to his/her individual growth and development.APOLLO TYRES LTD TRAINING AND DEVELOPMENT PROCEDRE Training and development of ATL Perambra aims to accomplish the following objectives:  To equip the personnel with conceptual. The card will be maintained in the prescribed from FR-06-A-04.  To create a culture of continuous leading among the all employees through systematic training with the ultimate objective of making ATL a performance driven organisation. TRAINING RECORDS 3 types of training records will be maintained by HR Department.  Training cards. Page 49 . For those programmes attended by more than 5 individuals. The training card will contain the details of all training programme that are attended by an individual employee. the list of participants will maintained in the individuals training programme in the prescribed from FR-06-A-06.  Organisational training programme monitor. an organisational training programme maintained as per from FR-06A-05 Individual training programme monitor.

The employees are provided training specialty about the company and the tyre industry in general. With a view to develop multi skill among engineering trainees. It using scientific techniques with a disciplinary approach.34%. • Training on communication and interpersonal skill programmes for associate managers and managers. production and technical fields. • • • Training on Jyotirgamaya for blue collared employees. TRAINING IN THE FORM OF THEME CENTERED INTERACTION. I t is for finding out areas where unneeded expenses are occurring and for reducing. quality & scarp reduction. then the organisation will achieve an unexpected growth. JYOTIRGAMAYA: On each working day about 6-7 employees are selected for training in a classroom atmosphere. Jyotirgamaya provide information regarding the changes happening in the industrial field. It also Page 50 . This helps to find out the defects in production and for finding out remedy. about the productivity. When the employees become aware of six sigma and they come into contact with the machineries used for this.APOLLO TYRES LTD TRAINING PROGRAMMES. A six sigma organisation means the defects in the production of 10 lakh parts must be below 3. Safety and fire training conduct for blue collared workmen. they are given exposure to engineering. SIX SIGMA :( introduced on April 16th 2007) Six sigma is basically meant for increased production and for running the organisation profitability. It’s objective is to give training for all the employees in the unit within a period of 1 year.

and well maintained library are other facilities provided. All employees drawing a salary below Rs. The various schemes for the employees are: 1. The management and the employees jointly find the solution for the problems. 3. There exists a well maintained relation between the employees and employers. ATMS -Apollo Tyres Mazdoor Sangh. arts and sports club. Page 51 . INDUSTRIAL RELATIONS There exists a good relation in the company. Transportation facilities. 6. Workmen’s compensation scheme. Group hospitalisation scheme. WELFARE The organisation provides good welfare services to its employees.Apollo Tyres Workers Movement. Housing loan interest subsidy and so on. ATWM. Employee deposit linked insurance scheme. ATSWU-Apollo Tyres Staff and Workers Union. Trade Unions • • • • ATEU .6000 are covered under group accidental policy and medi claim policy. 5. 5.APOLLO TYRES LTD helps to understand the fact that consumers are the owners and also to produce quality products. 4. 4. 2. The company runs a subsidised canteen on contract basis. Canteen facilities.Apollo Tyres Employees Union. A well transportation facility is given to all the employees from different destinations for which they have to pay a very less amount. Rest rooms with locker and washing facility.

It is given to retain their lost energy in the night shift and give motivation to the employees to come for night shifts. Employee self development scheme. Group personal accident policy. Workers • • Group personal accident policy.40% borne of the company. Two wheeler scheme – 40% borne of the company. Statuary welfare activities. • • Statuary. manager & above . manager and above. Apart from its soaps is distributed for the cleanliness of employees. Settlement grievances. • • Group Personal Accident Insurance Scheme (GPAIS). Page 52 . • ESI • Gratuity Some of the settlement grievances are. Each worker gets soap fully off cost and those who work in their production units 3 in number per month. Group Mediclaim Insurance Policy (GMIP). • Group Saving Linked Insurance Scheme (GSLIS). Car scheme – Asst. Management staff • • • • • • Group hospitalisation scheme. Medical claim.APOLLO TYRES LTD Taking the health aspects of employees those who in the night shift get 200ml of milk packets. Super annuation – Asst. Welfare activities are of 2 types.

Hours worked. The daily attendance reports for the employees specify the following: • • • • • • • Section/department. leaves etc. Grade. a punching system is maintained.APOLLO TYRES LTD • • • • Housing loan interest subsidy-50%.. co-operation and understanding. A leave book is maintained & it contains. Financial assistance co-operative society.. 6. social games and other welfare activities among them a spirit friendship . Schedule shift. Page 53 . • Leave waited. The aim and objective of welfare fund shall be to render financial assistance and to encourage cultural. incentives. Clock no. Periodically medical check up. The same is repeated while leaving the factory premises. Apart from it .. Other activities related to payment of wages. 2 wheeler interest subsidy-70%. sports. Date. • Leave balance. Each employee has to punch his badge in the electronic punching system while arriving for duty. Shift.Different registers are kept for different shifts for the effective functioning.TIME OFFICE This is concerned with registering the time in and out of the workers. • Leave credited.

Performance reports are maintained at various sections for the staff and managerial persons. A leave book is maintained and it contains leave balance. separate gate passes are issued. Job description :- Page 54 . These are done with a view to reduce the absenteeism in employees and motivate them to increase production. For materials.SECURITY AND SAFETY  SecuritY The security is concerned with the physical movement of men and material. SHIFTS OF WORKERS Shift A B C D(General) 6am-2pm 2pm-10pm 10pm-6am 9am-5pm Working hours (Table no 5.3) 7. shift engineer and shift superintendent department head. single point entry is adopted to control visitors.APOLLO TYRES LTD Attendance is cross checked with the attendance report of the workman and the attendance register maintained at various sections for the staff and managerial persons. leave credited and leave awaited. Performance reports are maintained in each section. The daily attendance report is verified by the superior . To facilitate the security measures. Security staff headed by the chief security officer works at all the shifts.

. 1. safety day. Onam/Christmas celebrations and plant visit by important officials. Maintain the data base of all indirect workforce including contract workmen. gather and assimilate intelligence for smooth functioning of the plant in an unionised environment. 3. Safety directions are placed at noticeable points in and around the plant premises. Fire extinguishers are placed reachable points and employees are well trained to use if necessary comes.. Deploy of contract workforce to various department for routine as well as project work. highly sophisticated equipments etc.  Safety The organisation follows all the provision under the Factories Act 1948. - Developments of security staffs in line with the requirement of the organisation and to keep a high morale of the forces. Ensure high degree of liaison with police . Those who work in production Page 55 . Monitor and control all inward and outward movement of vehicles . raw materials .APOLLO TYRES LTD - Be responsible for security of men. Keep strict vigilance . 5. fire force and government authorities. process materials . including housekeeping of plant. Principal accountabilities of chief security officer. finished goods. The plant is well equipped with safety machines and directions are given for the same. machinery . 2. Upkeep of environment management system . 6. material and personal. local administration . Event management:The security department plays a significant role in factory day. 4.. Their inward and outward movement is monitored as per the system prevailing.

c) Record keeping – A chart called the ‘L chart’ is maintained for the employees where all details regarding the various diseases of the employee will be recorded. All the facilities available within the company will be utilised and when further treatment is required the patients will be referred to nearby hospitals. and make them understand the ways in which this will affect the health of the company. then a brief investigation report will be prepared and submitted.. In Apollo . No major accident was occurred in the plant for past 10 years. b) Medicines – Basic medicines will be available in the first aid counter itself and other medicines will be prescribed to the patients to be purchased from outside. One among them is a general surgeon .. The various services provided by the medical officers are listed below. d) Advisory services – Advisory and counselling services are provided the employees with regard to their physical as well as mental problems. a separate book is given to each employee . Page 56 . If the injured require any leave or rest . a) Causality services – The main purpose is the causality function. e) Classes and Seminars – Medical officers conduct classes and seminars regarding the harmful effects of alcohol . Perambra plant to cater to the medical needs of the company. drugs . The injured will be provided first aid by the medical officers. smoking etc.APOLLO TYRES LTD department are given masks . safety gowns and shoes. which prescribes certain rules and procedures in order to create a working environment free of accidents. ABC of safety A-Always B-Be C-Careful FIRST AID Medical officer :- There are 2 doctors in Apollo Tyres Ltd.

The quality of work depends on the individual. then advance intimation shall be passed to hospitals for immediate receipt of patients. engineering head . To effective utilise the available resources. To equip them. security manager and medical officers over the phone. Therefore the medical officers also advices regarding good posture to be maintained. finance head . Incident controller shall prepare a brief accident report (FIR) to be submitted to the management immediately after the situation has come under control. HR and administration head . safety manager . OTHER ADMINISTRATIVE ACTIVITIES 1. a) b) c) To avoid panic and confusions. The procedures to be performed for such a situation are listed below: a) The details of the causalities that are taken to the hospitals will be intimated to the welfare officer.APOLLO TYRES LTD f) Posture and exercises . Selection Procedure. Page 57 . But if the facilities not enough .A healthy mind and strong body is required for the company to perform successful. c) Welfare officers shall co-ordinate with hospital to give utmost care and attention to the victims. b) He will also inform the Apollo Tyres Ltd head . exercises to be performed to maintain body and mind healthy and activity Emergency plan:Emergency is a situation warrented to seek external help or resources for controlling an eventuality which adversely affect the environment . man and material or objectives of emergency plan are to assign the individual roles and duties to perform in an emergency situation.

Tech. Technical : B.Induction Plan • • • • • • Workers : 2 days induction training Management staff : 15 days induction Quality Pledge Safety procedure Welfare measures Interaction with all department heads 3. Selection Procedure a. • • • • Management staff. Gradate Engg Trainee Non-Technical : CA/ICWA/MSW/MA(PM):Executive Trainee After – trainee absorbed as officer criteria Consistency in academic performance Group discussion Personal interview Employee children skill development scheme 1 year training in production Dependents of employees Minimum qualification – 8th std Physical fitness 2. 4.APOLLO TYRES LTD 2.Performance Appraisal • Employee Development Review(April-March) • Three – Tier system Page 58 . Absenteeism Management. 3. • • • • • • b. Performance Appraisal. Induction Plan. 1.

drawn Chronic absentees numbering 192 are brought under small group of 5 from purchasing and other financial areas. Page 59 . under each mentor. Attendance. o HR department publishes list of absentees during 1st half of the month to give them a chance for improvement during the second half of the month. The control measures are a. o After 15th of each month.Absenteeism Management Absenteeism among workmen has been a cause for concern for the company. production has suffered heavily in this account recently. attendance data of the group members are generated and circulated among the groups. Discipline & Development Programme Introduction of ADD programme effective in ATL An effort to improve the attendance of chronic absentees To maintain consistent production Operations of the scheme o person. o 192 workmen are brought under 23 groups. on a daily basis oversee attendance to ensure availability of his group members for work.APOLLO TYRES LTD • • • • Helps in setting individual/team goals Rated in respect of the achievements Mid – year review of the goals Personal attributes considered 4. o HR department monitor the attendance and stops those who absent from duty continuously for 3 days. It has therefore been decided to fight against the absenteeism contains among the regular workmen and production apprentices through attendance monitoring mechanism.

. the attendance for the previous month is published and committee meets and decides the course of action against defaulters. o o e. System Daily follow up 3 days – meet HR 6 days – stoppage 10 days – home visit 20 days (accident) home visit Task force Constitution (1HR +1Line Personnel) 12 task forces for 116 members Achievements : 10 absentees were covered to 100% attendance Individual Problem solving 34% habitual absentees shows improvement Training and counselling 2 days training module Individual counselling Leave Planner Page 60 .APOLLO TYRES LTD o In the 1st half of the succeeding month. b. are issued based on the gravity of each case. o o o o o c. o o o o o d.. o Individual appreciation letters signed by the mentors are sent to the residence in cases where remarkable improvement is shown. o Advisory/warning /suspension/pending enquiry etc.

Environment • • Eco – friendly surrounding Pollution free work practice Business focus • • • Production linked bonus Production linked LTS(Long Term Settlement) Zero over time Page 61 . In case of non – supervisory personnel cash payment is done in the following days. Perambra and intimate the accounting department who in turn will remit the salary. Safety Aspects : Primary importance 2. Production/engineering – 7th working of the succeeding month.up 3. Staff and service staff – Last working day of the month.APOLLO TYRES LTD o o 12% permissible limit or work station Festival leave plan o Leave sanctioning and monitoring Salary Payment All supervisory personnel are required to open a SB account with South Indian Bank. Employees focus (SHE) 1. Health • • • • Full time doctor Ambulance Dispensary Medical check .

Page 62 . All these sections are under the direct control of the HR Manager. which have seven subsections which are mentioned above. There is computerised punch card system followed in the company. They are all recorded in a systematic way. Each entry and exit to the plant is recorded. Perambra. Apart from this is a well maintained payroll system too. The attendance of the workers also account for their promotion. Absenteeism is being found out and proper reasoning is obtained. It has a well established industrial relation and this department gives more important to the welfare and safety of the employees . seniority and performance.APOLLO TYRES LTD • • Expansion of capacity Right sizing Promotion Promotion is purely based on attendance . Thus HR department is the strongest department of Apollo Tyres Ltd . also the time management is very good here.

PRODUCTION DEPARTMENT MANUFACTURING PROCESS Production department is required for the operation. and then the production schedule is finalized. Perambra consist of 2 zones.All the production activities are classified under these two zones. maintain quality and optimum level of production department of ATL. namely zone 1 and zone 2. STRUCTURE OF PRODUCTION DEPARTMENT PRODUCTION HEAD DIVISION A HEAD DIVISION B HEAD DIVISION C HEAD Page 63 .APOLLO TYRES LTD 4. The production planning starts with receipt of production ticket from Delhi which contains the quality required for branches. The requirement is then processed in the planning department and then converted into equivalent for production.


APOLLO TYRES LTD Banbury mixer Mills Dip unit Calander Dual extruder Bias cutter Thread skiver Brand building Thread Tyre building Bead building unit Tyre curing Post cure inflation Final inspection Warehouse (Chart no 5.4) Raw materials used in the manufacturing process Main raw materials used for the tyre manufacturing are. Page 65 Tyre building .

It gives good strength. tear. good process ability and low heat build up and good abrasion resistance. Vulcanizing Page 66 . Vulcanized rubber Carbon black Zinc oxide Accelerators Activators Reinforcing agents Process oils or Aromatic oils (makes easy the mixing) Anti – degradents Anti – oxidants Fillers Process aids Special additives Raw rubber: Rubber as such is a soft semi – solid material which does not have any properties required for tyre components like elasticity. resistance etc. wear and flex resistance. resistance. Materials used in rubber components The essential ingredients in rubber components are as given below: • • • • • • • • • • • • • Raw rubber or natural rubber. Natural rubber occupies the top position as the general rubber. Synthetic butadiene rubber (SBR) is the first synthetic rubber developed. SBR is also recommended for bead compounds for higher hardness. initiation.APOLLO TYRES LTD • • • Materials used for various rubber components. good crack. well whether resistance and fine process ability. Materials used in for tyre reinforcement. Auxiliary materials. hardness. It offers good strength and tear.

accelerators and activators is still soft like rubber band. During vulcanizing. tear and wear and flex properties suitable for a tyre compounding. The general activators are zinc oxide and stearic acid.APOLLO TYRES LTD Raw rubber when heated with vulcanizing agents become elastic. Textiles in the form of continuous filaments are the primary material for the tyre carcass. which is used as the booster to the primary accelerator. Material used for tyre re – enforcement Carcass and bead materials used in a tyre are called tyre re – enforcement. accelerator is used. The cross links are generally achieved by adding sulphur and sulphur donors. reinforcing agent are used. Activators Activators are used to improve the efficiency of accelerator and it improves the elasticity and the strength of vulcanizing agent. For improving the strength. Accelerators are classified on the basis of the speed of the vulcanizing imparted by it. Reinforcing agents A vulcanizing thus made of raw rubber. A secondary accelerator is the one. with cords in longitudinal direction called wrap and thin cotton filaments in the opposite direction called weft. sufficient number of continuous filaments is twisted together.It is also classified as Primary accelerator and secondary. stronger and harder and this process is called vulcanizing. Page 67 . Reinforcing agents are carbon black and silica. Bead wire is a special alloy steel wire with bronze plating used as a bead wire for tyre. the long chain rubber molecules are cross – linked to form a network thereby making it elastic. vulcanizing agents. To form a ply. Cords are then woven into fabrics in special looms. Accelerators To increase the speed of vulcanization. hardness.

low cost substance called fillers are added to reduce compound cost. Division A – Takes care of assembling activities. Division C. and corrosion inhibitor etc are added for specific vulcanization properties. Process aids Process aids are those substances that are added to rubber compounds for reducing viscosity of the stock and for improving process safety.APOLLO TYRES LTD Process oils Incorporation of re – enforcing agents in a rubber is often difficult and to facilitate easy incorporation process. Special additives Sometimes special additives like bounding agents. Page 68 . Division B. oils are used. through not common. namely Division A. hardening agents. These are also used to improve compound process ability at calendar and extruder. Division C – Takes care of the curing activities. lubricants and seperants. flex. and weather and to take care of these anti – degradents are added. Auxiliary materials Major auxiliary materials used in the tyre manufacturing process are dip solution. chemicals. Manufacturing process activities The entire production system has been broadly divided into three sections . solvents. Fillers Often. Division B – Takes care of building activities. Anti – degradents Most of the rubbers are highly susceptible to degradation when subjected to heat.


A compound is made by mixing the required additives into rubber. This mixing is accomplished in two or more steps using a Banbury mixer. This mixing is done in the chamber of the Banbury mixer under high shear and pressure using the rotors of the machine so that the ingredients and uniformly dispersed inside the rubber matrix. Different rubber compounds (differing in the recipe) are used in the different compounds of the tyre. The rubber compound is then used for the preparation of different components in subsequent stage of manufacture. 1. Tread 2. Sidewall 3. Tread cushion 4. Plies 5. Chafer 6. Flipper 7. Filler 8. Bead 9. Squeegees 10. Breakers Naturally the compounds prepared in the Barbary go to the respective equipment and process for further processing.

Various cements, solutions, lubricants and paints are prepared in the cement house sing rubber compound solvents and other raw materials. These are then used at various stages of tyre manufacturing.

A raw fabric (Rayon and Nylon) is having very poor adhesion to the rubber compound and has poor dimensional stability. During the dipping process an adhesive Page 69


coating (eg. Resorcinol, formaldehyde,VP latex dip) is applied to the surface of the fabric to improve adhesion. The fabric is also stretched and hot set to increase the dimensional stability. Dipping is accomplished in the dip unit and the dipped fabric is then used for the preparation of the different compounds as mentioned above.

Here compounds of the tyre like tread and sidewall are prepared from the rubber compound using a Dual extruder. Extruder is the process by which the rubber compound is given definite continuous shape. A thin sheet of rubber compound prepared using a small 2-roll calendar is applied to the bottom side of the tread. This compound is called tread cushion. The continuous profile is then cooled and cut to required length which is used in the assembling of tyre at tyre building.

Extruders are distinguished by the diameter of their screw and are a single or dual type. a) SINGLE EXTRUDER Rubber compounds after being broken down and warmed up on Mills, are fed in to the screw of the extruder from which with the help of dies, produces a green shape of treads, sidewalls, and other strips as per specified dimensions and contours, width, gauge and weights. These strips are cooled in water sprayed conveyors and then cut out into specified lengths with the help of skivers (rotary cutting knife) and booked in metal trays or wrapped in cotton liners. The word green denote uncured rubber (i.e. Non vulcanized) b) DUAL EXTRUDER Two separate set of mills on which two different types of compounds are broken down and heated and fed separately to two different screws. The two compounds after extrusion are extruded together in a common head and with the help of performer and

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final dies, emerge into a pre determined shape. The advantage of the dual extruder is that two rubber compounds of completely different composition can be extruded.

Fabric calendaring is the process of coating both sides of dipping fabric using rubber compound. This is accomplished using a 4 roll ‘Z’ type calendar. The coated fabric is cooled and wound in liner (in continuous length) to avoid sticking. This goes to the next stage of ply cutting.

6. PLY CUTTING (Horizontal and vertical Bias cutting)
For cutting a tyre several plies are required. For e. g a 16 PR nylon truck tyre used 8 plies and 2 breakers. Each ply is cut from the coated fabric rolls prepared by calendaring. This process of ply cutting is accomplished in a bias cutter. Each ply is cut at specified widths and angles. The width depends on the type of tyres and the angle of the cut depends on the type of services required. The cut plies then go to 3 roll for squeegee application. Components like chafer and flipper are also made at bias cutters. These are further slit using a slitter into small widths and would into rolls. Chafer rolls from slitter go to the tyre building and flipper goes to the bead flipping.

Squeegee calendaring is the process of making thin sheet of rubber compound usually by using a 3 roll or 4 roll calendars. Squeegees are used at the inner most layer of the tyre (drum squeegee) and also in between the different plies (ply squeegee).Drum squeegee is prepared in the 4 roll Z calendar. It is in liners this squeegee roll is sent to tyre building for assembling. The ply squeegee preparation and its application on to the cut plies are accomplished simultaneously at the 3 roll calendar after squeegee application the plies are sent to tyre building for assembling.

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Page 72 . plies (with squeegee applied on it) are assembled using a tyre building drum. The components like drum squeegee. breaker and chafer are applied next. The assembly (green tyre) is taken out after collapsing the drum. c)Bead Flipping The flipper fabric prepared at the bias cutter and slitter is applied around the fillerd bead bundle.APOLLO TYRES LTD DIVISION – B 8. Finally the tread and sidewalls are applied. TYRE BUILDING It is the process of assembling various components into the semi finished product called a ‘green tyre’. BEAD PREPARATION It consist of three stages: • • • Bead winding Bead Fillering Bead Flipping a)Bead winding Here several wires are passed through the head of a bead extruder and coated with rubber compound. The flipped beads are applied from the ends and locked in using the ply ends. This is accomplished by a tyre building machine. This is accomplished using a bead flipping machine. 9. The coated tape so formed is wound into bundles of definite turns and strands and of definite diameter. b)Bead Fillering Here a triangular shaoed continuous rubber profile (called bead filler) is extruded using a cold feed extruder and applied on the bead bundle using a fillering machine. The process is accomplished using a machine called the bead winding machine.


The different components that make a green tyre are the following: Plies Breakers Chafer Beads Tread Sidewall

The green tyre inspected and they applied with a lubricant inside and an antiblemish paint on the outside sidewall area. The green tyre is also availed to facilitate easy removal of trapped air during the final shaping and moulding operation. The green tyre is shaped and given the final contour using appropriate tyre curing moulds (fitted to tyre curing presses) by the application of pressure and temperature. The rubber compound gets vulcanized during curing and becomes tough and elastic and provides all the desired properties required in the tyre. The curing times vary depending upon the size of the tyre varying from 42 minutes for a passenger car tyre to ane hour for truck tyres.

Nylon tyres after press curing are kept under high pressure inflation to help shape retention and to reduce growth in service. This process of cooling tyre under high inflation pressurenis called post cure inflation (PCI).


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The tyres after PCI are subject to vend trimming. The tyres are then inspected 100% for visual effect. The tyres are also statistically sampled and tested for conformation to BIS specification and warehoused.

• • • • • Break down of machineries Loss of time for setting up of machines Loss due to difference of machine speed Loss due to stoppage of production Loss due to mistakes and correction of mistakes

8 pillars of TPM are as follows: 1. Autonomus maintenance 2. Equipment and process improvement 3. Planned maintenance 4. Education and training 5. Quality maintenance 6. Initial control 7. TPM in office departments 8. Safety, health and environment Production facility is the backbone of any manufacturing based organisation. Apollo Tyres is very much improved in production capacity. The per day production of Apollo Tyres Ltd is 270 tones. This achievement is only possible because of hard work of employees.

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Quality is the totality of characteristics of an entity that bears on its ability to satisfy, stated and implied needs. Quality is referred to as • • • • Fitness for use Fitness for purpose Customer satisfaction Conformance to requirements

GROUP MANAGER - Quality assurance

EXECUTIVE – Finished products

EXECUTIVES – Quality system & capability studies (Chart no 5.5)


SHIFT-INCHARGEPurchase / Production

Quality Assurance is the well planned and systematic activities implemented within the quality system and demonstrated as needed to provide adequate confidence that an entity will fulfil requirements for quality.


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loads and climate conditions. Tyres are also fitted on different vehicles to study the effect of different types of roads. Finished product (cured tyres) will be also checked by Quality Assurance. For Original Equipment (OE) Page 76 .APOLLO TYRES LTD QUALITY ASSURANCE LAB PROCESS CONTROL & AUDIT (Chart no 5. The test wheel simulates the running condition of a tyre. Chemicals and Fabric etc) are given to lab. o PROCESS CONTROL AND AUDIT: In shifts. These materials are realised for further processing only if the test result is OK. If the test result is not OK. primarily used to detect car ass strength and heat generation. Only OK tyre will be released to warehouse. Carbon. If any defect is noticed on finished tyre it will be held up. In the same way processed material samples are also given to lab for testing (e. all the production areas will be audited by Quality Assurance will check whether the processing is done within the required specifications. material is rejected. If the test result are within the required specifications above material is released for production. necessary corrections will be done and the defective processed materials will be held up.6) o LAB All raw materials that come to RMS are released for production only after lab approval. For that samples of raw materials (Rubber. In lab these raw materials samples are tested. Calendared Fabric etc). g : Mixed Rubber Compound. processed material will be held up for technical disposal. Samples of cured tyre are tested indoor on a test wheel. Dipped Fabric. If any abnormality is noticed. If the result is not ok.

6.APOLLO TYRES LTD there is 100% inspection by quality assurance. SYSTEMS DEPARTMENT The system department is responsible for computerized of different departments of Apollo Tyres Ltd. MAINTENANCE FUNCTION Page 77 . The simple structure of department facilitates speedy communication flow with in the department. Pulley wheel and Puncher. Haryana). GROUP MANAGER – SYSTEMS.PPC & IE EXECUTIVE SYSTEMS (Chart no 5. operates and co – ordinates all systems in the organisation.HCL solve all the problems related to the network connection. The different methods used for checking are Dimension. The main function of this department.7) MONITORING FUNCTION Security problems in the SAP (Systems Application and Products) were solved using Central Virus Scanning System and Firewall at the head office (Gurgaon.

they will need IT to map their production and ensure they don’t lose new or present customers. All the computers were connected using both point to point and star topology to form an Internet inside the plant. The main objective of production planning control is therefore to ensure optimum utilization of those resources as well as the capital looked up in work in progress inventory. weekly and monthly for providing reliability in the SAP system. its demand forecast and production cycle. material etc are used in the tyre plant run into several crores and it is necessary to make best possible use of these resources to achieve maximum economy in production costs. PRODUCTION PLANNING AND CONTROL DEPARTMENT The resources in terms of machines. The way the automobile sector is growing. Regular backups were taken daily. 7. Proper authentication was given to each department members using ID and a password. STRUCTURE OF PRODUCTION PLANNING AND CONTROL DEPARTMENT Page 78 . men. Apollo makes 250 different types of tyres today. IT helps them to keep track of every product.APOLLO TYRES LTD The systems departments in the plant solved network problems as well as computer problems.

required components are ordered at the right time to fit in with the plan of work schedule for the shop floor. To ensure that machines are bought out.Establishing production program in consultation with marketing departments.Planning and control of production schedule. The major responsibilities and functions of Production Planning and Control could be enumerated as follows: . To ensure that the proper man is doing the proper work in specified time consuming specified material at specified quality. IE & SYSTEMS ASSOCIATE MANAGER . . Page 79 . Scheduling of machines 2.PPC MANAGER PPC EXECUTIVE EXECUTIVE (Chart no 5.8) The major activities of Production Planning and Control could be enumerated as follows: 1.APOLLO TYRES LTD GROUP MANAGER – PPC. 3.

When a job will be done. Page 80 . Raw materials Liaison with material control and technical departments for requirement of raw materials as per the consumption pattern. How much to do in one lot Production planning and control is an important department in any manufacturing company. Authorise RMS for issue of raw materials to production floor. Machines Review of machine capacity and its limitation with respect to production programme to initiate corrective actions. The Production Program of Production Planning and Control is prepared based on the following: • • • • Machine capacity Labour required Raw material requirements Equipment and other tools required for manufacturing (moulds. Scheduling in brief is determination of 1. drums etc). Scheduling Machine scheduling includes day to day scheduling machine loading in the most optimum level.Ensure adequate production and inventory. machinery and equipment. Access of material handling equipment and storage systems and arrange for procurement whenever necessary.APOLLO TYRES LTD . 2. Review of progress and initiation of action to remove bottle neck planning and control of in process inventory at optimum level etc. materials and utilities to achieve the desired goal. Production planning will mainly consist of the evaluation and determination of production inputs such as labour (man power). Where to do this job (incase where is more than one machine) 3.

Page 81 .INDUSTRIAL ENGINEERING DEPARTMENT Industrial engineering department helps to maintain the machines which has been using for the production process. Thus this department helps to avoid the disturbance during the production process.APOLLO TYRES LTD 8.

Page 82 . issues like incentive schemes. 6. expansion and labour issue. Capacity calculation in various equipments from time to time consequent to various changes. maintainability and cost control to keep Apollo globally competitive. bonus settlements etc and represent the management in the meeting with the union/labour departments. implementation and follow up of incentive schemes in various zones. Prepare documents for long term settlements. 10. Analysis of capital expenditure request from various department and make recommendation to senior management committee. reliability. productivity. Conduct work-studies. Studying plant layout and material handling systems and suggesting improvements. practice and other developments. improvement studies in various equipment and fixation of norms. quality. design. 3. Design. Functions: 1. 2. Visit other industries for getting information regarding LTS methods. Planning and assessment of man power requirements of various departments periodically. 9.APOLLO TYRES LTD DIVISION HEAD MANAGER EXECUTIVES (Chart no 5. Explore the possibilities of capacity expansion and prepare project report. 11. 5. 4. 7. implement and image integrated production and service delivery system that assure productivity. Negotiation with unions regarding worries.9) Objectives: The main objective of this department is to plan. Prepare budgetary planning for capital and cash flow requirement. 8.

Preparation of machine utilization report. Associate with professional bodies like productivity council. 22. 15. 26. lost time. other officers and new recruits. 20. NITTIE etc and institution of engineers etc. Involve best practices and processors through global bench marketing in the context of global competitions and intense customer focus. 25. overtime etc. Computation of plant performance report on a daily basis and display. 18. 17. Furnish various other management information reports of the top management. new products etc. norms. supervisors. O & M (Organisation and methods) studies. Incentive earning computation and releasing of incentive earning list. 24. 13. scrap detail. At Perambra plant there is separate accounting and finance Page 83 . working progress and finished goods. 23. Suggest various cost reduction programmes and implementation. 28. Computation of various data and submission of application for various awards. 16. 19. Preparation and presentation of daily review report on critical parameters. 21. 27. absenteeism. productivity. Continues improvement of methods and equipments designed compatible to the best economic standards. Optimise inventory levels at various stages such as engineering store. 29. Conduct daily audit on man power. Conduct various training classes for workmen. line balancing etc. kaizen. Apply various industrious engineering techniques such as job evaluation. Computation of kilogram/man hour.FINANCE DEPARTMENT The corporate office situated at Gurgaon does most of the accounting and taxation jobs of ATL. Computation of indirect incentive earning rate. Incentive allowance computation and advice to finance and time office for payment. 9.APOLLO TYRES LTD 12. Extent the support to the line function term regarding manpower details. 14.

The strong performance of Apollo is combination of high growth in sale along with enhanced operation management. When.43 million during the previous year. MANAGER EXECUTIVES (Chart no 5. The fund for acquiring raw materials will be provided from the corporate office to Accounts and Finance Department. recording growth.469.10) Sales is performed and maintained by the corporate office of Apollo Tyres Ltd. 2008 amounted to an all time high of 42. STRUCTURE OF FINANCE DEPARTMENT DIVISIONAL HEAD MANAGER MANAGER ASSO . with regard to export of tyres they will be directly unloaded into the Cochin Shipyard premises rather than unloading to the corporate office godown and then to the port. wages and costing. This department deals with salary. April 1st to 31st March. e. SECTIONS UNDER FINANCE DEPARTMENT 1. 743. better working capital management. Gross sales during the financial year ended March 31.APOLLO TYRES LTD department. MANAGER EXECUTIVES ASSO . An annual cost audit is also conducted along with the company audit every accounting year i. Excise duty of the raw materials also comes under this department.83 million as against Rs. aggressive marketing and overall cost reduction measures adopted by the company.37. Accounts Page 84 .

Payroll 4. Costing 3. Excise 5. Finished goods stores 7.ordination and control Help in tax administration and tax planning Preparation of audit report Storage of raw materials. Raw material stores 6. finished goods and engineering goods Handle scrap disposal SHARE HOLDING PARTNERS Foreign holdings 25. Purchasing of engineering goods OBJECTIVES • • • • • • • • • To arrange adequate funds for the business To ensure proper utilisation of funds To increase profitability of business To maximise the value of the firm To do the analysis and appraisal of financial performance To anticipate the financial needs To maintain good relations with suppliers and monitor their performance Physical location and stocking of materials Minimization of damage FUNCTIONS • • • • • • • Financial forecasting and planning To advise top management on all financial matters and to suggest various alternative solution for any financial difficulty Co. Engineering stores 8.APOLLO TYRES LTD 2.67% Page 85 .

at the same time he has also some responsibilities. The role of finance manager is to prepare the accounts and auditing of all the financial transactions of the company and have the advisory function in the financial and establishment matters. The fundamental decision making areas of financial manager are capitalisation decision. investment decision decision.APOLLO TYRES LTD Government or Financial institutions Corporate bodies (non covered above) Directors and their relatives Other including Indian public 29% 4.84% Finance is the backbone of every organisation. financing decision. So finance manager plays an important role.07% 32.43% 8. Page 86 .


Global sourcing of raw material. Opportunities: • • • Leadership position in the commercial vehicle segment will enable the Company to leverage new and related business opportunities. Global presence with the accusation of Apollo Tyres South Africa (pty) Ltd. international process and system certifications. Raw material price volatility.APOLLO TYRES LTD • • • • • • • • • • Continued market leadership in the dominant industry segment of truck and bus tyres. Strong brand recall in a price sensitive Indian market. Growth in Overseas markets like Europe. Maintain a healthy relationship with trade unions More training facilities must be given to employees The company should invest more on advertisement. Responsive to changes in market conditions and product profiles. New product segments like Truck/Bus Radial (TBR). Threats: • • Imports from neighbouring countries at competitive prices. Off The Road tyres (OTR. on account of closeness to natural rubber growing belt. Page 88 . Economies of transportation cost. Dynamic and progressive leadership. Capital intensive business. willing to implement change. High usage of information technology systems to hasten the flow of information and leverage opportunities across 140 locations in India. Extensive distribution network in India and South Africa. Global quality standards. retreading and allied automotive services. Weakness: • • • • • No presence in two and three wheeler segment. (Formerly known as Dunlop Tyres International(Pty)Ltd.


It uses concepts developed in Industrial Organization (IO) economics to derive five forces which determine the competitive intensity and therefore attractiveness of a market. The objective of corporate strategy should be to modify these competitive forces in a way that improves the position of the organization. An "unattractive" industry is one where the combination of forces acts to drive down overall profitability. Porter has identified five competitive forces that shape every industry and every market. These forces determine the intensity of competition and hence the profitability and attractiveness of an industry. Since that time it has become an important tool for analyzing an organizations industry structure in strategic processes. A very unattractive industry would be one approaching "pure competition". Page 90 . Porter in his book „Competitive Strategy: Techniques for Analyzing Industries and Competitors“ in 1980. Porters model supports analysis of the driving forces in an industry. Porter’s model is based on the insight that a corporate strategy should meet the opportunities and threats in the organizations external environment. Porter of Harvard Business School in 1979. competitive strategy should base on and understanding of industry structures and the way they change. The model of the Five Competitive Forces was developed by Michael E. Attractiveness in this context refers to the overall industry profitability. management can decide how to influence or to exploit particular characteristics of their industry. Especially.APOLLO TYRES LTD A MODEL FOR INDUSTRY ANALYSIS: Porter's five forces analysis is a framework for the industry analysis and business strategy development developed by Michael E. Based on the information derived from the Five Forces Analysis.

The buying industry (automobile) hinders the supplying industry in their development (e. The relationship to powerful suppliers can potentially reduce strategic options for the organization. the buying industry often faces a high pressure on margins from their suppliers.APOLLO TYRES LTD The Five Competitive Forces The Five Competitive Forces are typically described as follows: Bargaining Power of Suppliers The term 'suppliers' comprises all sources for inputs that are needed in order to provide goods or services. · The buying industry has low barriers to entry. Bargaining Power of Customers Page 91 . so their bargaining power is low. · · · · There are no substitutes for the particular input. The switching costs from one supplier to another are high. Supplier bargaining power is likely to be high when: · The market is dominated by a few large suppliers like MRF. In such situations. The supplier’s customers are fragmented. reluctance to accept new releases of Tyres). There is the possibility of the supplier integrating forwards in order to obtain higher prices and margins.g. · · The buying industry has a higher profitability than the supplying industry. JK Tyres rather than a fragmented source of supply.

The product is undifferentiated and can be replaces by substitutes. These are typically · · Economies of scale (minimum size requirements for profitable operations). the bargaining power of customers determines how much customers can impose pressure on margins and volumes. In such a situation. The threat of new entries will depend on the extent to which there are barriers to entry.APOLLO TYRES LTD Similarly.g. Scarcity of important resources. Protected intellectual property like patents. prices. · Switching to an alternative product is relatively simple and is not related to high costs. · Cost advantages of existing players due to experience curve effects of operation with fully depreciated assets. The supplying industry operates with high fixed costs. High initial investments and fixed costs. there is a concentration of buyers. · · Customers have low margins and are price-sensitive. The supplying industry comprises a large number of small operators. licenses etc. · · · Brand loyalty of customers. customer loyalty) at any time. qualified expert staff.g. There is always a latent pressure for reaction and adjustment for existing players in this industry. Customers bargaining power is likely to be high when · · · · They buy large volumes. The customer knows about the production costs of the product. market shares. e. new entrants could change major determinants of the market environment (e. Threat of New Entrants The competition in an industry will be the higher. Page 92 . the easier it is for other companies to enter this industry.

This category also relates to complementary products. Distribution channels are controlled by existing players. Current trends. · Existing players have close customer relations. Close customer relationships. The relative price for performance of substitutes. Competitive Rivalry between Existing Players This force describes the intensity of competition between existing players (companies) in an industry. margins. Players have similar strategies. Competition between existing players is likely to be high when · · There are many players of about the same size. · There is not much differentiation between players and their products. hence.g. and hence. Switching costs for customers. Page 93 . there is much price competition. the treat of substitutes is determined by factors like · · · · · Brand loyalty of customers. Similarly to the threat of new entrants. Legislation and government action.APOLLO TYRES LTD · · Access to raw materials is controlled by existing players. from long-term service contracts. They could potentially attract a significant proportion of market volume and hence reduce the potential sales volume for existing players. Threat of Substitutes: A threat from substitutes exists if there are alternative products with lower prices of better performance parameters for the same purpose. e. · · High switching costs for customers. on profitability for every single company in the industry. High competitive pressure results in pressure on prices.

APOLLO TYRES LTD · Low market growth rates (growth of a particular company is possible only at the expense of a competitor). Diagram of Porter's 5 Forces SUPPLIER POWER Supplier concentration Importance of volume to supplier Differentiation of inputs Impact of inputs on cost or differentiation Switching costs of firms in the industry Presence of substitute inputs Threat of forward integration Cost relative to total purchases in industry BARRIERS TO ENTRY Absolute cost advantages Proprietary learning curve Access to inputs Government policy Economies of scale Capital requirements Brand identity Switching costs Access to distribution Expected retaliation Proprietary products BUYER POWER Bargaining leverage Buyer volume Buyer information Brand identity Price sensitivity Threat of backward integration Product differentiation Buyer concentration vs. industry Substitutes available Buyers' incentives THREAT OF SUBSTITUTES -Switching costs -Buyer inclination to substitute -Price-performance trade-off of substitutes DEGREE OF RIVALRY -Exit barriers -Industry concentration -Fixed costs/Value added -Industry growth -Intermittent overcapacity -Product differences -Switching costs -Brand identity -Diversity of rivals -Corporate stakes Page 94 .


transportation etc. All departments at the plant are being connected through SAP which gives real time connectivity with each other. Employees are provided with facilities such as subsidized canteen.APOLLO TYRES LTD FINDINGS •ATL is the first tyre company to receive ISO 9001 certification and one the few tyre manufactures to obtain QS 9000 certification. The workers are not completely satisfied with the wages they are paid. The management is sometimes forced to accept demands made by the unions. The factory premises are kept clean which comes under a dedicated system known as Environment Management System (EMS) Factory is located at an ideal location that allows easy access to land. Safety posters and slogans are exhibited inside the plant and various safety awareness programs are also conducted. Page 96 . Trade unions play vital role as bargaining agents. • • • • • • • • • • • Workers health and safety are given prime importance A good co-ordination exists between different departments. air and sea transportation. The products of the company are known for its high quality standards. All the plants of Apollo tyre group are being connected with the head quarters through WAN and SAP which critical decision making easy.

Each should have an in house marketing department that can take care of the local fluctuations in market. The company should invest more on advertisement. Page 97 .APOLLO TYRES LTD SUGGESTIONS • • • • • • • • Maintain the relationship between employees and employers There should be training program for better understanding of SAP A bit more promotional activities could enhance building brand image Maintain a healthy relationship with trade unions More training facilities must be given to employees The company should enter into two/three wheeler markets.

Transparency and communication are cornerstones of corporate practice. ever expanding and profitable and in constant pursuit of customer satisfaction is Apollo policy to design. In spite of fierce competition and local problems the Perambra plant thrives and move forward to its target of 310 MT/day and thereby achieve their 9000 crore goal by the end of 2010. A fair wage system prevails in ATL.. Page 98 . The industrial relation with the local union is fairly good. Apollo is focused on fast and flexible.APOLLO TYRES LTD CONCLUSION Apollo tyres Ltd is the 7 th fastest growing tyre company in the world. There are good working conditions and industrial harmony among the employees. The company is facing cutthroat competition from Indian market as well as foreign market. Apollo tyres boast a vibrant and dynamic. The company provides better working condition for employees. The employees enjoy working as a team and with customers to create superior and distinct production and services. manufacture and service our products to provide the level of quality and value that meets ever customer needs. Proper training to workers and efficiency of the workers must be increase to increase production. Proper and adequate training is given to the employees. Despite of all these challengers Apollo has done well in the past and with a booming economy and a focused progressive leadership at the top. Apollo stands first in the production of truck tyres. never ending improvement in order to create an enterprise that is dynamic. In spite of recession the company is still making sufficient profit. profession and non hierarchical culture. The company is facing a cut throat competition in Indian market and international market. which leads to higher productivity.

they go ahead and create opportunities. they are always looking out for new opportunities. Apollo Tyres. These are the company’s stated areas of corporate excellence. At Apollo Tyres the three corporate pillars of People.APOLLO TYRES LTD across levels. in its journey towards becoming a best in class global manufacturer. Quality and Technology underpin all activities and processes. BIBLIOGRAPHY Page 99 . If opportunities do not come their way. Over the years they have created opportunities for growth. to ensure that each individual employee is aligned with the goals and aspiration of the company. opportunities for success and also opportunities for a bright future. & P. Research Methodology.wikkipedia. New Delhi. 2006.C. H.Methods & Techniques. 2. 4e.apollo tyres .com Manuals Apollo annual reports Apollo journals Job sheet of various departments Page 100 . Web Sites www.APOLLO TYRES LTD BIBLIOGRAPHY Books reference www.R. Delhi.R..M. Kothari. Aswathappa K. Tata McGrawHill. New Age International Publishers. 2005.


46 4.608.86 27.06 Year ended 31.55 5.11 37.41 878. Interest 6.248.08 4.64 2. No Particulars 1.03.47 112.83 Page 102 .32 Year ended 31.98 520.168.562. Depreciation 7.65 (552.Total Expenditure a) Decrease/ (Increase) in work in progress & Finished Goods b) Consumption of Raw Materials c) Staff cost d) Excise Duty e) Other Expenses Total 4.496.829. Operating Profit 5. Gross sales/Income from operations 2.Other Income Total 3.91 7.469.2009 45.711.03.77 42.791.APOLLO TYRES LTD PROFIT AND LOSS ACCOUNT OF APOLLO TYRES Sl.43 980.2008 42.946.849.075. Profit before Tax 8. Provision for Tax 265.56 6.15 668.64 3.23 42.360.732.07 1.10 3.530.60 2.79 92.47 45.74) 23.334.270.731.

02 1.95 203.68 634.APOLLO TYRES LTD -Current -Deferred -Fringe Benefit Tax 9.Net Profit 439.00 750.41 297.41 175.78 598.143.120.18 975.71 967.585.569.75 195.00 441.61 469.305.30 750.00 94.53 419.74 348.051.06 543.85 80.13 265.45 417.00 1.67 77.28 340.689.78 971.67 42.838.76 144.36 370.01 121.13 84.66 950.51 460.70 48.30 148.12 473.23 1.41 1.43 398.33 54.38 38.41 920.41 302.03 BALANCE SHEET PARTICULARS Mar 09 Mar 08 Mar 07 Mar 06 Mar05 Apollo Tyres Ltd SOURCES OF FUNDS : Share Capital Reserves Total Total Shareholders Funds Secured Loans Unsecured Loans Total Debt Total Liabilities APPLICATION OF FUNDS : Gross Block Less : Accumulated Depreciation Less:Impairment of Assets Net Block Lease Adjustment Capital Work in Progress Investments Current Assets.65 1.43 305.72 902.00 694.85 191.60 195.55 1.29 155.50 1.30 1.384.85 1.48 330.66 38.40 576.70 1.228.82 1.80 46.00 369.50 1.13 695.85 223.34 538.77 1.93 0.81 1.43 45.52 110.14 231.52 2.39 233.355.37 1.00 1.18 1.12 156.02 381.05 87.00 2.51 541.34 281.310.180. Loans & Advances Inventories Sundry Debtors Cash and Bank Loans and Advances Total Current Assets Less : Current Liabilities and Provisions 50.148.71 462.94 618.79 Page 103 .14 237.196.06 451.34 595.94 840.53 1.71 513.46 258.

06 0.120.63 626.84 0.62 237.25 569.38 2.02 Net Deferred Tax -156.58 0.08 658.21 1.38 139.02 69.56 542.73 380.07 568.55 74.94 Miscellaneous Expenses not written 0.29 152.12 10.49 113.26 105.89 0.23 Contingent Liabilities 282.85 565.29 Page 104 .384.35 1.49 -141.21 334.14 188.20 289.051.APOLLO TYRES LTD Current Liabilities 460.597.96 Deferred Tax Liability 167.83 93.13 Provisions 95.26 8.07 223.06 Total Assets 2.27 388.26 11.91 466.76 Net Current Assets 484.20 1.63 Total Current Liabilities 555.54 115.694.32 437.70 -105.61 -103.15 off Deferred Tax Assets 10.44 -129.06 1.12 831.