organisational study on aglass manufacturing firm

7/29/2019 organisational study on aglass manufacturing firm

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THE OXFORD COLLEGE OF BUSINESS MANAGEMENT

Glass industry in India

Glass industry in India is poised to grow rapidly owing to its extensive use in the numerous

sectors. The market is driven by increasing disposable income and willingness to spend on

better living standards due to rising aesthetic sense among consumers as well as glass being

the preferred medium of packaging. The total glass industry is worth INR 180 bn in 2010

The unique attributes of glass like its optical properties, chemical durability, and recyclability

account for a range of glass products making it an integral part of the social existence. It is

being used for innumerable consumer products ranging from tableware to automotive glass,

for lighting and construction, and most importantly as packaging material food and

beverages, cosmetics, and chemicals. The ever increasing demand for container glass for both

conventional as well as new and specialty products as a result of pioneering researches ensure

the continued success of global container glass market. The global market for container glass

is projected to grow at a CAGR of approximately 7.9% for the period spanning 2011-2013.

Glass as a packaging material is being increasingly preferred by consumers inclined towards

a healthy and sustainable lifestyle. At the same time, the industry is also encouraging the use

of glass packaging due to features of better shelf life, design possibilities and recyclability.

The factors driving the global container glass market include mainly the growth in beverage,

cosmetics, and pharmaceutical industry. However, the development of plastic and PET

containers has provided a packaging alternative thus creating a challenge for the globalcontainer glass market.

The global container glass industry is dominated by Europe and the US, where the container

glass category accounts for a sizeable amount of the overall glass market revenues. Both the

US and European regions reported an increase in container glass revenues in 2010, in

response to improving economic conditions, and rising consumer awareness about the

benefits of using glass packaging. In addition, continuous efforts on the part of the

governments to promote recycling of glass containers will lead to an unprecedented growth in


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2THE OXFORD COLLEGE OF BUSINESS MANAGEMENT

the container glass market. In the recent years, the emerging nations in the field of container

glass category, like India and other developing countries, have acquired a dominant position

posing as potential threat and as well as opportunity for the existing markets.

The current landscape of the global container glass market is intensely competitive with

numerous large and regional players operating in the market, competing on the basis of price,

quality, and other marketing attributes. The leading players in the global container glass

industry include Saint-Gobain, Owens-Illinois, and Vetropack, among others.

We have predicted the future growth of the global glass container market by combining SPSS

Inc.s data integration and analysis capabilities with our relevant findings. We employed

various significant variables that have an impact on this industry and created regression

models with SPSS to determine the future direction of the industry.

Overall, the glass container market in India has been growing at a healthy rate of over 10 per

cent, with F&B segment contributing handsomely due to prospering FMCG sector. Food

packaging is witnessing healthy volume growth due to the arrival of organized retail market.

This has led to high competition in the packaging segment, and consequently has resulted in anumber of innovations in the sector. The adoption of Narrow Neck Press & Blow (NNPB)

technology in the production of glass containers has brought a revolution in the Indian glass

packaging industry. It has resulted in decreasing the weight of the glass containers by 25-30

per cent. This technology also offers benefits such as better control over glass distribution

and increased productivity, thus making glass packaging more cost-effective and convenient

for the consumers.

All major industries create wealth but if there is one industry that plays a unique role by way

of both creation of wealth through a wide range of manufacturing activities and also by way

of preserving the wealth or value created by many, many other industries, it is packaging.

Apart from the huge value addition and employment involved in these activities, packaging

has served the Indian economy by helping preservation of the quality and lengthening the

shelf life of innumerable products ranging from milk and biscuits, to drugs and medicines,

processed and semi-processed foods, fruits and vegetables, edible oils, electronic goods etc.,

besides domestic appliances and industrial machinery and other hardware needing


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transportation. With water becoming a consumer product, polymer material-based bottles are

becoming a universal presence. Packaging, as distinct from mere packing, plays its most

visible and catalytic role in a modern economy with the widespread adoption of branding ofproducts and development of consumer preferences. To the extent that any consumer product

is packaged in a manner that meets the criteria of safety, convenience and attractiveness, it

gains market share. In the aggregate, packaging as a sect oral activity boosts consumption and

economic growth. Heightened competition in all product sectors within the country as also

the increasing need to look for export markets have contributed to the rising demand for

appropriate, and at the same time cost-effective, packaging material and technologies.

The packaging industrys growth has led to greater specialization and sophistication from the

point of view of health (in the case of packaged foods and medicines) and environment

friendliness of packing material. The demands on the packaging industry are challenging,

given the increasing environmental awareness among communities. The World Packaging

Organizations (WPO) slogan, Better Quality of Life through Better Packaging, sumps up

the important place that packaging occupies in a modern economy. To ensure that public

appreciation of this role and the policy-makers support to the industry are not diluted,

attention should be paid to basic issues like collection, segregation and reuse of synthetic

packaging material and observation of regulatory requirements.


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Indian Packaging Industry Market:

The Indian packaging industry itself is growing at 14-15% annually. This growth rate is

expected to double in the next two years. Indian Packaging industry is USD 14 billion and

growing at more than 15% p.a. These figures indicate towards a change in the industrial and

consumer set up. However, the Indian fascination for rigid packaging remains intact. It is

estimated that more than 80% of the total packaging in India constitutes rigid packaging,

which is the oldest and the most conventional form of packaging. The remaining 20%

comprises flexible packaging.

Rigid packaging constitutes glass bottles, metal cans, aerosol cans, battery cell cans,

aluminum collapsible tubes, injection molded plastic containers made of PVC, PET, HOPE,

barrels made from HOPE, paperboards, a corrugated boxes. However, with the expanding

middle class and rising income levels, the patterns of consumption are bound to change

substantially and the demand for quality and convenience-based products will increase.

Concurrently, the increased interaction with the developed world will considerably influence

the aesthetic and quality norms of the Indian consumer and lead to better consumptionstandards. This is expected to stimulate greater consumption of branded products and

increase the use of rigid and flexible packaging.

Flexible packaging contains multi-layered laminated sheets of single or a combination of

substrates such as plastic, paper or aluminum. Flexible packaging finds varied use because of

its ability to provide strength, moisture resistance, aroma retention, gloss, grease resistance,

heat retention, salability, printability and low odor. Flexible packaging has gained vast

acceptability because of the protection it offers to the product against environmental threats

like moisture, heat, and chemical reaction. More so, convenience in handling the product and

the cost benefits it provides are added advantages. Nonetheless, plastic, which is the most

commonly used substrate in flexible packaging, is facing pressure because of issues of

environmental protection and safe disposal. These issues act as a major impediment in

flexible packaging becoming an all-pervasive medium. Paper and paperboard, on the other

hand is environment friendly and also enjoy the advantages of easy handling and efficient


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process implementation. Moreover, flexible packaging mandates additional capital

requirements and technical know-how for efficient manufacturing operations.

Although substrates like plastic have gained vast acceptability, attractiveness of paper and

paperboard consumption remains. Currently, India is ranked 15th in the world for its paper

and paperboard consumption and is expected to improve its rank in the future. Paper is the

fastest growing substrate segment with a growth rate of 6-7%. The total demand for paper

currently is estimated to be around 6 mn tones, of which about 40% is consumed by the

packaging industry. If the demand for paper continues to grow at the same rate, total paper

consumption is expected to reach 9.5mn tones by 2010.

Laminated products including form-fill-seal pouches, laminated tubes and tetra packs are

growing at around 30% p.a. There are about 600-700 packaging machinery manufacturers,

95% of which are in the small and medium sector located all over India.

Germany and Italy are the latest suppliers of packaging machinery to India but focus is now

shifting on Taiwan, Korea and China. Indian packaging machinery imports are USD 125 million. Indian packaging machinery exports are rapidly growing. India's per capita packaging consumption is less than USD 15 against worldwide

average of nearly USD 100.

The large growing middle class, liberalization and organized retail sector are thecatalysts to growth in packaging.

Food and Pharma packaging are the key driving segments. On the packaging machinery side, while a wide range is manufactured in India, the

industry imports machinery, especially at the high end.

Germany and Italy are the largest suppliers of packaging machinery to India butfocus is now shifting on Taiwan and China.

The import (customs) duty for packaging machinery is 25.58% for 2007-08. Indias imports at 20 & 25% of its total packing machinery import indicate further

opportunities for Italian companies to explore.


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Some important Packaging sub-sectors:

Corrugated Packaging & Situation in India:

A flourishing organized retail have raised the expectations that consumption of

corrugated packaging will begin to expand again as the number and volume of goods

packaged in corrugated increases. MNCs are demanding corrugated boxes of international

standards and the pattern of buying the packaging is changing.

Prices of corrugated sheet and converted boxes have remained low due to the over-

capacity, manual operations and low productivity. Besides, transport constraints and high

freight costs have meant that small to medium sized corrugated box plants are located near

the customers.

The over 4,000 corrugated boards and sheet plants are highly labor-intensive,

employing over half a million people both directly and indirectly. The industry is

converting about 2 million tons of Kraft paper into corrugated boxes. Factories are spread out

in all parts of India, even in the remote industrially backward areas.

This present scenario is already being challenged by the sweeping changes that are

beginning to take shape. More and more in-line automatic plants are being set up, as

corrugated box makers gear up to meet the new demands for high precision boxes with

attractive graphics and large integrated production capacities.

Inline Automatic Board and Box making plants will ease out the present semi

automatic production processes. Deployment of Folder Gluers, Rotary Die cutters will be on

the increase. Use of corrugated for display/promotional packs, POPs and dispensers.Advances in multicolor, flexi printing will facilitate in-house flexi printing and do away with

screen printing, contract printing on offset presses.


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Pharmaceutical Packaging & Situation in India

Pharmaceutical packaging occupies a considerable portion of the overall drugs and

pharmaceutical market in India and is growing steadily with the same pace of the industry.

Pharmaceutical packaging consists of various types of glass, pet bottles, strip and blister

packs, injectibles, ampoules, bulk packs, etc.

The Indian pharmaceutical packaging industry is witnessing a spurt in growth. Today, the

packaging industry in India is considered a sunrise industry and its linkages are extensive and

highly employment creating. On one side, it involves manufacture (and sometimes import) of

a wide range of packing material - paper, paperboard, cardboard, a range of polymer productsincluding rigid and flexible packaging material, aluminum foil, tin an good old wood and

steel. Other backward linkages of packaging including printing labeling and binding

/adhesive tapes etc. Of course machinery for making / processing these products and for

packing / packaging is another segment closely linked to this industry. Growth will follow

upward trends in global medication consumption, which will expand at a strong pace as aging

demographic patterns lead to an increasing number of diseases and disorders.

Pharmaceuticals will assume an expanding role in worldwide health care delivery based onnew product introductions and economical advantages over other forms of patient treatment.

Besides upward trends in medication consumption, the adoption of stricter regulations and

standards governing the production, storage, distribution and labeling of pharmaceuticals will

boost global growth opportunities for packaging products and accessories. Historically,

pharmaceutical packaging requirements focused exclusively on preserving the quality of

enclosed medication. These requirements are now being extended to cover such criteria as the

prevention of product tampering and counterfeiting, the assurance of product dispensing

accuracy and the promotion of patient compliance with product dosage schedules.

As most of the consumers, you actually take a decision on which product to buy when we are

in the supermarket before the shelves. It is important that the packaging let you having a

truthful and instant appreciation of the product inside, while at same time jumping off the

shelf, speaking to you, providing instant convincing information about the quality of the

product. The packaging has therefore the prime tasks to be appealing, while being functional

and reliable.


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Unlike other materials, glass adds a touch of class to the products contained inside while

guaranteeing the highest level of protection and longer shelf life. You can easily sense theelegance and the beauty of a bottle of Champaign, of a wine glass or flacon of perfume.

No other packaging material matches the shelf impact of glass. The clarity, shape, and feel of

glass containers contribute to the premium image of products ranging from fine perfumes to

liquor to gourmet foods and beverages.

Packaging industry serves the following purposes in India:

1. Containment: Most products must be contained before they can be moved from one place

to another. To function successfully, the package must contain the product. This containment

function of packaging makes a huge contribution to protecting the environment. Faulty

packaging (or under packaging) can lead to spillages a result in major losses and serious

damage.

2. Protection and Preservation: Packaging plays a vital role in protecting products as they

go from the manufacturer to the consumer. Packaging is designed to ensure that the productreaches the consumer in good condition. The product is protected during transport and

distribution; from climatic effects (heat and cold, moisture, vapor, drying atmospheres); from

hazardous substances and contaminants; from infestation.

3. Supplementary Product Protection: Packaging can also provide supplementary product

protection. This may be achieved by forms of cushioning such as shredded papers, sheets of

corrugated paperboard, foamed plastic or wrappings. Packaging therefore contributes to food

safety, quality and nutrition. Packaging technology has made major contributions toadvancing food science and food safety and reduction of food spoilage.

4. Communication:A package must protect what it sells and sell what it protects. Modern

methods of consumer marketing would fail were it not for the messages communicated on the

package. The information provided on packaging allows the consumer to make informed

decisions on the products purchase and use.

5. Convenience: Packaging plays an important role in allowing products to respond to the

demands and needs of modern consumers. Frozen food packs, microwavable containers, wine


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cardboard casks, easy-open beverage and food cans and aseptic cartons are good examples of

convenience packaging. These types of packaging reflect the demand for convenience and

quick food preparation in a way that guarantees freshness. Light weight medical devices arepackaged in peel-open, pre-sterilized containers designed for easy use in operating rooms,

patients rooms, or laboratories. In the administration of drugs, unit-dose packaging, solid and

liquid, in small containers allows sealed, unused drugs to be returned to stock. Medical

packaging also reduces the risk of accidental overdose or improper use by children (child

resistant closures).

6. Environmental Aspects: Packaging reduces the amount of waste going to landfill.

Without the benefit of packaging to preserve food, a higher proportion of food would become

spoiled and consequently consigned to garbage collection for land disposal. When the food is

packaged, the unwanted portions such as skins, outer leaves and trimmings, remain at the

processing point where they can be economically recovered and used in the manufacture of

valuable byproducts.

7. Reduction of Pilferage: Packaging of a wide variety of products sold from self-service

counters is designed to reduce stealing. The product may be sold in a blister package sealed

to a large paperboard backing. The large card makes the package more difficult to conceal

and steal. Other examples of security packages are lock-on caps and tamperproof closures.

8. Marketing Trends: Marketing trends are placing increasing emphasis on the look, sales

appeal and quality of retail packaging. Packaging helps sell products by providing product

differentiation and presentation, greater brand awareness and convenience. The continuously

changing demands of consumers will require higher quality graphics and promotional links

between graphics and advertising to support brand identities, plus the ability to reflect current

consumer trends and images.


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Factors Affecting Growth of Packaging Industry in India

1. Urbanization

Modern technology is now an integral part of nation's society today with high-end

package usage increasing rapidly. As consumerism is rising, rural India is also slowly

changing into more of an urban society. The liberalization of the Indian economy, coupled

with globalization and the influx of the multi-nationals, has improved the quality of all types

of primary and secondary packaging. Also industrialization and expected emergence of the

organized retail industry is fuelling the growth of packaging industry.

2. Increasing Health Consciousness

As people are becoming more health conscious, there is a growing trend towards well packed,

branded products rather than the loose and unpackaged formats. Today even a common man

is conscious about the food intake he consumes in day-to-day life.

3. Low Purchasing Power resulting in Purchase of Small PacketsIndia being a growing country, purchasing power capacity of Indian consumers is lower; the

consumer goods come in small, affordable packages. Apart from the normal products packed

in flexible packaging, the use of flexible in India includes some novel applications not

usually seen in the developed world. Products like toothpaste, toothpowder, and fairness

creams in laminated pouches are highly innovative and are not used elsewhere. Another

typical example of such applications is tobacco and betel nut-based intoxicants and mouth

fresheners catering to unique Indian taste.

4. Indian Economy Experiencing Good Growth Prospects

The Indian economy is growing at a promising rate, with growth of outputs in agriculture,

industry and tertiary sectors. Overall economic growth has proved to be beneficial for the

consumer goods market, with more and more products becoming affordable to a larger

section of the population.


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5. Changing Food Habits amongst Indians

Changing lifestyles and lesser time to spend in kitchens are resulting in more incidence ofeating away from homes resulting in explosive growth of restaurants and fast food outlets all

over the country. Indians are trying out newer cuisines and also purchasing similar food items

for their homes. Therefore, the review period has seen new products like pasta, soups, and

noodles being launched in India, fuelling the growth of packaging industry in India.

6. Personal health consciousness amongst Indians:

With growing awareness towards contagious diseases like AIDS and other STDs, awareness

towards usage of contraceptives and disposables syringes have increased the demand for

packaging required for the same.

7. Rural Marketing Pushing Demand for Sachets

India comprises of a big rural market and there has been growing focus on rural marketing,

whereby manufacturers are introducing low-priced goods in smaller pack sizes. Low priced

sachets have proved to be extremely popular in smaller towns and villages, where people do

not prefer to buy larger packs due to financial constraints.


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Global Glass Market

The global market for glass packaging is thriving on the back of the increasing consumer

demand for pure, green, and sustainable food and beverage packaging. Glass the fact that

glass containers are chemically inert and pure, and thus safer to be used, their popularity and

demand is notably high among consumers. Further, the perception of glass containers as

having a high quality or premium image compared to plastic and metal containers facilitates

growth.

Its key property of being chemically inert and transparent makes glass the most suitable

medium of packaging of liquor, pharmaceutical/life saving drugs and food items. Recyclable

is another major advantage of glass which makes a preferred choice for packaging. In

addition to the above benefits of glass, factors like increasing demand from emerging markets

of India and China, rising cosmetic sales, changing lifestyle, increasing per capita is also

driving for the growth of the industry and as well as the country wealth increases.

Unlike plastic, cans, and multi layered cartons, glass containers do not need a petroleum-

based plastic layer or other chemical additive to preserve the taste of foods and beverages,

avoid corrosion or decrease gas permeability. Glass does not deteriorate, corrode, stain orfade, so products inside glass container remain as fresh and pure as they were bottled.

Major Centers

The Indian glass processing industry is clustered in six geographical locations that fall near

the six industries or metropolitan cities. It is very interesting to note that there are certain

areas as big as Italy where you won't find a single glass processing unit. These areas are

dependent on the glass processors in the six clusters to cater to their processed glass plants.

Can you believe a state having a population of 230 million (yes that's million) does not have a

single processing unit?

The processing clusters are located in and around the following cities :New Delhi. The

national capital has some of the biggest and most reputable glass processors in the country.

GSC Glass, Gold Plus (which recently announced setting up a float line), Mico Glass, and

Gulati glass are some of the glass processors in the region, and all are located in a belt of 100


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km in the capital region. GSC and Gold Plus glass stand out among the processors in the

capital region; in fact, GSC glass could be termed the most advanced and largest glass

processor in the country. Incidentally GSC was the first glass processor in the country when itstarted to process glass in 1994.Mumbai. The country's financial capital, as it is dubbed, has

some of the very best names in the processing industry. Sejal Glass, Fishta Glass, and Viral

Glass are a few of the outstanding names in the region. The processing industry in this region

is benefiting from the boom in construction activities that has been going on for quite some

time. Other than these two major industry clusters. The remaining clusters are in and around

the cities of Chennai, Hyderabad and Bangalore, and in the eastern coast of the country in

Kolkata. One prime reason these clusters formed in these particular regions is the spate of

construction that has been happening in these cities over the last five years. If you travel to

any of these cities today, you will see how the skyline is changing. Overnight, new structures

are rising, and you will see endless facades of glass also rising. Looking at this one would

guess that this is the region where every glass processor would want to be, so what is the

reason that a value-added glass industry in the country is not booming?

Low demand drivers

Consumer awareness. Perhaps, the most important reason for low volume of value added

glasses can be attributed to consumers. As glass has gained increased popularity in the last

fifteen years, most consumers in India are not aware of type of value-added glass and their

respective advantages. Consumers are not aware of the availability of various types of glass

and what benefits each one gives. Most customers have the perception that glass is something

that is transparent and very fragile. Fragmented nature of the industry. It is no secret that the

glass processing industry in India is much disorganized. Because of the fragmented nature of

the industry, glass processors, whole sellers, glaziers, and all other participants are short-term

driven. Almost no effort has been put into customer service, reducing costs, or systematically

developing markets. spiraling Costs. The glass industry is also weighed down by the spiraling

cost of manufacturing. Energy costs are increasing, as are those of raw materials and

infrastructure. The regulatory framework of building codes for safety and energy also needs

to keep pace with industry growth and new glass uses. In case value-added glass has to make

inroads in India at a scale and pace comparison to European countries, then prices will have

to come down and in a hurry. Lack of knowledge among architects. It may seem strange that


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many architects are not aware of the type of value-added glass available, and many turn to

glass processors to suggest a type of glass for a particular application. Because glass is a

relatively new product in building applications, those who use are still learning aboutapplications and benefits of various types of glass. Price sensitivity of Indian consumers.

Despite robust economic growth during the last decade, Indian consumers and the Indian

market are very price sensitive. With a price differential between basic flat glass and value-

added glass, consumers would rather opt for the basic glass type. Low penetration in the

residential sector. Use of value-added glass has gained popularity in commercial buildings to

a large extent, but residential buildings, which are a major source of demand for these glass

types, are not using much of thee products. Value-added glass is finding application in only a

minuscule number of residential units. Lack of codes. Another dire problem facing the value-

added glass industry is back of any codes for the products. There are no government

guidelines for the use of any particular type of glass. There was an initiative by one of the

state governments to make the use of tempered glass mandatory in commercial buildings, but

it has yet to see the light of the day. A drive to adopt a ruling similar to that of Germany's for

use of low E glass in windows can drive demand for value added glass in India.

An overriding theme for glass packaging is that of reduced growth opportunities in mature

regions and mature product categories. Fast-developing economies in Asia Pacific, Latin

America and Middle East and Africa regions, meanwhile, are pivotal in supporting current

and forecast global volume sales growth for glass.

As disposable incomes increases amongst these dynamic economies and the retail

infrastructure continues to develop, a subsequent rise in consumption of packaged food and

beverages drives growth of glass.


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Different types of containers:

The influence of competing pack formats impacts glass share as dynamic packaging

performer, lightweight PET, offers consumers a conveniently lightweight pack, suited to the

on-the-go lifestyle.

Harshest impact on glass is seen in carbonates and bottled water sales. The global glass

stronghold of spirits is additionally seeing pack substitution in favor of PET amongst more

economy lines, most apparent in North America. Beverage can advances in beer and more

niche packaging developments exist to challenge the dominance of glass in wine.

The growing consumer trend towards eating and entertaining at home, itself being furthered

by tightened consumer spending in the weaker economic climate is promoting greater

packaging growth in the off-trade channel as against weaker on-trade performance.

This cocooning trend is producing retail growth for glass in its key alcoholic drinks

categories of beer, wine and spirits. In developed regions, positive growth for glass is further

observed in sauces, dressings and condiments.

In particular, table sauces, pickled products and pasta/wet/cooking sauces respond to a

widening consumer interest in other world cuisines whilst Asia Pacific's rise in purchases of

packaged, branded products is a further driver for forecast glass growth.


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Introduction

Samyu Glass Pvt. Ltd. was established in the year 2009 and is dedicated to themanufacture of high quality glass containers. They cater to the package needs of hot/

cold food processing, Pharmaceuticals, cosmetics and other industries. This company

was cradled by the most arduous and sincere entrepreneurs in the country, benefited

with the support of ever increasing demand for glass containers, economy of the state

and the presence of a diligent group of individuals eager to attain growth and success.

Outstanding product quality, dedicated customer service and the creation of

innovative new products have always been central to our business. Its willingness to

take on challenges and see them through is their hallmark.

Samyu Glass Pvt. Ltd., a leader in product innovation, has designed andmanufactured a wide array of products for many of the worlds most recognized

brands. The factory is located in Andhra Pradesh, South India, and in close proximity

to the raw-material resources, major ports and our customers. Within a short time of

operations the Company has built up an excellent reputation for quality and caters to a

large and demanding customer base with a product range covering Flint, Amber and

Green containers. The Company has an installed capacity of producing 200 MT perday of Glass and has state of the art equipments designed to produce Glass containers

in 100 ml 1000ml range, in different shapes and in Flint, Amber and Green glass.

The manufacturing facilities are among the best and state of the art to achieve high

levels of productivity and quality.

Vision

At Samyu Glass Pvt. Ltd., we have a clear vision of what we would like to accomplish, and

we constantly strive to meet this challenge. In the next 5 years, we would like to spread ourbusiness establishments and services across the world, and to be a pioneering leader in the

manufacturing of glass products in the global market. We strongly believe that excellence can

be achieved only through innovation. We aspire to be a globally respected corporation that

provides best business products and services, and sticks to the basic values and principles that

were the pillars on which this company was initially incorporated upon.


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Basic Principals

Samyu Glass Pvt. Ltd. has always been a principal-driven company. These principals

continue to direct the growth and business of our company. These principals are an integralpart of us and the manner in which we conduct our business:

Leadership: We must strive to set standards in our business and transactions and be an

exemplar for the industry and ourselves. We must have the courage to shape a better future

for the society at large.

Responsibility: We must conduct our business fairly, with honesty and transparency.

Everything we do must stand the test of public scrutiny. We must continue to be responsible,

sensitive to the laws, communities and environment in which we work.

Reliability: We must be caring, show respect, compassion and humanity for our colleagues

and customers around the world, and always work for the benefit of the communities we

serve. We must surpass customer expectations consistently. We must bring prosperity to our

investors, security to our employees, and productivity excellence to our customers and

business partners.

Excellence: We must constantly strive to achieve the highest possible standards in our day-

to-day work and in the quality of the goods and services we provide. We strongly believe that

excellence can be achieved only through innovation. We must be committed to growth and

diversification. Constantly identifying new opportunities, looking out for new challenges and

this must become our way of life.

Primary Competitive Advantages

Transparent dealings Utmost client satisfaction Ability to deliver bulk order Stringent quality check

No of Staff 700

Year of Establishment 2009

Product Range

Perfume Glass Bottle Beverage Glass Bottle Juice Glass Bottle


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An Overview

With an exclusive range of glass products, we, Samyu Glass Private Limited, has captured a

huge market share. Incepted in the year 2009, we have carved a niche for ourselves as one of

the prominent manufacturers, suppliers, exporters, importers and traders of a wide range of

glass bottles. The products we manufacture are Alcohol Glass Bottle, Beverage Glass Bottle,

Juice Glass Bottle, and more. Our range is widely used into various industries such as

Hot/Cold Beverages, Pharmaceuticals, Cosmetics and Food processing.

Our proficient team, plays a crucial role in the marketplace, includes designers, managers,

quality analysts, packaging inspectors, sales and marketing personnel, administrator staff, etc.

They are highly experienced with complete knowledge of the processes involved in product

manufacturing and their applications. With their expert guidance, we design and produce

various others glass products according to the latest market trends and specifications given by

the clients.

In the near future, we plan to expand our export base and become leader in the domain of

glass bottles manufacturing.

Product Portfolio

We are engaged in manufacturing, exporting, importing, trading and supplying a wide range

of glass products, which are well-tested by our experts. The products are made using quality

raw material that is procured from renowned vendors of the market. Our spectrum ofproducts includes:

Perfume Glass Bottle Beverage Glass Bottle Juice Glass Bottle

These products are available in various volumes such as 720ml, 500ml, 180ml, 200ml,

320ml, etc.


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Assured Quality

Since our foundation, supreme quality has always been primary objective of our organization. Hence,

we have a quality control wing, which is managed by a team of experts who supervise all the

production processes and ensure that products go without defect. We are committed to use best

quality material in the manufacturing of alcohol glass bottle, juice glass bottle, and other products.

Also, the end products are checked on numerous parameters, some of which are as follows:

Design Size Durability Accuracy Finishing

Sophisticated Infrastructure

We have the- state-of-the-art infrastructure that is outfitted with necessary machines and equipment

for carrying out smooth production process within committed time frame. Our facilities are divided

into various departments such as processing unit, quality testing unit, warehousing, dispatching, etc.

Every unit has been provided with adequate resources and upgraded technology to produce a

comprehensive range of glass products. Time to time up- gradation of our facilities allows us to attain

timely accomplishment of the targets. Our infrastructure spreads over a vast expanse of land that

allows our professionals to work in close proximity.

Our Forte

We enjoy immense popularity and recognition in the domestic as well as international markets and are

known for our flawless products. Some of the numerous reasons, why we are preferred over our

competitors are listed below:

Easy payment modes Utmost customer satisfaction Safe and durable products Use of innovative technology Optimum quality of products Versatile infrastructure set up Efficient and experienced personnel Timely delivery of the consignment.


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Products:

Industry served Juice and mineral water Industry Pharmaceutical Industry Perfumery industry

Design Studio

As a global leader in the design and manufacture of glass, Samyu Glass is committed to

delivering innovative and creative packaging solutions to customers. The Corporate Design

Center is a product of this commitment.

The Samyu Glass Corporate Design Center is a state-of-the-art facility and offers a complete

range of design solutions to customers in categories as diverse as perfumes, cosmetics, skin

care, beverages, food, wine, and pharmaceuticals. The center's solutions cover a wide gamut

of packaging materials and components.

The center has cutting-edge infrastructure and is peopled with experienced professionals. It

offers 3-D industrial design, and is equipped with an in-house prototype and model making

workshop.

The design center continuously tracks the latest trends in fashion, perfumery, cosmetics and

art and incorporates best practices into its packaging solutions. As a result, our solutions are

fresh, creative and contemporary.

The Corporate Design Center also has a center of innovation and development, offering

marketing support in the form of point of sale design, graphic design, merchandising designs,

exhibition design etc


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Quality Policy

To Gain the confidence and respect of our customers in the field of Glass container

manufacturing by providing quality products that meet and exceed Customer expectations in

terms of Quality, Delivery and cost.

This shall be achieved by

1.Continual improvement of our Technology and skills to meet and exceed customers

statutory quality requirements.

2. Cost reduction through judicious use of available resources in all Business processes.

3. Development of Human resources through systematic Employees Involvement,

Motivation and Training.

4. Tuning of our business practices through feedback from our customers and suppliers.

Quality Assurance

Quality Checks:

At Samyu Glass, quality is of paramount importance. To ensure consistency and quality, a

Six Sigma initiative is being rolled out at both the Indian plants. At the corporate level, too,

we are carrying out a Business Process Excellence initiative.

Quality inspection involves five levels of checks.

Level 1 happens at the IS machine, immediately after the bottle is formed. Here, the line

operator, with the quality control checker, does hot end sampling for dimensional checks.

Hot-end ware rejection is an automatic process to ensure quality of the bottles after bottle

swabbing. Next, the bottles are put into an annealing chamber, where they are gradually

heated and cooled to de-stress.

The bottles then pass through a series of automatic and camera inspection checks by

equipment like M, M-Cal, VERITAS and VISIGLAS. These machines check for body

defects, neck finish, bubbles, foreign matter etc.


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The bottles are finally automatically shrink-wrapped, and a sample of the packed bottles is

put through a QA process to check for defects. The container used for transport is fumigated

and also checked for cleanliness and hygiene prior to stuffing.

Highlights of Samyu Glass Pvt Ltd:

State of art equipment Global network base Cost effective quality products Experienced executive teams Leader in Product Innovation Proximity to raw materials /major ports Stringent quality control policies On time services Dedicated work force

OUTLOOK

The demand for clear figured glass is very good. We are gradually increasing our production

and, thereby, bringing down cost of production per unit. Prices are also looking up. It is

expected that they shall continue in this trend for this calendar year. Our present production

quality is also acceptable in the market and we are getting the benefits of increased prices.

We plan to introduce some new designs in the coming year.

In colored figured, we have made 3 new colors this year that were not made for many years -

coolex, blue, green. This is other than grey that we usually make. We plan to add new colorsin the coming year also. Our colored figured plant needs cold repairs. We have to start

preparations for the same and have to order out refractoriness that has a lead time of 8-9

months. Prices of colored figured are also up, but since colored figured demand is only 20-

25% of total demand and 3-4 plants at a time make colored figured, there is a strain on orders.


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Internal control system and their adequacy

The Company has adequate system of internal controls to ensure proper safeguarding of the

assets. The Company has appointed external firms of Chartered Accountants as internalAuditors.

Financial performance

During the year the turnover amounted to Rs. 3886.98 lakhs compared to Rs. 3635.47 lakhs

in the previous year. After providing for interest and depreciation amounting

to Rs. 364.46lakhs & Rs.133.97 lakhs, the net loss comes to Rs. 1618.85 Lakhs against net

profit of Rs. 893.77 lakhs of previous year.

The loss from operations is Rs. 401 lakhs only, balance is provision made for severance and

full and final settlement of Allahabad Plant workers and other write-offs of not recoverable

debts.

Samyu Glass offers several competitive advantages over other suppliers of flacconage. These

include:

Strong manufacturing presence Wide sales and distribution spread Significant cost advantages Decoration services and accessories

Strong Manufacturing Presence

Samyu Glass is one of the largest manufacturers of flacconage glass for the pharmaceuticals

and perfumery businesses today, with an installed capacity of 1,115 tons per day, and sales of

more than $200 million worldwide. We also manufacture glass bottles for specialty food and

beverages. Samyu Glass has invested more than $110 million in creation of significant new

capacity, and is among the top five manufacturers of perfumery bottles in the world.


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Sales & Distribution Spread

Samyu Glass has a large geographic footprint, with a sales and distribution presence in mostmajor markets across the globe. Our significant marketing presence in Europe, USA and

South America enables us to build more intimate relationships with customers, and respond

to their needs quickly and efficiently.

Corporate Social Responsibility

As a citizen of corporate India, Samyu Glass takes its corporate social responsibility

seriously. We have a variety of programs designed to help employees, local communities and

the under privileged.

Programs cover:

Education

Funding computers at a local school Improving infrastructure of the school

Community Development

Making drinking water more accessible for local communities by building tanks Building roads to make local villages more accessible, programs for senior citizens, etc,

Research Design Innovations

Glass can be molded into an infinite number of shapes and sizes for consumer appeal andform and functionality. And, creative labeling, embossing and other decorative treatments can

also enhance customer appeal.

Two properties of design:

1. Significance - having importance or meaning2. Utility - quality of being useful


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ORGANISATION STRUCTURE:

Most organizations today are designed as a bureaucracy in whom authority andresponsibility are arranged in a hierarchy. Within the hierarchy rules, policies, and

procedures are uniformly and impersonally applied to exert control over member

behaviors. Activity isorganized within sub-units (bureaus, or departments) in which

people perform specializedfunctions such as manufacturing, sales, or accounting. People

who perform similar tasks areclustered together.The same basic organizational form is

assumed to be appropriate for any organization, be it agovernment, school, business,

church, or fraternity. It is familiar, predictable, and rational. It iswhat comes immediately tomind when we discover that ...we really have to get organized.

Organization design is a formal guided process for integrating the people, information

and technology of an organization. It is used to match the form of the organization as

closely as possible to the purposes the organization seeks to achieve. Through the

design process, organization act to improve the probability that the collective effort of

members will be successful. Typically, the design is approved as an internal change

under the guidance of an externalfacilitator. Manager and members work together to

define the needs of the organization thencreate system to meet those needs most

effectively. The facilitator assures that a systematic process is followed and encourages

creative thinking.

HIERARCHICAL SYSTEM:

Western organizations have been heavily influenced by the command and controlstructure ofancient military organizations, and by the turn of the century introduction

of Scientific

THE DESIGN PROCESS:

Organization design begins with the creation of a strategy- a set of decision guidelines by

which members will choose appropriate actions. The strategy is derived from clear, concise

statement of purpose and vision and from the organization basic philosophy


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Organization Structure of Samyu Glass Pvt. Ltd.

WORKERS

MANAGING DIRECTOR

SENIOR MANAGER

ASSISTANT MANAGER

FACTORY MANAGER

SENIOR ENGINEER

ENGINEER

SUPERVISOR

DEPUTY SUPERVISOR


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FUNCTIONAL DEPARTMENTS

Managing

Director

HR FINANCE MARKETING QUALITY PRODUCTION


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Departmentalization by function organizes by the functions to be performed. The functions reflectthe nature of the business. The advantage of this type of grouping is obtaining efficiencies

from consolidating similar specialties and people with common skills, knowledge and

orientations together in common units.

Functional departmentalization - Grouping activities by functions performed. Activities can be

grouped according to function (work being done) to pursue economies of scale by placing

employees with shared skills and knowledge into departments for example human resources, IT,

finance, manufacturing, marketing and engineering. Functional departmentalization can be used

in all types of organizations.

Human Resource Department:

Human resources are a term with which many organizations describe the combination of

traditionally administrative personnel functions with performance, Employee Relations and

resource planning. The field draws upon concepts developed in Industrial/Organizational

Psychology. Human resources have at least two related interpretations depending on context. The

original usage derives from political economy and economics, where it was traditionally calledlabor, one of four factors of production. The more common usage within corporations and

businesses refers to the individuals within the firm, and to the portion of the firm's organization

that deals with hiring, firing, training, and other personnel issues. This article addresses both

definitions.

The objective of human resources is to maximize the return on investment from the organization's

human capital and minimize financial risk. It is the responsibility of human resource managers to

conduct these activities in an effective, legal, fair, and consistent manner.

Marketing Department:

Marketing is defined by the American Marketing Association as the activity, set of institutions,

and processes for creating, communicating, delivering, and exchanging offerings that have value

for customers, clients, partners, and society at large. The term developed from the original

meaning which referred literally to going to market, as in shopping, or going to a market to sell

goods or services.


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Production Department:

Production is the functional area responsible for turning inputs into finished outputs through a

series of production processes. The Production Manager is responsible for making sure that raw

materials are provided and made into finished goods effectively. He or she must make sure that

work is carried out smoothly, and must supervise procedures for making work more efficient and

more enjoyable.

In a manufacturing company the production function may be split into five subfunctions:

1. The production and planning department.

2. The purchasing department.

3. The stores department.

4. The design and technical support department.

5. The works department.

Finance Department:

Finance, accounting is the system of recording, verifying, and reporting of the value of assets,

liabilities, income, and expenses in the books of account (ledger) to which debit and credit entries

(recognizing transactions) are chronologically posted to record changes in value (see

bookkeeping). Such financial information is primarily used by lenders, managers, investors, tax

authorities and other decision makers to make resource allocation decisions between and within

companies, organizations, and public agencies. Accounting has been defined by the AICPA as

The art of recording, classifying, and summarizing in a significant manner and in terms of

money, transactions and events which are, in part at least, of financial character, and interpreting

the results thereof."

Source: http://www.syfes.com/1.html


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3.1-HUMAN RESOURCE DEPARTMENT

STRUCTURE OF HR DEPARTMENT

Table-3.1

Today we are living in competitive world. So every sector role is vital. At the same way in the

organization human resource role is very central. Every human being has the ability and potential

to do remarkable things if they are provided with opportunities and climate to understand,

develop and utilize his or her potentials. Unfortunately, the development of people has been aneglected phenomenon in the past and therefore, ignored by most of the organizations.

These organizations tended to view people as mere instruments for accomplishing organizational

goals and, therefore, felt that they need to be administered or managed. But it is not true. In fact,

complexities of modern organizations as apparent from changing technology, increasing size of

business, larger volumes of production and greater emphasis on specialization lay stress on

cutting down the costs of production, improving the quality of product or service, enhancing

market share and maintaining effective and efficient leadership.

MANAGING DIRECTOR

DEPUTY MANAGING

SENIOR MANAGER (HR)

ASSISTANT MANAGER (HR)

FACTORY MANAGER


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Recruitment:Recruitment in Samyu Glass is a very fair and transparent process with adequate opportunities

to look for suitable candidates internally as well as from outside. Applicants are generally invited

on the basis of specific advertisements in newspapers. A committee of officers handles the entire

recruitment process comprising screening of applications, preliminary short-listing, interviews,

and final selection. All decisions of the Recruitment Committee are recorded in respect of each

candidate.

Recruitment process steps

Source: http://hrmadvice.com/blog/2008/06/15/understanding-high-level-recruitment-process/


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Overview of the recruitment process steps:

1) Job Position Opening The most important process step for the successful recruitment

and selection of the good candidate. The manager and the recruitment specialist define the profile

of the position and the profile of the suitable candidate. The recruitment specialist has to

be prepared for detailed discussions to have a good definition of the ideal job candidate.

2) Selecting recruitment source The recruitment specialist has to decide about the

correct recruitment channels to be used and the amount of job resumes, which can be expected to

select from. This part of the recruitment process decides about the speed of the whole process.

3) Selecting job candidate The process when the recruitment specialist and the managerselect the best candidates to make the offer to them. This part is usually the process step with the

biggest risk of the delay in the recruitment process.

4) Making an offer The nicest part of the recruitment and selection process. The

recruitment specialist summarizes the requests of the manager and the wish told by the job

candidate and tries to convert the job candidate into a new hire for the organization.

Performance Management:The Companys performance management system is in itself a benchmark that provides ample

opportunities and motivational incentives to employees so as to reward and retain good talent

within the Company. These incentives include: performance linked incentives, good work

awards, letters of appreciation, special increments, promotions, nomination to external training

programmers in India and abroad, public felicitation, and appreciation. Some plants have Best

Employee and Employee of the Month awards

Training and Development:SAMYU Glasss new performance management system incorporates a process called

Competency Assessment and Training and Developmental Needs wherein appraisers are

specifically called upon to identify and assess training needs of employees at specific intervals

that do not coincide with performance appraisals. This is so that training needs can be assessed

objectively. Training is imparted to take care of an individuals career development as well as

functional and skill enhancement. Competency and development training inputs include skill and


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general performance enhancement, communication skills and career development. Functional

training needs are identified and conducted by functional departments while corporate HR

organizes competency and developmental inputs.

Employee Welfare and Perquisites:

Employee welfare receives prime attention at Samyu Glass. It has several schemes for general

welfare of employees and their families. These cover education, healthcare, retirement benefits,

loans and financial assistance, and recreation facilities

Employee Satisfaction:

The salient points of the survey of employees are shared below:

People are treated fairly regardless of religion and gender.

Samyu Glass Pvt. Ltd. is a safe place to work.

Management is competent in running business.

Employees feel good about what Samyu Glass does for society.

Management thinks positively.

AWARDS:

Awards are instituted by the company in the recognition of outstanding work performance,

useful suggestions for the improvements, & contributions to technical/academic knowledge.

COUNSELING:

Counseling services are provide to enhance employees competence & job satisfaction, to prepare

them for future responsibilities, to establish better working relationship & to cope up with

personal problems. Counseling is carried out by HRD appraisers & professional counselors.

CARRER PLANING:

This is ensuring that people of the right caliber are available to meet the present & future

requirements of organization. The process identifies the necessity inputs aim at imparting

technical/managerial knowledge, interpersonal skills & attitudes that will helping dealing with the


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external & internal environments. Other factors to develop potential include activities such as

exposure to new functional projects.

SUCCESSION PLANING:

The manager in Samyu Glass organization will prepare a succession plan to all position under

him with the guidance of Deputy managing, identify the right incumbents with high potential

for

all positions, concerned HOD & unit chief shall implement the process. HR departments shall

Co-ordinate this activity. Succession planning & career planning shall be reviewed every 6

month in the company.It shall endeavor to uphold the dignity of individuals, by making feel proud partners in

progress,

through the following measures:

Ensure a high degree of selectivity in recruitment of employees/trainees explicitly onCriteria of their knowledge, skills & attitudes, so as to secure super achievers &

nurture them to excel in there.

Impact such induction, orientation & training, as to match the individual to the task &inculcate a high sense of organizational loyalty.

Provides facilities for all round growth of the individual by training in & outside theorganization, lateral mobility & self development through self motivation.

Groom every individual to realize his potential in all facts while contributing to attainhigher organizational & personal goals.

Build teams & faster team work as the primary instrument in all activities. Recognize worthy contributions in time & appropriately so as to maintain a high level

ofemployees motivation & morale. Appraisal & promotion shall be ethical &

impartial.

Implement equitable, scientific & objective system of rewards, incentives & control. Contribute towards health & welfare of employees.


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`3.2-MARKETING DEPARTMENT:

STRUCTURE OF MARKETING DEPARTMENT

Table-3.2

MARKETING

Marketing deals with identifying and meeting human and social needs. One of the shortest

definitions of marketing are meeting needs profitably.

AMERICAN MARKETING ASSOCIATION offers the formal definition of marketing

Marketing is an organizational function and a set of processes for creating, communicating and

delivering value to customers and for managing customer relationships in ways that benefit the

organization and its stake holders

MANAGING DIRECTOR

DEPUTY MANAGING

SALES & MARKETING MANAGER

REGIONAL MANAGER

FIELD MANAGERS

REPRESENTATIVES


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MARKETING MANAGEMENT

Marketing Management can be defined as the art and science of choosing target markets and

getting, meeting and growing customers through creating, delivering and communicatingsuperior customer value.

Marketing mix

Marketing mix is defined as the set of marketing tools the firm uses to pursue its marketing

objectives. McCarthy classified these tools into 4 broad groups called 4 Ps of marketing:

Table-3.3

Source:http://business-fundas.com/2011/the-4-ps-of-marketing-the-marketing-mix-strategies/

PRODUCT:

The following features of the products are considered before releasing a product for sale.

Quality

Brand

Packing

Legal Aspects.
http://business-fundas.com/2011/the-4-ps-of-marketing-the-marketing-mix-strategies/http://business-fundas.com/2011/the-4-ps-of-marketing-the-marketing-mix-strategies/http://business-fundas.com/2011/the-4-ps-of-marketing-the-marketing-mix-strategies/http://business-fundas.com/2011/the-4-ps-of-marketing-the-marketing-mix-strategies/


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PRICE:

The price is the simply amount a customer pays for the product. If the price outweighs theperceived benefits for an individual, the perceived value of the offering will be low and it will be

unlikely to be adopted, but if the benefits are perceived as greater than their costs, chances of

trial and adoption of the product is much greater.

PROMOTION:

Promotion is a communication process for informing the customer and company about the

product, which they create for sale. It covers also adoption of method for increasing sales by

motivation of customers, stockiest and retailers and sales force. Samyu Glass Pvt. Ltd. Adopts

various types of sales promotion tools like discounts, gifts, other incentives, and sometimes

company sends their dealers and distributors on tour in Darjeeling, Shiliguri, Sikim etc.

Samyu Pvt. Ltd. invites contract of advertisement to private agencies, which look after

all the functions regarding advertising. Samyu glass uses different modes of media vehicle to

reach the people such as:

Magazines


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3.3-PRODUCTION DEPARTMENT:

STRUCTURE OF PRODUCTION DEPARTMENT

Table-3.5

In Samyu Glass Private Limited, production department takes on a very decorative position in

the entire array of company affairs. The production department is concerned with the planning

and organization of the production system. It is responsible with the overall situation of the plant

And the machinery, production planning and organization as well as overall capacity utilization.

INDIVIDUAL SECTION (I.S.) MACHINE

Individual Section (I.S.) machine produced first time in 1925 is now used all

over the world as the most dominant machine for bottle and jar production. In this machine,

there are number of individual sections. During the initial years of production of this machine

there were only four sections. Machines with 6, 8, and 10 sections operating double gobs are

now available and in operation in India. The number of sections in a machine depends on the

size of the orders expected. Machines working either single, duel, triple or quadruple gobs are

available throughout the world. The largest machine has 12 sections.

MANAGING DIRECTOR

DEPUTY MANAGING

PRODUCTION MANAGER

PRODUCTION SUPERVISOR

WORKER


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Individual Section machine does not rotate. The moulds stay in the

same position and just open and close. A transfer arm pivoted between a blank and blow

mould transfers the parison from one mould to another.

MECHANISM

1. Shear Mechanism2. Scoop Mechanism3. Funnel Mechanism4. Baffle Mechanism5. Plunger Mechanism6. Neckring Mechanism7. Invert Mechanism8. Blowhead Mechanism9. Vertiflow MechanismThe Operation of making glasses:

1. Shear mechanism - shears the gob2. Scoop mechanism - guides the gob3. Mould opening & closed mechanism - Blank mould closed4. Funnel mechanismguides the gob in required shape5. Baffle mechanismON operation6. Plunger mechanismON7. Counter blow operation8. Settle blow operation9. Neckring mechanism - Parison transfer to blow mould10. Blow head mechanism - Final blow11.Take-out mechanismtakes the bottle to the machine conveyor


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SHEAR MECHANISM

The shear mechanism consists mainly of two sector gears, two arms and bracket.

The shear blades are fixed on the shear arms. The function of the shear mechanism is to shear

the gobs in proper shape and size for the container making process.

SCOOP MECHANISM

The scoop mechanism consists of a piston and cylinder arrangement. The purpose of

scoop mechanism is to supply the gob to the different sections of the I.S. machine for glass

formation.

FUNNEL MECHANISM

The funnel mechanism consists of a piston and rod and a cylinder. The arm is dipped

in an oil well and the OFF operation is spring controlled. The purpose of funnel mechanism

is to hold the funnel arm and to guide the gob in the required shape to the blank mould.

Improved cam design resulted in speed increase up to 33% during downstrokeand 35% during upstroke

Less mold equipment wear Prolonged mechanism service life Reduced inventories for funnel mechanism and spare parts Greater maintenance convenience Compatibility with existing mold equipment Externally accessible ball check valves Enlarged air passages Integrated cushioning ring Permanent lubrication Precise mechanism movement


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BAFFLE MECHANISM

A baffle mechanism consists of a long piston and rod and a cylinder. The twisting of the

baffle of the baffle arm is achieved by a cam provided at the bottom of the cylinder. Thefunction of the baffle mechanism is to hold the parison while giving counter blow and then to

give the settle blow.

Faster Baffle operations Improved alignment between blank molds and baffles Less wear on mold equipment Improved motion and repeatability of baffle arm Prolonged service life of the baffle mechanism 60% less force on the baffle mechanism creates smoother baffle operation No baffle

arm overlap into adjacent section in the "Off-Position"

Equal settle blow air pressure build-up in all cavities Quick-Change Baffle Head reduces job-change time Quick conversion capabilities (SG / DG / TG) Improved operating safety Compatibility with existing mold equipment

PLUNGER MECHANISM

The function of plunger mechanism is to provide the counter blow air for parison

formation and to give the plunger ON movement for the formation of the neck of the glass

container. It consists of a piston and cylinder arrangement.

For Precision Parison Forming Quick Exchange for Different Processes Low Friction Design for Narrow Neck Press & Blow Precise Plunger Alignment Improved Plunger Cooling Improved Efficiency and Reduced Job-Change time


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NECKRING MECHANISM

The neckring mechanism consists of a splined shaft and two cylinders, which are air

operated. The function of neckring mechanism is to hold the neckring and to transfer the ware

than the blank mould to the blow mould.

50% higher cooling efficiency Easier handling at job change Rigid design Well proven damper cylinder

INVERT MECHANISM

The invert mechanism consists of a racked piston and a cylinder. The end operations are

cushioned by two hydraulic cartridges. The function of invert mechanism is to rotate the

neckring mechanism for parison transfer.

Cartridge valve

Predictable cooling helps produce more consistent container quality Reduced cooling time leads to potential for higher production speed Easier mold change helps reduce down time Fumes carried away thus providing better working environment No heat load on section helps increase mechanism life Conversion of VertiFlow Molds to use of existing mold stock

BLOWHEAD MECHANISM

The blow head mechanism consists of a piston and rod and a cylinder. The cam and

cam roller movement determines the swing of the arm. The cam is immersed in an oil well.

The function of the blow head mechanism is to provide the final blow air for the complete

formation of the bottle in the blow mould cavity.


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Blow head arms

Improved cam design resulted in speed increase up to 37% during down stroke and24% during upstroke

Less wear on blow head arms and blow heads Prolonged mechanism service life Reduced inventories for blow head mechanism and spare parts Greater maintenance convenience Compatibility with existing mold equipment Externally accessible ball check valves Enlarged air passages Optimized upstroke piston rod cushioning Integrated air and lubrication piping

VERTIFLOW MECHANISM

The vertiflow mechanism consists of an air chamber and a damper, which is air

operated. The function of the vertiflow mechanism is to provide the cooling air for the

cooling of the blow moulds in an I.S. machine.

The Production Process

Glass MeltingThe furnace melts cullet (crushed, recycled glass), sand, soda ash, limestone, and other raw

materials together. Molten glass usually ranges in temperature between 2,300 and 2,800 F.

Furnace Control systems monitors and controls firing temperature.

Gob Distribution

At the end of the furnace, the glass stream is distributed to different forehearth for the

respective production line. Molten glass is conditioned in the forehearth and its temperature

gradient is equalized to ensure uniform temperature homogeneity. Plungers intercept the

stream of molten glass from the forehearth and cuts gobs individually by mechanical shears.

The gob distributor then routes the gobs into blank moulds at the I.S Machine.


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Container Forming

Gobs of glass are delivered to blank moulds to form a parison. The ring finish and

internal bore are created. It is then transferred to molded side, where compressed air andvacuum are applied, stretching & cooling the parison to exact inner cavity profile of the

mould, forming the final shape of the container.

Annealing Lehr

The glass containers are then submitted through a special type of oven called a Lehr

designed specifically for annealing glass. Glass is heated to the annealing point and then

slowly cooled to room temperature. This process relieves the internal stresses, making the

glass much more durable.

Cold End Coating

After annealing, a layer of polyethylene wax, is applied via a water based emulsion. This

makes the glass slippery, protecting it from scratching and stopping containers from

sticking together when they are moved on a conveyor. The resultant invisible combined

coating gives a virtually unscratchable surface to the glass.

Cold End Inspection

All containers are monitored regularly throughout the production process and the

end product is subject to exhaustive computer, laser, electronic, mechanical and manual

checks to ensure it passes the most stringent health and safety standard requirements.

Typical faults flagged up in this process include small cracks in the glass called checks,

foreign inclusions called stones, bubbles in the glass, called blisters and thin glass. Rejected

containers are recycled back into the furnace.

Bottle Filling

A completely hygienic process throughout all the pipe works and valves are

stainless steel the only flexi hoses on the site are between tanker and intake bay. Product

can be processed at sales gravity or high gravity product then diluted and carbonated.

Flavored Alcoholic Beverages and soft drinks can be made from concentrate or from a

recipe.


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Packaging

Depending on Customer requirements the final product can be packed in a multitude of

ways. Cases ranging from 4 to 30 bottles, neck though packs and tray and shrink wrappingare all options that are available.

Palleting & Wrapping

Glass containers are staked automatically on pallets and separated by cardboard into rows

before going undergoing the shrink wrapping process. This involves a hood type film being

placed over the pallet before being heated until the pallet contents are in a compact unit

ensuring minimal movement of the product in transit.

Warehousing

The Pallets of Container Glass move along a railing system into the automated

warehouse. All individually racked, packaging integrity is maintained. All pallets remain in

storage until distribution to the customer or directed to the in-house filling lines.

Roles of Production department in Samyu Glass Pvt. Ltd.

Creating awareness among department personnel. Identification of resource requirement and provision of adequate resource. Participation in design review when necessary. Implementation of storing/handling instruments. Quality assurance department will be provided information by production department

for traceability of products.

Handling, Storing & preservation of materials & products.

Responsibilities of Productions Department Heads:

To schedule the production program to achieve the set targets. Monitor and review of manufacturing activities with the shop supervisors to achieve

targets.

To monitor and ensure safety precautions are adhered to during production activities.


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To co-operate with engineering department for any design modification or reworkactivities during production.

Interacting with customers and updating the production status. To ensure optimum work in progress in the shop floor with the co-ordination from the

procurement team.

Motivate the workers. To study and improve the stator pressing process in co-ordination with shop

supervisors and engineering department.

To identify the requirements of production resources tools and fixture for effectiveproduction shop floor.

The relationship between R&D and Production is also very important, if R&D is latein developing a new product the loss in income to the company may be severe. If this

occurs it may not be possible to meet production targets for extended periods.


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3.4-FINANCE DEPARTMENT:

STRUCTURE OF FINANCE DEPARTMENT

Table-3.9

Money makes many things happen, goes the saying and obviously financial management is

the one of the four important areas of the management.

The major objective of any business firm is to make profit for its proprietor, apart from the

primary objective of enhancing long-term shareholder value. To reach this objective, the firm

purchases, organizes and manages various factors of production, and then produces the output

to sell, and all these processes require funds. Finance is, therefore, said to be the circulatory

system of the economic body of the firm.

Financial management is the administrative function, which relates to management of cash

and credit. The central feature of the financial department is the formulation of the firms

strategy in determining the most effective use of funds and selecting the most favorable

sources of additional funds that the firm would require in future.

MANAGING DIRECTOR

DEPUTY MANAGING

FINANCE MANAGER

ACCOUNTANT

OPERATIONAL PERSONS


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Function of Financial Management:

The function and responsibility of the finance and account wings include the following:

Analyze the financial results of all operation, report the facts to management andmake recommendations concerning future operations.

Develop the best plans to obtain the external funds needed Determine the financial resource required to meet the corporation operating and

capital expenditure program.

Establish and maintain a system of financial control governing the allocation and useof the funds.

Planning and forecasting Coordinating of other deportment

Source: http://www.managementstudyguide.com

WORKING CAPITAL:

Working capital is that position of the assets of a business which are used in or related to

current operations and represented at any one time by operating cycle of such items as againstreceivables, inventories of raw materials, stores, work in progress and finished goods,

merchandise, notes or bills receivables and cash. In accounting, working capital is the

difference between the inflow and outflow of funds (net cash inflow).

WORKING CAPITAL MANAGEMENT:

Working Capital Management is concerned to manage the current assets, the current

liabilities and interrelationship that exist between them. Working Capital Managementinvolves both setting working capital policy and carrying out that policy in day to day

operations. The goal of working capital management is to manage the firms current assets

and liabilities in such a way that a satisfactory level of working capital is maintained.


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MAJOR FUNCTIONS OF FINANCE DEPARTMENT

INVESTMENT DECISIONS:

Investment decisions refer to selection of various assets on which funds are invested, it is

concerned with allocation or deployment of funds among various short term and long term assets.

In short it is concerned with asset mix decision.

FINANCING DECISIONS:

Financing decisions also called as Capital Structure decisions are concerned with selection of

various sources of financing and their appropriate mix. It involves the study of internal and

external sources of financing. It covers both Debt (External) and Equity (Internal) sources offinancing.

STRATEGY:

The company follows the long term & short term strategy for all departments. It is the

process of establishing long term quality goals &defining the approach to meet these goals

SOURCES OF SHORT TERM FINANCING

Credit

SOURCES OF LONG TERM FINANCING


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The company is maintaining centralized cash system. All the cash and bank transaction

disbursement made through corporate office. But factory units are maintaining small petty cash

transaction, monthly once petty cash transactions reconcile with main accounts. The companymaintaining banking account in different branches:

I. ANDHRA BANK.

II. BANK OF INDIA.

III. STATE BANK OF INDIA.

IV. SYNDICATE BANK.

V. AXIS BANK.

VI. UCO BANK

Major function of finance department at Samyu Glass Pvt. Ltd. is as

Follows:

Preparation of budget, appropriation of accounts, re-appropriations, surrenders asavings.

The functions relating to its entire obligation like salary to employees payment ofrent,

Legal and professional charges, audit fees, vehicle etc. Operation and maintenance, printing and stationary expenses, charges like payment of Interest on loan, interest on working capital loan, bank charges and other interest. Company is also getting income from interest through Bank Deposit, company hire Purchase system for purchasing material, vehicles, machineries and equipment. The function relating to purchases include making payment to supplier, getting the Discounting allowed by the supplier and takes the advantage of cash advance being

received by the customers.

Administration of Taxes i.e. Sales Tax, purchase Tax, Income Tax etc


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3.5 MATERIAL MANAGEMENT DEPA

organisational study on aglass manufacturing firm

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