Customer in Focus

Plastic Injection Molding Components & Assembly

About Vignesh Polymers Vignesh Polymers is one of the fastest

growing Moulding Industry in South Indiatoday, catering to the White Goods andAutomobile Sectors from 2005.

The Company has two State of ArtManufacturing Facilities in Chennai (CertifiedISO 9001:2015 & 1ATF 16949:2016) andGoa.

40 Injection Moulding Machines ranging from160T to 2000T including Vertical InjectionMoulding

Over 220 Components Ranging from1.5 grams to 7.0 Kg

Specialized post moulding activities likeAssembly, Printing, Welding & Painting

Driven by over 255 qualified professionals.

149 219 373 525809

1181

1950

2013 2014 2015 2016 2017 2018 2019 Target

49 58 66

129

205

255

2013 2014 2015 2016 2017 2018

10.4 11.6

24.4

30.5 30.3 29.6

2013 2014 2015 2016 2017 2018

74%

14%

5% 5%

2%

InjectionMolding

SubAssembly

Painting

Printing

Welding

Business Areas

Sales Value in (MINR)

Sales in Qty (Million)Head count

FOUNDER / CEO: R.B.SIVAKUMAR

The Company has been promoted by RB.Sivakumar a first Generation Entrepreneur, a Post GraduateDiploma Holder in Plastics Mould Making technology from CIPET – Ahmedabad

Experience of over 20 years in various capacities in Plastic Industry ,worked in Companies likeNational Plastics Ltd, Pentadaewha Auto Parts, Supreme Industries and GM Pens

Undergone training in Korea and Taiwan for understanding the best practices in manufacturing ofplastic components which requires high precision and quality

His tireless efforts has helped to become a Global Supplier/Bench Mark Vendor to Major OEM’s

CEO Profile

Vignesh Polymers

Started at

Pondicherry

Vignesh Polymers

Shifted to

Padappai

Got SQ Mark

Certificate

Business Started

with Samsung India

Electronics-Chennai

Enhanced the Machine

Capacity with 13

Molding Machines

ISO/TS-16949

Completed

Mile Stones

New Plant

Started In Vallam

Entire Plant

Automated with

Robot System

Business Started with IFB with

New Plant-Goa with 12

Machines

Warehouse-Chennai &

Paint Shop-Goa Started

Vallam plant with capacity

of 28 Molding Machines

Injection Moulding – Capacity Machine Capacity

TonnageVallam-Chennai Verna-Goa

TotalMilacron Toshiba LS Woojin TKC Milacron

160 - - - - 2 - 2

180 - 1 - - - - 1

250 - 1 - - - 1 2

350 2 - - - - 2 4

450 - 2 - - - - 2

500 3 1 - - - 3 7

650 3 2 - - - - 5

660 - - - - - 1 1

750 - 1 - 1 - - 2

775 - - - - - 2 2

850 1 - - - - 1 2

950 - 1 - - - - 1

1100 2 - - - - 1 3

1300 3 - - - - 1 4

1500 - - 1 - - - 1

2000 - - 1 - - - 1

Total 14 9 2 1 2 12 40

Organization Structure R.B.Sivakumar

Managing Director

S.BaburajanGeneral ManagerGoa Operations

VikramkumarFinance

ThangarajHR & Admin

C.IndrasenPPC & Sales

DilipProduction

M.SelvakumarQuality

NatarajMachine Maintenance

SasikanthMould Maintenance

ThiyagarajanHR & Admin

LakshmanFinance

Venkat RamanaStores

P.GopinathChief Operating

Officer

SridharIT

JeganathanSafety

J.RaviPlant Head/

New Projects

U P SelvakumarNPD

Jose P JosephPurchase

SaravananStores

JohnsonWare-House

G.SivaprakashAGM-Operations

Jithendar SinghProduction

Senthil MuruganMachine Maintenance

ShanmugamMould Maintenance

Suresh/Nandakumar

Quality

BalasubramaniPPC

PrabakharPaint shop

Strengths & Strategy

ORGANIZATIONAL GOALS

Decreases Costs Improve Productivity Increased Quality Increased Capacity

FOCUS AREA VALUE DRIVERSBUSINESS

OUTCOMES

Increased Productivity

Reduce Manufacturing cost

Improve Quality Improved Labour

Efficiency Higher Energy

Efficiency Equipment

Efficiency

Reduction in Scrap

Decrease Manufacturing cost

Maximize Energy Efficiency

Increased Output

Improved Machine Level performance

Continuous Improvements

Avoiding Quality Failures

Extending Equipment Life

Aligning Resources to Priorities

Efficiency Optimization

Reduced Man Hours

Improve Process Stability

Improve Plant wide OEE

OVERALL EQUIPMENT EFFECTIVENESS(OEE)

Industry Segments Served

Automotive

Engine Components

Automotive Lightings

Automotive Bumpers

White Goods

Manufacturing Unit

Ware-Housing & Assembly

Paint Shop

Chennai Plant-

2015

Ware-House

2018

CERTIFICATIONS

ISO 9001:2015

IATF

16949:2016

Goa Plant-

2017

Paint Shop-

Goa 2018

Manufacturing Plant -LandmarkInjection Molding

Sub Assembly

Painting

Printing

Welding

We Used Special type Raw Materials PA6, PA66 GF 30% & 35% PBT-PET PP & PE (filled/unfilled/glass filled) GPPS ABS-FR PC ABS ABS-Sparkling Materials ABS

We are running Multiple Colors in White Goods

White Silver Blue Red Violet Black Grey

Manufacturing Units – Vallam Chennai

Ware House – Mambakkam Chennai 60000 sq. ft Assembly / Ware house for Stocking FG/SFG – 2018

New Plant Setup for IFB – 2017

Manufacturing Unit – Verna Goa

Paint Shop & Assembly Unit–Verna Goa New Plant Setup for IFB – 2018

Our Esteemed Customers

Home Appliances – Refrigerator

Case

Vegetable

Tray chilled

Room

Guard fre up S

Guard Variety

Guard Jumbo

Fresh Max

Guide

Single Door Refrigerator

Case

Veg low

Guard Variety

Guard fre up S

Ice maker

Guard egg

Cover Veg

Ice cube

Double Door Refrigerator

Krishna-Base

Door lid spin

Door lid wash

Door handle

Ec Wash

Cover top Outer tub

Spin Basket

Home appliance – Washing Machines

Door lid TC

Cover TC

Cover Panel

Home Appliances – Air Conditioners

Home Appliances - Washing Machine @ Goa

Fitting water outlet-AH2

Duct lower BA

Throttle Shell - BA

Diffuser - IB

Cylinder head cover

Duct lower

Air filter PA

Body air cleaner HCI K1.4 & G1.6

Cover air cleaner 1.4

Mid shell

Automotive – Engine Components

G02A

650 LED Body

660 LED Body

Extension C

Extension A

660A RCL Body

Bull Body

Automotive – Lighting Components

Automotive – Bumpers

Skid Plate FR Bumper

Skid Plate RR Bumper STD

Skid Plate RR Lower

ISO/TS 16949:2009 ISO9001:2008

Accreditations ISO 9001:2015 & IATF 16949:2016 Audit Completed Oct-2018, Waiting for Certificate

BEST VENDOR 2015

OUTSTANDING AWARD 2017

PRO 3-M AWARD -2016

PRO-3M AWARD 2016OUTSTANDING AWARD 2016

Best Vendor Awards From Customers BEST PERFORMANCE AWARD 2017MACHINE & UTILITY IMPROVEMENT AWARS 2018

Global Recognition – By Samsung

Industry Players Visit for Best Practices

Initiatives @ Vignesh Polymers

Centralized Material Feeding Systems

POKA-YOKE Monitoring System

Robot Installation & Conveyor System

Real Time Visual Display Monitoring System

Industry 4.0(Internet of Things –IOT)

Centralized Material Feeding System

Centralized Material conveying system capable of managing up to six material receivers, with a smart suction unit and centralized high efficiency filter.

Integrated with volumetric dosing units, Hopper Dryers Reduced Man effort , Avoids Mix up of materials and saving in loading Time.

Material Bin/ Dehumidifier Entire Material Conveying Arrangement

POKA-YOKE Monitoring System POKA-YOKE is a mechanism in any process that helps an equipment operator avoid

(yoke) mistakes (poka). Its purpose is to eliminate product defects by preventing, correcting, or drawing

attention to human errors as they occur. Robots has interfaced with Weighing Machine For Part weight POKA-YOKE System.

If part weight out of

Spec Robot Move the

part Rejection bin

If part weight Within

the Spec Robot Move

the part to Conveyor

POKA-YOKE

Robots & Conveyor System Eliminate Machine and Operator idle time

during molding process. Increase output with consistent Cycle time. All Robots having EOAT Application

Eliminate Man power Movement & Reducing Manpower

Assembly issues avoided Avoid Handling issue (Damage &

Scratch)Robot System Conveyor System

Real Time Visual Display Monitoring System

Every Molding Operator Table installed with a 24’’ Visual Monitor Based on Mold change Visual Displays shall be updated Machine Operating Work Instruction displayed visually to avoid manual error Visual Inspection Displayed for how to Inspect/Pack the material Customer Matrix/Defect Matrix displayed to know about Product Knowledge To know Recent Internal & External Quality issues

Real Time Dash Board Monitoring of all Machineswith OEE detailsCan monitor remote locations machinesAvailable as a mobile app

IOT@ Vignesh Polymers

Real time Overall Plant Performance Analysis

IOT@ Vignesh Polymers Real Time Alarm Monitoring of all Machines

Shop floor wise OEE Comparison Analysis Real Time Operational Parameters Analytics

Automated Scheduled Reports by Mail end of each shift and consolidated for the Day

IOT@ Vignesh Polymers

Tablet Interface for Rejection/Downtime Reason entry Tablet Interface for Operations Team to View

Historical Data while on the Move in Shop floor

Employee Recognition – 10th Anniversary 2017

Vignesh Polymers

A Trusted Product Manufacturing

Partner