PRESENTATION ON

POM SUBJECT Roll Student name

MATRIX CERAMIC LTD. no.
73 Chirag padaliya

PRESENTED TO PROF. SANDIP 80 Rajkumar patel

TRADA 87 Chetan pujara
PREPARED BY GROUP NO. 4 108 Milan Thacker
115 Pintu Vaishnav
117 Anil Vekriya

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STUDIES
 OVERVIEW OF CERAMIC INDUSTRY
CERAMI
C
INDUSTR
TILES Y
SANITAR POTTER
INDUST
Y WARE Y WARE
RY

WALL FLOOR

VERTIFI PORCELI
ED N
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 CERAMIC TILE INDUSTRY IN INDIA
• Demand of tiles is increased by almost double
than the growth of real estate growth.
• Per capita consumption of India is 0.15 sq.
meter, while in European country demand is
2.5 sq. meter.
• Demand of ceramic tiles is increased due to
following industries:
• IT industry.
• Housing industry.
• Retail industry.
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 SWOT ANALYSIS
Strengths:
• Consistent growth of 12-15 percent in spite of slowdown in
economy.
• The Indian ceramic export market is rising at the rate of 15
percent per annum. (44% of unorganized sector)
 
 Weakness:
• Not much importance given on brand building and network
thus creating hindrance for export growth.
• Low per capita consumption (0.15 sq.mt. p.a.) as compared
to developed nations.
 
 
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 SWOT ANALYSIS
 Opportunities:
• The construction and Housing Boom to provide bolstering
demand for ceramic tiles.
• The untapped rural market supported by a strong growth
witnessed by Indian Agriculture provides tremendous
potential for the domestic ceramic manufacturers.
  
Threats:
• Freight, supply of power and gas remains the key cost-
related issues impacting the industry.
• Basic Customs Duty on import of ceramic tiles from China
and raw materials imported from abroad should be corrected
to prevent dumping of tiles from China.
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 INTRO. TO MATRIX CERAMIC LTD.

• Matrix ceramic limited is ISO 9001 certified

company situated at Morvi city.
• It is engage with production of floor tiles, its
new plant Atom ceramic limited is under
construction for production of wall tiles.
• It is also planning to expand for “Third firing
zone” as a forward integration.
• Recently it produce floor tiles having size
300x300 mm.
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 FACILITIES OF MATRIX CERAMIC LTD.

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 PRODUCTION
PROCESS

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 PRODUCTION PLANT LAYOUT

SORTIN
DERYE G
R GLAZE FINISH
KILLE GOOD
LINE
N S
PACKGIN
G INVEN
TORY
PRESS

BOLL RAW
SPRAY MILL MATERIALS
DRYER
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 RAW MATERIALS
(REQUIRMENT IS 170
TONS/DAY)
Sr. No. Raw material Daily requirement
(In ton)
1 Morvi clay 87
2 Kachchh clay 57
3 Bikaner clay 12
4 Chemicals 6
5 Water Up to 170

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 BOLL MILL SPRAY DRYER

• 240 TONNS/DAY • 250 TONNS/DAY

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 PRESS DRYER LINE

• Minimum 6 & • 100 C Temperature.

maximum 14 strokes
per minute.
• Capacity of 1400 HP.
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• One tile spends 26
minutes in dryer line.
• Length is 40 meter
(half of Killen length)
 GLAZE LINE & DEPARTEMNT
• Glaze department:
• This department prepares color mixture for background
printing on tiles.
• Color chemical will vary with quality of dried raw materials.
• Glaze line:
• It is an assembly line during where, prepared glaze color
applied on glaze.
• Here company has maximum 3 workstations in glaze line for
maximum 3 colors printing.

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 KILLEN
• Length of Killen is 90 meters.
• Temperature of Killen is 1170 C, maintain by Natural gas.
• Killen is divided in 3 zones.

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 SORTING
• Finally tiles are divided in 4 different grades.
• First, second, third and Reject grades in the ration
of 80:12:6:2.
• Tiles are graded on following most common
problems:
• Carbon dust.
• Glaze dust.
• Improper printing.
• Crack in body.
• +- dimension.
• +- size (1 mm).
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 PARETO CHART
120

OUT OF 20 DEFECTIVE TILES100

12
10
80
8
6 60 Column2
4
2 40
0
ON
ST

ST

ZE

20
DU
DU

SI
TI
SA
ON
ZE

EN
A

RB
GL

0
M
CA

DI

GLAZE ... CARBON ...DIMENSA...

Column2
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 CAUSE & EFFECT DIAGRAM

GLAZE CARBON
DUST DUST
PRINTIN FUEL OF
G SPRAY
PROBLE DRYER NOT
M DESIRABLE
OUTPUT OF
FIRST CLASS
PRESS PRESS TILES
PROBLE PROBLE
M M

DIMENSATIO SIZE
N ERROR

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 PACKAGING
• Different packing boxes are used for
different grade tiles.
• Each box contains 10 tiles or 10 feet2.

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 STORAGE & WAREHOUSE
ENTRY LOADIN
OF G OF
GOOD GOODS
S SECON
D
CLASS

FIRST
PATH
CLASS
THIR
D
CLASS

REJE
CT

WAREHOUSE LAYOUT
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 BENEFITS OF LOCATION
• Favorable labor climate:
• Cheap, discipline, trained workers.
• Proximity to market:
• Morvi emerges as a ceramic hub.
• Quality of life:
• Bank, Hospital, Education facilities.
• Proximity to resources:
• Clay of Morvi, Kachchh & expertise, supplier.
• Transportation facility:
• Kandla & Mundra ports & link with NH-8.B.
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 PROCESSES OF COMPANY
• Core processes:
• Order fulfillment process.
• Customer relationship
process.
• Supplier relationship process.
• Supportive processes:
• Raising fund.
• Recruitment.
• Welfare of workers.
• Logistic activities.
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 PRODUCTIVITY OF FIRM
• Productivity = total production of box in day /
total manufacturing hours of day.
• Productivity = 5000/24 = 208 boxes/hour.

RESOURCE FLEXIBILITY:
• Rigid workforce. (Within department)
• Multi skill workers.

FIXED AUTOMATION:
• Because manufacturing process produce only one
type of product in a fixed sequence.
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COMPETATIVE CAPABILITIES & PRIORITIES

Sr. Capabilitie Priorities

No. s
1 Cost Low cost leadership Y
2 Quality Top quality
Consistent quality Y
PREVANTIVE COST (3.5 Corer / 3 years)
3 Time Delivery speed
On time delivery Y
Development speed
4 Flexibility Customization
Variety Y
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 MFG. PROCESS STRUCTURING:
• Continuous line flow layout
• Boll mill is exception (Batch process).
• Product is arranged around resources.
PRODUCTION STRATEGY :
• Make to stock: Somany ceramic Ltd. & other retailors.
• Assemble to order: Dried clay mixture from spray dryer.

SELLING STRATEGY:
• Push strategy: Tiles are in stock then sell.
• Pull strategy: On high volume order (Min. 15 days)
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 BOTTLENECK

• Here bottlenecks are Press, Dryer line &

Killen because it constrains production.
(Spray dryer & Boll mill has more
capacity)
• Company has to order Press, Dryer &
Killen from only one company because it
is interrelated with each other.

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 INVENTORY MANAGEMENT

FIGURES ARE IN tons

Sr. Rae Daily Safety Lot Cycle
No. material requiremen stock size inventory
t
1 Morvi clay 87 20 20 10
2 Kachchh 57 160 20 10
day
3 Bikaner clay 12 120 20 10
4 Chemical 6 10 NA NA
5Suppliers
Water Up to 170are available in Morvi city,
of all chemicals
so the lot size is flexible.
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 VOTE OF THANKS

• We are grateful to Dr. Bhoraniya (Chairman), Mr.

Kishor Patel (Plant overhead), Mr. Satish Patel
(Production department), Mr. Raju Patel (Finance
department) and all the employees of Matrix ceramic
Ltd. who guided us and provided their valuable
guidance and cooperation during the course of the
project.

• We are also thankful to Mr. Sandip Trada who helped

us as and when required with his guidance.
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 THANK YOU VERY MUCH
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