Initial Information of Kabra ExtrusionTechnik Ltd By [Group-10, Section B] Antrish Singhal, WMP6071 Archit Khandelwal, WMP6072 Parul Kumar

Bhatia, WMP6094 Pradeep Aggarwal, WMP6096 A report submitted in fulfillment of the assignments for MANAC-2 WMP 2013

Indian Institute of Management, Lucknow Noida Campus 2010

Date: 04-09-2010

.................. 4 2..................................................... 4 Cost Sheet .....1 Products ..........................1..................3 Production Process ....................................1 2....................................................................................................................... 8 ...................... 3 2............................ 3 2...........1................... 3 Analysis ....................................2 2.................................................................Table of Contents 1 2 Assignment ..... 3 PVC Electrical Conduit Pipe .2 PVC Casing-Capping ......................................

. PVC Casing-Caping 2. .1. aircraft etc.1 Products The company at one of its factory manufactures following products: 1.1 Assignment The assignment is to provide initial information obtained from the company. Street light and traffic light signals. PVC Electrical Conduit Pipe 2. railway coaches. 2 Analysis 2.1 PVC Casing-Capping Applications: y y y Open wiring in industrial / residential and commercial buildings. ships. Wiring on buses.

2. ships. railway coaches. Can be used as ceiling suspended ducting. House meter and water pump connections.2 PVC Electrical Conduit Pipe Applications: y y y y y Open and concealed wiring in industries/residential and commercial buildings. .1. Being light can be used on false ceilings and sleevings. Street light and traffic signal connections. aircrafts.2 Production Process RAW MATERIALS y y y y y y PVC Resin Calcium Carbonate Wax Stearic Acid One Pack (Heat Stabilizer) Titanium Dioxide Mixing y Raw materials are mixed and powder blend is prepared in high speed mixers under closely controlled and monitored conditions.y y y Can be used in telecoms wiring and terminals. 2. Concealed wiring on buses. Can be used for bare conductors. etc.

o Screw barrel  Screw is used as a mixing and pumping element. Mixer Loader y The mixture is then loaded on to the loader. This loads the mixture into the extruder. The main components of extruder are: o Hopper  The machine is fed with dry blend PVC compound through hopper. The screw is rotated in a heated barrel in which feed opening is placed radically or tangentially at one .Heating y The mixture so prepared is transferred to the heating chamber where the mixture is heated up to 130-135 degree Celsius for 12 minutes. Cooling y The heated mixture is then cooled for about 5 minutes to 45 degree Celsius. Extrusion y This is the process of converting a plastic raw material into homogeneous melt under controlled temperature and mixing and then forcing the material under pressure through a shaping die orifice and subsequently setting the required shape by means of a cooling and sizing system.

Extruder DIE y The opening that allows plasticated material to form particular shape is achieved through DIE. An electric motor is connected to the tank which empties the water from the tank and fills it again with fresh water. different Dies are used for Casing-Capping and Electrical Conduit. Printing . cools the pipe coming out of DIE.end of the barrel and die axially at other end. filled with water. Vacuum Tank y This tank. The rotating screw takes the material from a feeder through a heated barrel zone and compact it against the breaker plate and other restriction so that pressure builds up which forces the material through the restriction to the extrusion die where it is given form of shape. Different sizers are used for Casing-Capping and Electrical Conduit. Dies can take on a variety of shapes and have adjustable openings. So.

Cutting unit y This unit cuts the pipe at desired length.y Pipe coming out of vacuum tank goes under the printing machine which prints the name of the company on the pipe. The whole production process is shown below: . Haul-off unit y This function of the haul-off unit is to drive the pipe away from unit without jerking at constant speeds.

3 0.00 .500 12.25 Price (in Rs.15 0.)/kg 61 12 75 72 110 110 Quantity Produced Monthly Production in batches (if whole month is worked on single product) 780 1950 Product Casing & Caping Electrical Conduit Batches Produced Per Day 30 75 No.3 0.5 0.000 1 2 3 4 5 6 Manager (1 NO) Accountant (1 NO) Watchman (3 NOS) Supervisor (1 NO) Labor (7 NO) Lab Assistant (Quality Inspector) (1 NO) Plant & Machinery S.NO. of pieces in a batch 100 25 Monthly Weight Production in per piece pieces (in grams) 78000 300 48750 600 Salary & Wages Salary/month 15.000 10.00 515700. 1 2 3 4 5 PLANT & MACHINERY Extrusion Machine 30 Kgs Mixer/Cooler Belling Machine PVC Pipe Testing Equipment Chilling Plant 6 Tonnes PRICE (RS) 2791600.000 6.000 42.000 7.00 250000.00 250000.3 Cost Sheet Direct Material (Per Batch) Material PVC Resin Calcium Carbonate Wax Stearic Acid One Pack (Heat Stabilizer) Titanium Dioxide Quantity Used (in Kg) 25 2.00 324800.2.

56.100/- 30000. Building & Water 1 2 3 4 5 6 7 8 Twin Screw Mixer/Cooler Chilling Plant Air Compressor Water Pump Scrap Grinder Belling Machine Lighting Total 59 HP 22 HP 15 HP 2 HP 15 HP 7.6 Air compressor 2 HP 7 Water Pump .2 Nos.5 HP 9 HP 15 HP 135 HP Consumption/month = 135 HP X 0.75 KW X 0.00 30000.862/Other Expenses (Per Month) Rent Printing (This involves printing company name and logo on products) Maintenance and general overheads 80. Total = Rs. 4.5 per unit X 208 (hours/month) = Rs.00 Useful life = 5 yrs.192. (Depreciation is charged on straight line basis) Annual Depreciation = 4192100/5 = 838420 Power.000 10. 4.000 .000 10.6 X Rs.

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