North South University

School Of Business
Summer 2011
Course: Production Management (MGT 314.1)

Group Project: Rahimafrooz Batteries Ltd. (RBL)

Prepared for:
Mr. Adeyl Khan (Ayn) Honorable Faculty North south university

Prepared by: Nexus
TanzinaMahmoodAuditi Farah TajneenAlam Minhaz Isa Hossain Shukh Kaiser RajibKundu Atia Afrin ID# 081 911 030 ID# 073 363 530 ID# 073 522 030 ID# 071 737 030 ID# 071 731 530 ID# 073 655 030

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Letter of Transmittal
August 10th, 2011 To Mr. Adeyl Khan Honorable Faculty School of Business North South University Basundhara Residential Area, Dhaka. Sub: Submission of project report Sir, We are glad to meet the deadline to submit our project report. Here we tried to discuss the manufacturing of the Rahimafrooz Batteries and the steps and resources involved in the production process. We tried to enrich the project paper with whatever knowledge we had from the perspective of our course. While doing the project we found similarities with our study materials that made us understand the course contents very clearly and we enjoyed a lot doing the report. Please find the concerned report attached to this letter. If you have any kind of inquiry regarding our work, we would highly appreciate if you feel free to address us. Sincerely, TanzinaMahmoodAuditi (Coordinator, Cell-01675-188528, e-mail: tanzina_auditi@yahoo.com) Members Farah TajneenAlam Minhaz Isa Hossain RajibKundu Shukh Kaiser Atia Afrin

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ACKNOWLEDGEMENT First of all we are grateful to Almighty Allah for enabling us to work on this report and for making the circumstances favorable to accomplish our task. This was done under the course curriculum of MGT 314. Without them.operations management. Adeyl Khan for assigning us the project and for all his kind support to accomplish it. We also wish to thank and give the due respect to our family and friends for their cordial support and help they offered throughout the process of preparing the whole report. The project intends to develop a report on the production process of automotive batteries in Rahimafrooz batteries limited. We also wish to thank our honorable faculty Mr. Page | 3 . We want to thank all of the people who were with us while we were doing this report. favorable circumstances could have been impossible to found by us.

a few other business ventures. Rahimafrooz Batteries Ltd. dealers and retailers. Excellence. scale. Zirani Bazaar. Energy. Inspiring people. motorcycle. the company has also implemented the occupational health and safety management system. moving to a new factory in Savar. in order to ensure occupational health and safety of its employees. Rahimafrooz has grown in size.Executive Memo Over the decades. The expertise and reputation of Rahimafrooz as a manufacturer of quality batteries locally and internationally has inspired the Group to invest in setting up a new battery factory at Ishwardi EPZ to cater to the growing potential in the international battery market. As of 2009. Customer Delight . Rahimafrooz has strengthened our market leadership at home while reaching out to international markets. (RBL) is the largest lead-acid battery manufacturer in Bangladesh. Automotive and Electronics Division. Rahimafrooz operates in four broad segments ± Storage Power. The Group today has Eight Operating Companies (SBUs). energy and power solutions. It manufactures about 200 different varieties of batteries for automotive. As part of the same strategy. with market leadership at home and export endeavours to more than 44 countries around the world. As a result of these initiatives. Gazipur. and a non-profit social enterprise. the Group currently employs more than two thousand people directly and a further twenty thousand indirectly as suppliers contractors. which are certified in both ISO 9001 as well as ISO 14001 standards. Innovation. the Group recently decided to spin-off the Industrial Battery manufacturing facilities of RBL as a separate business unit. IPS and other applications in its factory located at West Panisail. Page | 4 . The Company maintains high standards of operations. to a world class retail chain ± the team at Rahimafrooz is committed to ensuring the best in quality standards and living the Group¶s five core values ± Integrity. retail. Furthermore. RBL will now be able to devote more resources towards meeting the increasing demand of the local market. and diversity. Ranging from automotive after-market products. OSHAS 18001 standard. The company is one of the leading regional players.

Eltek ± Norway and AEES ± France to ensure the quality of the battery. Rahimafrooz has different technical collaboration agreements with the Lucas Battery Company. Technical support Group (TSG). This report is to focus on the production of automotive batteries in the factory of Rahimafrooz. RBL has state of the art manufacturing plants. Optus and Delta are gaining equity as international brands. Page | 5 . of UK. Its capacity in automotive and other appliance battery is over a million N50 units per annum and has provision for further expansions. It is equipped with the latest technologies along with completeair treatment and lead-recycling management system. Hawker Batteries. and Invensys.Lucas and Spark are the leading names in the local automotive battery market while Volta.

Contents Introduction Product Description Materials Requirement Manufacturing Process Manufacturing layout Production Constraints Recommendations Conclusion References Appendix Page # 7 8 10 11 13 14 15 16 17 18 Page | 6 .

This is why the demand of this is increasing day by day. but also for getting power as backup.INTRODUCTION Automotive batteries are now days used in not only in vehicles. They have their own production facility and equipment¶s. Rahimafrooz is top manufacturer of batteries in Bangladesh. RBL use the traditional way to produce batteries.People are buying their product as they found it reliable. But they use quality equipment¶s with quality workers who are adding value to the product by offering better quallity. They are highly organized and they maintain their production process with extensive care. Page | 7 . RBL has established themselves as a brand in the market of automotive batteries.

Automotive SLI batteries are usually lead-acid batteries. UPS service. Lead-acid batteries for automotive use are made with slightly different construction techniques. or may have parallel strings of batteries. Lead-acid batteries are made up of plates of lead and separate plates of lead dioxide. the chemical reaction is reversed: the lead sulfate reforms into lead oxide and lead. When the battery is recharged. is typically inexpensive and long-lasting. which are submerged into an electrolyte solution of about 35% sulfuric acid and 65% water. With the plates restored to their original condition. and the ignition system of a vehicle¶s engine. An automotive battery is a type of rechargeable battery that supplies electric energy to an automobile. the process may now be repeated. often equipped with Diesel engines. Now a day. automotive battery is also used for IPS.1 volts for a total of 12. depending on the application of the battery. The batteries that Rahimafrooz produces are suitable for both automotive and home appliances use. indicating liquid electrolyte.6 volt at full charge. The batteries that Rahimafrooz produces are suitable for both automotive and home appliances use. Page | 8 . the lights. and are made of six galvanic cells in series to provide a 12 volt system. changing their surface to lead sulfate. The "flooded cell" type. may have two batteries in series for a 24 volt system. This causes a chemical reaction that releases electrons. It is used power the starter motor. UPS service. automotive battery is also used for IPS. the acid of the electrolyte reacts with the materials of the plates. Heavy vehicles such as highway trucks or tractors. Each cell provides 2. An automotive battery may also be a traction battery used for the main power source of a vehicle.PRODUCT DESCRIPTION: Now a day. allowing them to flow through conductors to produce electricity. As the battery discharges. but requires more maintenance and can spill or leak.

More costly alternatives to flooded batteries are "Sealed" or "Valve regulated" battery of the absorbed glass mat (AGM) type which uses a glass mat separator. and a "gel cell" uses fine powder to absorb and immobilize the sulfuric acid electrolyte. Once the engine is started. Page | 9 . These batteries are not serviceable (typically termed "maintenance-free") and do not require replenishment of electrolyte under normal use. They are constructed of many thin plates with thin separators between the plates. The starting (cranking) or shallow cycle type is designed to deliver large bursts of power for a short time. this article deals with the classic.Flooded batteries are distinguished by the removable caps that allow for the electrolyte to be tested and maintained. as is needed to start an engine. However. Starting batteries are intended to have a low depth of discharge on each use. Both types of sealed batteries may be used in some automotive applications where leakage is a concern. and may have a higher specific gravity electrolyte to reduce internal resistance. flooded-type of car battery. the battery is recharged by the engine-driven charging system.

the connection point between the battery and whatever it powers. Lead terminals.MATERIALS REQUIRED FOR MANUFACTURING Batteries are made of five basic components: y y y y y A resilient plastic container. Page | 10 . Positive and negative internal plates made of lead. Later on they do the assembly of these products in this factory. better known as battery acid. a dilute solution of sulfuric acid and water. Plate separators made of porous synthetic material. Electrolyte. All these materials are required for the production of a battery. They used to import these materials from abroad.

The cover is dropped on and sealed when the battery is finished. the pasted positive and negative plates must be separated to prevent short circuits. Expander material made of powdered sulfates is added to the paste to produce negative plates. They follow the universal manufacturing process.Rahimafroz designed their manufacturing plant in a systematic way where this six steps are done one by one. Fine pores in the separators allow electrical current to flow between the plates while preventing short circuits Page | 11 . For a typical 12-volt car battery. the case is divided into six sections.  Step 2:The process continues with the manufacture of grids or plates from lead or an alloy of lead and other metals. Separators are thin sheets of porous. Most automotive battery containers and their covers are made of polypropylene. Inside the battery. The detail description of what happens in which stage are given below. shaped somewhat like one row in an ice-cube tray.MANUFACTURING PROCESS: Overall manufacturing process is dived into six steps. or cells.  Step 1:The manufacturing process begins with the production of a plastic container and cover. insulating material used as spacers between the positive and negative plates. A battery must have positive and negative plates to conduct a charge.  Step 3:A paste mixture of lead oxide which is powdered lead and other materials like sulfuric acid and water is applied to the grids.

Elements are dropped into the cells in the battery case. During this step. The battery is then filled with electrolyte . or posts. The battery is checked for leaks. The cells are connected with a metal that conducts electricity. and there is one element per battery cell. This unit is called an element. are then welded on. or finishing. When the battery is fully charged. it moves to another line where the case is cleaned. if necessary.a mixture of sulfuric acid and water.or battery acid -.  Step 5: The final step is charging. a positive plate is paired with a negative plate and a separator. and the labels are attached. Step 4: In the next step. The lead terminals. Page | 12 . and the cover is attached. the battery terminals are connected to a source of electricity and the battery is charged for many hours. or compartment in the container.

they need to complete the steps one by one. Step 1 Step 2 Step 3 Step 4 Step 5 Production process begins with production of the cover and container Manufacture of grids or plates from lead or an alloy of lead and other metals A paste mixture of lead oxide is applied to the grids A positive plate is paired with a negative plate and a separator Charging. the workers can¶t go for the next one. Page | 13 .LAYOUT OF MANUFACTURING The layout that is used by RBL is a product layout. Before completing one step. packaging and labeling As the company use product layout.

None of them are that much severe. Rahimafrooz has no exception on their production process. They also have to go through some troubles while producing batteries. But they reduce the production efficiency sometimes.PRODUCTION CONSTRAINTS Any kind of production process has to go through some sort of difficulties. Following problems Rahimafrooz has to face during the production process. y Shorted cell due to failure of the separator between the positive and negative plates Shorted cell or cells due to buildup of shed plate material building up below the plates of the cell y y Broken internal connections due to corrosion Broken plates due to vibration and corrosion Low electrolyte Cracked or broken case Broken terminals Sulfating after prolonged disuse in a low or zero charged state y y y y y Page | 14 .

Page | 15 .  Reducing bottlenecks. Whileautomotive batteries are being used in other purposes too.  Improve the production facility with more production equipment.RECOMMENDATIONS As the demand is high for the automotive battery. Rahimafrooz should improve their production process to enhance their production of battery.  Try out some other production layout to check whether it can improve the production quantity more. following steps can be followed by RBL to enhance their production.  Increase number of employees for production.  Find out ways to remove or reduce the production constraints. They should allocate more workers for those steps which requires more time to reduce the time to manufacture a complete battery.

As the demand will go up. they will need to increase the production. Page | 16 . In this situation where Rahimafrooz is leading the market in Bangladesh as battery manufacturer. This is what Rahimafrooz should focus on now. Currently they are producing well and a steady production rate is being maintained. This can be done easily without setting up new plant if they can reduce the constraints which are wasting some of their resources now. If those can be removed. they will be able to get more production. But still there are some problems that have been faced by them. they need to retain the consumer satisfaction.CONCLUSION So this was all about the production process of automotive battery in Rahimafrooz batteries factory.

d.(n.a.a.).).com/Portals/tabid/62/Default.REFERENCES  (n.aspx  (n.rahimafrooz. retrieved on August 5th .(n. Rahimafrooz official website.from http://en.). Automotive battery .). retrieved on August 5th.d.org/wiki/Automotive_battery Page | 17 .from http://www.wikipedia.

APPENDIX Page | 18 .

Tejgaon. Dhaka 1215 Tel: 9113696. 9113522 Fax: 8115305. and/or Overseas Rep(s) (if any) Rahimafrooz Group Rahimafrooz (Bangladesh) Ltd. Rahimafrooz Distribution Ltd. Type of organization Type of Business Corporation. Rahimafrooz Superstores Ltd. 1954 Page | 19 . 9126968 Parent Company (if any) Subsidiaries. Rahimafrooz Batteries Ltd. Rahimafrooz Globatt Ltd. Rahimafrooz Batteries Limited 705 Nakhalpara. Rahimafrooz Accumulators Ltd. Rahimafrooz Energy Services Ltd. Rahimafrooz CNG Ltd.Private Manufacturer Retailer When established? April 15.Company Profile Template Name of the Company Address: Rahimafrooz Batteries Ltd. Rahimafrooz Renewable Energy Ltd. Associates.

Traditional Major business Power and energy activities ( basic products and services offered) Primary/priority markets? Local market. investment.g. main issues? Business Model: (e.g. General guiding policies that are to govern all activities Business Goals and Objectives) Business Strategy: Diversification) (e. changing markets. technology. labour force) Current priorities. Enriching lives with your trust Economic Intent: (e. home based. markets/product range in past few years? Major Customers (current) General people who need power sources. No diversification. profit making. Decentralized. office bound) Organizational Structure Be the market leader in the sectors they are involved. Decentralized. They has different departments to maintain different business sectors. Centralized.g.g. General consumers Changes to Product portfolio has been developed. speculation) Value Chain: (break down Value is added through quality products.Recent changes in company or affecting company? (e.g. Profit making by offering quality product with added value and Intent of the organization. Their focus is on better product offering. service. Vision Statement: Mission Statement: Values: (e. value) Page | 20 . retail. non for profit making.

g. ISO)? Workforce No. Rahimafrooz Batteries has achieved all the certification of ISO. Of full-time employees : 500 No. word of mouth) Part time Managers Line workers Traditional Interview Traditional Interview Traditional Interview Skill test Page | 21 . Standard Operating Procedures.g.Accreditations (e. Of part-time employees: 100 Contractors (% of workforce) Casual staff (% of workforce):50 Average length of service Full time Part time Managers Line workers 15-20years Less than a year 15-20years 5-10years Graduates HSC Master¶s Degree Average Qualifications/educational background: Full time Part time Managers Line workers Recruitment ± processes Full time used? (e.

Name: teams relevant to your project Assembly line Size: Hours of Structure work/shifts: supervision: 8hours Line manager of 100people Page | 22 . work areas.Key processes.

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