Professional Documents
Culture Documents
1.1 Introduction
Manufacturing industry refers to those industries which involve in the manufacturing and
processing of items and indulge in either creation of new commodities or in value
addition. The manufacturing industry accounts for a significant share of the industrial
sector in developed countries. The final product can either serves as a finished good for
sale to customers or as intermediate goods used in the production process.
world.
ii) The country is expected to rank amongst the worlds top three growth economies and
amongst the top three manufacturing destinations by 2020.
iii) Favourable demographic dividends for the next 2-3 decades.
iv) Sustained availability of quality workforce.
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vii) Strong consumerism in the domestic market. Strong technical and engineering
capabilities backed by top-notch scientific and technical institutes.
Chapter 2
Group Profile
2.1 Introduction
After Pioneering the growth of the flexible packaging industry in India, Uflex has gained
an unchallenged identity. Since its inception in the year 1983 it has turned into a multi
billion company that values quality and customer satisfaction amongst other priorities.
With consumers spread across the world, Uflex enjoys a global reach. Headquartered in
Noida (National Capital Region, New Delhi) it has state of the art manufacturing
facilities in India & Dubai. It has also established offices in UAE, Europe, North America
and enjoys a formidable market presence in more than 85 countries.
Uflex facility enjoys ISO 9001 and ISO 14001 certifications and has FDA and BGA
approvals for their products. It is also a part of the D&B Global Database and winner of
various prestigious national and international awards like the top exporter of BOPET and
BOPP films, and the Worldstar award for packaging excellence. FPA, AIMCAL and the
DUPONT Awards in 2004-2005 are the latest in this series.
Being a multi faceted organization it has integrated its operations from manufacture of
Polyester chips, Films (BOPET, BOPP and CPP - both in plain and metalized form),
Coated Film, Laminates, Pouches, Holographic films Gravure cylinders, Inks and
adhesives to all types of packaging & printing machines, offering total flexible packaging
solution.
Uflex has always been committed to the industry by providing technical know-how and
being the trend-setter in the flexible packaging industry. Being on the edge of innovation,
Uflex endeavors to be the first to come up with advanced products that cater to the
changing demands of the packaging industry.
As part of the Uflex Group, it has over twenty years of experience in polymer
technology. Setting milestones of success and innovation, Uflex is widely known for
manufacturing and supplying products, delivering apt services around the world.
2.2.3 Innovation: Strive to be the best- in technology and business, actively contributing
to the evolution of best practices and striving to develop new packaging solutions to
address customer needs.
2.2.4 Global Perspective: Leveraging the power of global insight, relationships,
collaboration and learning to deliver exceptional packaging solutions to the clients
wherever they do business.
2.2.5 Speed in all directions: To set the principle of Speed and efficiency in every
activity in responding to internal and external customers with a sense of urgency.
Anticipating market opportunities and continuously striving to practice "quick decision
quick investment quick execution quick adaptation and quick customer service".
of 10 microns per meter is used to achieve accurate and mirror surface that is required for
electronic engraving on the cylinder. PLC controlled Galvano Line is used to maintain
proper hardness and roughness of copper cylinders.
Chapter 3
Chemical Division
Chapter 4
Maintenance Department
4.1 Objectives
a) Direct and coordinate the operations and activities of the physical plant maintenance,
including but not limited to: facilities engineering administration, layout, design, and
construction, equipment maintenance, utilities operations and maintenance, building and
grounds maintenance, facilities protection and security, departmental safety, and
environmental compliance.
b) Provide engineering consulting services, surveys, and recommendations to all
Departments; to outside architect/engineer firms performing services for the facility and
to public utilities.
c) Ensure compliance with applicable federal, state, and local laws, regulations, statutes,
and codes, securing required permits, and coordinating with appropriate local authorities.
d) Contract with and oversee the activities of various contractors and consultants for the
fulfillment of facility engineering responsibilities.
4.2 Functions
4.2.1 Management responsibility
The maintenance manager should set goals, plan, organize, and control the activities
under his jurisdiction. All goals should be specific, well defined, and quantifiable, with
an estimated time of achievement given for each goal. Each goal should be
communicated freely and clearly to all those involved. Goals should be reviewed
regularly by the maintenance manager, maintenance supervisor and operations
representatives.
4.2.2 Organisation
Plant maintenance, engineering, operations and production must share responsibility in a
coordinated effort to optimize facility performance. Plant maintenance, as a service
function, has responsibility for safe, efficient, and technically sound execution of
maintenance work. Engineering has responsibility for providing technical information,
guidance, and support to operations and maintenance as part of the team effort.
Operations and Production, as equipment owners, have accountability for their
maintenance costs.
4.2.3 Administration
Administrative operations of the maintenance department includes: program coordination
for the department and liaison with all other departments for the procurement and
maintenance of all real property, production equipment, utility services, and
communication services. Preparation of maintenance department budgets. Coordination
with other departments in the preparation of their maintenance budgets. Preparation of
project cost estimates, proposal, justification, and management of capital projects and
expenditures. Maintenance of records of planned and current construction and
maintenance contracts.
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Maintenance Approach
Signification
Breakdown
Maintenance
Preventive
Maintenance
Scheduled Maintenance
Predictive
Maintenance
Condition-based
Monitoring
Proactive
Maintenance
Detection of Sources of
Failures
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Chapter 5
Project Summary
5.1 Introduction
My association with Uflex Group started on 20th January 2015. I was assigned to undergo
project based training at the Chemical Division, Maintenance Department of the group. I
was given the project Strategy to improve plant maintenance performance and
reliability and lower maintenance costs. I am working closely with the associates in
order to complete my project without causing any hindrance to their work. When I
researched for my work I have found out poor maintenance strategies for production
machines lead to shorter equipment lifespans, cost overruns and longer delivery times.
Then I started to look for the ways to maintain equipment at the right time in an optimal
manner, while lowering production costs and use of resources. Concept of Value
Engineering has been extensively used during this process.
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l) We should be proactive and imagine problems so that we can solve and eliminate
them before they happen.
m) We should develop sense of ownership, build and develop skills, make competent
people at shop-floor level.
5.2.3 Actions for improvements in the coming years
a) We should align the capital project groups output to the on-going needs of
maintenance and operations. E.g. Insure all asset and instrument tag numbers have
procurement and design information catalogued in individual files; have drawings and
manuals easy to access for maintenance; etc.
b) We should show and introduce the benefits of world class practices to managers,
supervisors and leading hands. And show and introduce corporate and senior managers
to world class practices and methods so that can see the benefits to their bottom lines.
c) We should align operations and maintenance efforts through a production plan and
schedule that covers both producing product and maintaining equipment well enough to
make product.
d) We should follow all our statutory obligations well with full documentation and
excellent procedures and practices.
e) We should select the best vendors and suppliers and form a long-term partnership
and alliance with them. This will not only save time, gives us access to good prices, lets
us to use their expertise to solve problems and let us focus on our business.
f) We should introduce proactively build flexibility and redundancy into the plant so we
have options to address problems quickly. E.g. install tie-ins to processes in readiness to
use mobile plant if the installed item fails.
g) We should apply Failure Mode and Effects Analysis and Reliability Centered
maintenance on new and old plant and equipments. On new equipment get the vendor to
do the FMEA/RCM based on our industrys historical maintenance problems.
h) We should select and use equipment that does not breakdown when it fails. We
should implement design protection into equipment that stops it breaking if it is
overloaded or run wrongly and make use of the grade of material that is not affected by
the failure mechanism.
i) We should buy equipment that can be supported and maintained locally, otherwise we
will have to pay a lot more for parts and also will have to wait for the service.
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Chapter 6
Conclusion
The requirement for maintenance process has change drastically from the old concept of
fix-it-when-it-broke to a more complex approach, which entailed adopted maintenance
strategy of a more integrated approach and alignment. Nowadays, management has
become aware that maintenance will also be part of the investment decision-making, thus
prompting managers to take into account the sources of funding and the impact
investment has on credit lines and taxes and not only to focus on upfront cost and
depreciation rates. The goal of maintenance program is also changing and with the rapid
technological development, improvement of equipment and technology will be one of the
key aspects of improved maintenance practiced for better productivity, effectiveness and
profitability.
It has been great honour and privilege to undergo summer industrial training at Uflex
India Pvt. Ltd, Chemical Division, Noida. I strongly believe that this training has explore
me to how the professionals perform and also to applications aspects of what I am
learning in the classroom. All the associates have been very helpful to me. They have
cleared all my doubts very patiently. Catering facility at Uflex has been fantastic.
I think interns should be allowed to visits the other departments besides doing their
projects. This will help them to understand the industry in a better way. They will be able
to gain knowledge of each section of industry from manufacturing to marketing. Interns
should be allowed to have the conveyance facility. Once again thanks for giving me
opportunity to have training in this esteemed organization.
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Chapter 7
Bibliography
The information and data used in this project report has been sourced from a large of
websites, analyst reports, government publications reports. This section mentions the key
information sources:
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