Part B

Manufacturing Process
Today industries practice different manufacturing processes. Manufacturing processes
are a series of steps that are used in conversion of raw materials into final goods.
Some types of manufacturing process are:
 Continuous Production
 Mass Production
 Batch Production
 Job-shop production

In each of the different Manufacturing processes the factory has a different layout.
Such as:
 Project
 Manufacturing cell
 WorkCentre
 Assembly Line
 Continuous Process

Industry Visit

JM Plastopack is a company that works in the Plastic Film Industry. Their

manufacturing plant is based in Sanand, Ahmedabad. The Plant is situated in a plot of
roughly 30000 sqft.
The main plant building houses the machines divided into two sections.

Section 1
This section houses one of the most critical machines of the plant. The LDPE
processing and converting machine is where they convert PP granules in the rolls of
LD films.
They use a mix of Manufacturing cell and continuous process in this section.
Why manufacturing cell?
As per manufacturing cell the layout is dedicated to the processing of similar type of
products and similar type of processing requirements.
In Section 1 of the plant they process LD films of different specifications that require
different types of processing.

Why continuous process?

As per continuous process the factory runs 24-hrs a day, 6-days a week. Thus there is
continuous production and processing of material.

Section 2
This is the final section of the production facility and houses different machines. Here
the company uses a process layout in which they have grouped similar processing
activities together. The advantage of such a layout is that the number of machines
required is low. The machine’s utilization is flexible and the inventory of finished
goods is low.
Process done in Section 2:
 LD or BOPP film rolls are loaded onto the machines.
 Each machine requires two workers- one senior operator and one helper.
 Functions performed on the machines:
1. Heating- The film is heated for easier processing
2. Adhesive Application
3. Drying
4. Rolling
 After the processing is completed the final inventory is kept in the stock area
and transported.
 The inventory stock is not kept for too long, as the demands are higher than
the supply.
 Part C

Analysis- Manufacturing Process

The company runs productions 24-hours, divided into two shifts. So they exercise the
continuous production technic. Their production is divided in to different sections,
which is a representation of manufacturing cell concept (Process Layout).
The execution of these processes in the company is very efficient. Due to the
sectioning of the manufacturing process each cell deals with only similar type of
processes and thus reduces the movement of inventory, spares and workers. The only
movement that happens is the movement of the intermediary finished goods from one
section to the other.
In the second section of the factory there are four machines for the final processing of
the goods. Two machines out of the four work on similar type of material that is
LDPE and one machine works on BOPP material. The BOPP machine is a
multifunction two-stage machine that does printing (4-colour, 2 stage printing) and
adhesive application on the BOPP film. But the base functions of all machines are the
same. The fourth machine is an advanced fully automatic machine that was freshly
purchased from China but hasn’t gone into complete production as of yet. But as per
the factory manager’s assessment the newer machine is far superior and faster than
the old ones and will greatly increase their capacity. With the induction of the new
machine they will be able to meet higher capacity (up to 10x increase in production
with reduction in the number of labors required for the operation of the machine)
demands from clients.
These finished goods are essentially intermediary goods that other companies use as
raw material. JM Plastopack manufactures only one finished product that goes
directly to the end user, i.e. Self-adhesive LDPE film (commonly known as cello-
tape). The factory also houses one manual cutting machine that cuts larger tape tubes
into multiple smaller sizes. The company, in an attempt to increase output, has
ordered two fully automatic slitting machines.
 Analysis- Technology
The company primarily uses Indian machines for their entire production process, with
an exception of one new machine that has been imported from China. The reason for
the new acquisition from China was predominantly based on superior technology and
cheaper price.

Technology
Section Existing Alternate
Name Kabra Extrusion
Function Conversion PP-LDPE
Capacity 190kg/hr
Wastage !0kg
Raw Material (input) Manual
Spares No Stocking
Output 400kg roll
1 operator and one
Section 1 Labor worker

Machine 1
Function Adhesive application
Channel Single
Speed 70m/min
Operation Manual
Output 90kg/hr
1 operator and one
Labor worker
Spares Available

Machine 2
Printing and Adhesive
Function application
Channel Single
Speed 70m/min
Operation Manual
Output 90kg/hr
1 operator and one
Labor worker
Spares Available
15 Cartons (100m X 72
Min Order rolls)

Machine 3
Function Adhesive application
Section 2 Channel Double
 Speed 260m/min
Operation Automatic
Output 300kg/hr
Labor 1 operator
Spares Imported

The role of technology is such that at all possible times there are only 25 workers on
the factory floor. With the induction of newer machines the labor requirement will be
further reduced.