INTRODUCTION:

This report contains a study on different process carried out in a plastic products manufacturing
company. I have attended the internship program in WIN HI-TECH EXPORTS, a consumer and
commercial plastic products manufacturer and exporter. They mainly manufacture different types of
plastic products like buckets, mugs, sim pads, cover blocks etc which are mainly used in casting
process in construction companies.
The domestic plastic sector has been deregulated and delicensed. Compulsory licensing is required
for the following three items only viz. Hydrocyanic acid and its derivatives, Isocyanates and Diisocyanates and Phosgene and its derivatives, some of which are used in the production of
polymers. We all know plastics are very hazardous to our atmosphere, Instead of producing new
plastic materials we can recycle the old damaged and unused plastic products to produce new
plastic products. This will not make our planet completely plastic-free but will control the damage.
Products from the Indian plastic industry are exported to over 150 countries round the globe with
the major trading partners being the European Union, USA, China, UAE, Saudi Arabia, Turkey,
Nigeria, Indonesia, Egypt etc
In its pursuit to achieve export excellence, various export promotional activities are undertaken by
Plastic promotion council. These include participation in international trade fairs; sponsoring
delegations to target markets; inviting business delegations from the overseas to India; organising
buyer-seller meets both in India and the overseas etc. and servicing the needs of its members.
ROLE AS AN INTERN:
As an intern in this industry, I was given an opportunity to learn the outlook of various processes
involved in various department of the organisation, beginning from raw materials procurement till
the finished products being delivered to the customers. I have gained knowledge of the working of
different departments like recycling, manufacturing, quality assurance, packaging, accounts and
export departments.
I was given the job of assuring the quality of the finished product which is ready for end customer
in both domestic and export aspect. Inspecting the damages is both easy and tough job because we
got to think it in a consumer point of view as if we are using the product. I also worked in
packaging and account section for in-field experience.
SCOPE AND LIMITATIONS:
The Indian Plastic Industry has undergone dramatic changes since its inception be in the form of
government initiatives or be it the no of players entering or their fluctuations in their operating
scale. In the coming days, plastic will definitely have a bigger role to play particularly because of its
wide utilisation areas and diverse applicability.
Although some controversies have crept in due to inadequate knowledge of the production
techniques and their extent of adverse effects; still the industry believes that modern R & D efforts
and government initiatives encouraging plastic usage will definitely help in overcoming these
discrepancies.
COMPANY PROFILE:

# INDUSTRY AND PRODUCT

I have done my Internship program in WIN HI-TECH EXPORTS. The company is located in Out
skirts of Tirupur. They manufacture and exports consumer and commercial plastic products. They
mainly manufacture different types of plastic products like buckets, mugs, sim pads, cover blocks
etc which are mainly used in casting process in construction companies. They manufacture products
of three varieties based on the kind of raw materials used. They are as follows:
1. PVC
2. PP
3. PS
PVC (Poly Vinyl Chloride)
PVC name comes from the shortened words of Poly Vinyl Chloride" which is English equivalent.
Polyvinyl chloride is a plastic which is rather widely used. It is one of the most valuable products in
chemical industry. Over 50% of PVC is used in construction sector in the world. PVC is cheap and
easily mounted as construction material. PVC has taken place of wood, concrete and clay which are
traditional construction materials in many areas recently. Although it is an ideal construction
material, there are worries on PVC for environment and human health.
One can count the usage areas of PVC as door and window profiles, vinyl front covering, pipe and
fitting materials, electrical cables, decorating and hobby materials. It is used very commonly for
pipe lines in material, water and waste water industry as it is flexible and cheap. PVC is a
recyclable, i.e. reusable plastic. The international recycle code has been determined as 3.
PP (Polypropylene)
Polypropylene is a thermo-plastic polymer which has a wide usage field from the parts used in
automotive industry to the textile and food packing. The polypropylene which is gained by making
monomer propylene as polymer is terribly resistant to chemical solvents (acid and alkalis).

The most common commercial polypropylene has got a level between the polyethylene (LDPE)
whose crystal shape is low density and HDPE whose crystal shape is high density. Young module
(elasticised module) is at the middle level, too. Nevertheless, it is less harder than LDPE and much
less crispier than HDPE. This allows polypropylene to be used for the engineering plastics such as
ABS. Polypropylene has a very good resistant to wearing. It is low costly and has got a good stroke

resistance. The friction coefficient is lower and gives good electricity isolation. Its chemical
resistance is good. It is suitable to all of the thermo-plastic processes. The melting temperature of
the polypropylene is around 160C. In spite of that, it has such disadvantages: it has less UV gleam
resistance. It shows high thermal dilatation. It is hard to paint and cover it. The resistance to outside
weather conditions is less and open for oxidation. It is flammable and interacts with the solvents
containing chlorine.
PS (Polystyrene)
Polystyrene is a polymer that is produced through the polymerisation of the styrene in monomer
status. It is made from oil. It is rather used with PS shortening in plastic industry. Polystyrene is a
thermo-plastic in solid state in room temperature but it is brought to the solution status while it is
processed with injection or extrusion. After that, its hardening is made by cooling it. It has a good
resistance to UV gleams, good stroke and tensile resistance and a facility of low price and process.
It has a superior resistance to acid and alkali and salt.
It is extensively used on the plastic parts of the thin walled cans, cooling towers, pipe, foam, rubber,
various tools, auto parts, panels and electronic tools. It is often used on single use of glasses, plates,
yogurt pots and buttermilk pots.

# HISTORY
The parent company was started in the year 1985. Initially the parent company was called as
KARUNAMBIGAI PLASTICS started by P. SAHASRANAMAM and P. CHITHAMBARAM. It
becomes a well renowned firm for consumer durable plastic products. After partition between
brothers in late 2000 Mr.P. SAHASRANAMAM take over the parent company and renamed it as
POWER HI-TECH DURA PLAST. This company started exports and commercial product
manufacturing after his sons debut. Mr.S. KARTHIKEYAN, Proprietor of the manufacturing cum
export concern carries out the companys day-to-day affairs. It is well equipped unit with a
production capacity of minimum 5 tons of finished goods per day. The companys yearly turn over
will 3 crores.

# MISSION,VISION AND QUALITY POLICY

Their mission is to be the leading manufacturer and supplier of consumer and commercial durables
and supply for both domestic and foreign usage. They strive to produce quality product with

reasonable cost. Being a plastic industry with environmental hazards as problems, they used to
recycle the wastage and produce new products.
No unethical practices are followed. They have a strict policy of No Child Labour. No policies of
supplying products to customers without bill are done. Rate structures are followed in accordance
with market RESIN price for domestic products and export products are priced in guidance with
Plastic Export Promotion Council.

# PRESENT PERFORMANCE AND FUTURE PLANS

At present they are using RESINS for manufacturing. There are about 60 employees totally working
in the factory, 10 for administration, 50 for production etc. The firm has totally 3 manufacturing and
process facilities with the power capacity of 500HP. At present they produce minimum of 4 tons per
day.
They plan to import fully automated CNC and robotic technology machines form China in 1 year,
then the companys production capacity will get doubled with low man power requirement. Now
that are exporting their products to UAE and in near future the network will get widen.

ORGANIZATION STRUCTURE:
# ORGANIZATION CHART

DEPARTMENT STRUCTURE

BRIEF ON EACH DEPARTMENT:

PROCUREMENT DEPARTMENT:
The procurement department of the company manages the purchase of Raw Materials from their
suppliers and verify whether sufficient raw materials are available in the stock for 1 week of

production. This is because incase of any chaos situation they should be able to produce the
products to fulfil the crucial and important orders.

PRODUCTION DEPARTMENT:
Injection moulding is a method to obtain moulded products by injecting plastic materials molten by
heat into a mould, and then cooling and solidifying them. The method is suitable for the mass
production of products with complicated shapes, and takes a large part in the area of plastic
processing.
A typical injection moulding machine is divided into 2 units i.e. a clamping unit and an injection
unit.
ClampingUnit:The functions of the clamping unit are opening and closing the die, and the
ejection of products. There are 2 types of clamping methods, namely the toggle type shown
in the figure below and the straight-hydraulic type in which a mould is directly opened and
closed with a hydraulic cylinder.

InjectionUnit:The functions of the injection unit are to melt plastic by heat and then to
inject molten plastic into a mould. The screw is rotated to melt plastic introduced from the
hopper and to accumulate molten plastic in front of the screw (called metering). After the
required amount of molten plastic is accumulated, injection process is stared. While molten
plastic is flowing in a mould, the machine controls the moving speed of the screw, or
injection speed. On the other hand, it controls dwell pressure after molten plastic fills out
cavities. The position of change from speed control to pressure control is set at the point
where either screws position or injection pressure reaches a certain fixed value.
It is however important to note that all flow speeds, injection speed, shot lead time, screw rotation
speed and other particulars need to be controlled by the machinery operator. The
entrepreneur may also appreciate that the time allowed for the plastic to cool down also has
an effect on the end product properties which requires considerable know-how and skilled
handling of production line processes.

The theory of injection moulding can be reduced to four simple individual steps: Plasticising,
Injection, Chilling, and Ejection. Each of those steps is distinct from the others and correct control
of each is essential to the success of the total process.
i.

Plasticising - describes the conversion of the polymer material from its normal hard granular
form at room temperatures, to the liquid consistency necessary for injection at its correct
melt temperature.

ii.

Injection - is the stage during which this melt is introduced into a mould to completely fill a
cavity or cavities.

iii.
iv.

Chilling - is the action of removing heat from the melt to convert it from a liquid
consistency back to its original rigid state. As the material cools, it also shrinks.
Ejection - is the removal of the cooled, moulded part from the mould cavity and from any
cores or inserts.

Much savings can be realised by making informed decisions early in the product design process.
The product designer should have several tools and forms of knowledge at his disposal. In the early
stages of design, and throughout much of the design process, the designer can employ qualitative
knowledge in the form of personal experience and tabulated rules of thumb. Hence a brief overview
of what things to consider while developing the product requires to be deliberated upon.
FINANCIALDEPARTMENT:
Theactivitiesexpectedfromafinancedepartmentcoverawiderangefrombasicbookkeepingto
providinginformationtoassistingmanagersinmakingstrategicdecisions.Whattoexpectfrom
yourfinancedepartmentwilldependlargelyonfactorssuchashowmuchinvolvementthe
owner/managerhasintheorganisation.
finance department will be responsible for all the day to day transactional accounting for the
business. This will include the tracking of all transactions and the management of any
government reporting. In very small owner-managed businesses this role is often filled by a
family member with accounting experience. An outside accounting firm is usually used for
annual financial statements and returns. In larger organisations this role will extend right
through to preparing the financial statements with an external auditor engaged for assurance
purposes.
The finance department is also responsible for management of the organisations cashflow and
ensuring there are enough funds available to meet the day to day payments. This area also
encompasses the credit and collections policies for the companys customers, to ensure the
organisation is paid on time, and that there is a payment policy for the companys suppliers.
In most organisations there will be some form of forecast prepared on a regular basis to
systematically calculate the ongoing cash needs.
MARKETING DEPARTMENT:
The company is concentrating on both domestic and foreign sales. Purchase orders are collected by
the department manager and he will ensure all the consignments are fulfilling in stipulated time.
The sales will be effected to any person or company as the case may be either directly or through
authorised agents. Both cash and credit sales are entertained. The transportation charges of the
goods are to be borne by the customer who purchases the goods. The mode of payment mainly we
entertain is through cheques and drafts only. Certain cases may also be dealt with cash rarely.

PROCESS STUDY:
PROCESS FLOW:

POLICIES AND PROCEDURES:

There are some risk management policies carried out in the organisation in order to maintain
constant flow of supply of goods and brand image stabilisation. They are:
Business Operations:
The Company functions under a well defined organisation structure.
Flow of information is well defined to avoid any conflict or communication gap between two or
more Departments.
Second level positions are created in each Department to continue the work without any interruption
in case of non-availability of functional heads.
Sufficient stock of raw materials is kept to ensure continuous production.
Effective steps are being taken to reduce cost of production.
Back-up Captive power generating capacity for uninterrupted production.
Liquidity:
Proper financial planning is put in place.
Annual and Quarterly Budgets and Variance Analyses are prepared to have better financial
planning.
Daily, monthly cash flows are prepared.
Credit:
Systems put in place for assessment of creditworthiness of Customers.
Provision for bad and doubtful debts made to arrive at correct financial position of the Company.
Appropriate recovery management and follow up.
Market:
Raw materials are procured from different sources at competitive prices.
Alternative sources are developed for uninterrupted supply of raw materials

Demand and supply are external factors on which company has no control, but however the
Company plans its production and sales from the experience gained in the past.
The Company tries to reduce the gap between demand and supply.
Proper inventory control systems have been put in place.
Disaster:
The property of the company is insured against natural risks, like fire, flood, earthquakes, etc.
Fire Hydrants have been installed at all manufacturing locations. Other apparatus like extinguishers
filled with chemical, Foam etc. have been placed at fire sensitive locations and regular fire safety
drills are carried out.
First aid training is given to watch and ward staff and safety personnel.

TOOLS AND TECHNIQUES:

Color Pigmentation
Attractive plastic products are key elements that appeal to the customer, since similar products vary
nominally amongst various manufacturers. Usually the production manager decides on the color in
consultation with the owner and then develops the pigment mix in terms of quantity and quality to
meet the desired color schemes. The color pigments are then bought from the market and added to
the plastic resins which are then churned in the coloring machine. Once the resins are colored
according to the desired intensity, they are dried and cooled before being subsequently poured into
the injection moulding machine.
IMPLEMENTATION OF 5S TECHNIQUES
Sort
Allunneededtools,partsandsuppliesareremovedfromthearea.Thecompanylayoutisfixed
accordingtoprocessbutthecompanydoesnotconsistofasystematicarrangementforvarious
materialhandlingandstorage
SetinOrder
Aplaceforeverythingandeverythingisinitsplace.
Shine
Theareaiscleanedastheworkisperformed

Standardise
Cleaningandidentificationmethodsareconsistentlyapplied.
Sustain
5Sisahabitandiscontinuallyimprovedthecompanyculture

BENEFITS
1.Theproductionratewillincreaseduetosystematicarrangement.
2.Thespaceutilisationwillincrease.
3.Theatmosphericconditionswillimprove.
4.Cleanandhygienicconditionisachieved.
5.Itisconvenienttohandleandoperateeachandeverymaterial.
6.Moralsupportoftheoperatorsandworkmensareimproved.
7.Storagespaceisincreasedwithinthesamearea.

QUALITYSYSTEMSAPPLIED:
Land Requirement
The land requirement is around 10,000 sq feet in an industrial area where all utilities and facilities
are properly available. The required amount of infrastructure is allotted for the production, storage
and packaging units. Around 5-7 set of complete machineries are bought from various vendors for
the production of different products. The land will also allow ample spaces for the raw material and
finished good warehouses and a properly built office building.
CoveredAreaRequirement
The proposed setup is assumed to be totally covered with around 95% of the total area to be utilized
for construction work. It is recommended that the office and warehouses be built on the production
hall to allow maximum utilization of space. It is also suggested that minimum space be utilized for
office to allow maximum space available for storage of raw materials and finished goods inventory.

OBSERVATIONANDANALYSIS:

WORKALLOTTEDEXECUTIONSTRATEGYANDCOMPLETIONANDRESULT:

1.

QUALITYASSURANCESECTION

Iwasinstructedtoinspectallthefinishedgoodsinthecompanybecausequalityassuranceisthe
importantproceduretobecarriedoutinaorganisation.Qualityassurancemeansdeliveringthe
productwithpromisingqualityandexcellence.Isuccessfullycompletedtheworkbythinkinginthe
customerspointofview.

2.PACKAGINGSECTION
Packagingistheimportantbecauseitleadsthegoodstogetintothecustomerhandswithoutany
damageandwillavoidreturns.Simpadsandcoverblocksarepackedusingcartonboxesand
labelledwithcompanysealinit.

3.ACCOUNTINGSECTION
Accountingsectionistheheartofthecompany.Fromacquiringtheorderfromthecustomerto
maintainingthecreditdetailswillberecordedintheaccountsdepartment.Iwastoldtoviewallthe
quotations,purchaseordersandshippingbillsgeneratedinthecompanyandfileitforthefuture
use.Icompletedalltheworkallottedtomeandgainedgoodknowledgeabouttheprocesscarried
outineachandeverydepartment.

CONCLUSION
WIN HI-TECH EXPORTS is planning to set up a common facility centre for mould making, mould
repairing, machinery repairing, machinery spare parts manufacturing, injection moulding etc. under
Small Industries Cluster Development Programme scheme. The proposed annual capacity of the
unit is 6000 Engineering service hours for mould making and repair per year. The required technical
knowhow for production is indigenously available.
Though plastics are hazardous to our environment but the usage of plastics is inevitable. Regarding
my overall internship experience, it was very good experience and i have gained ample amount of
knowledge about process carried out in the plastic industry.