A Project Report on

Gokul Overseas, Ahmedabad

Subject: Operation Management

Submitted to: Prof. Avani Patel
Submitted by:
Name Roll
No.
Ghelani Nisarg P161
3
Mathukiya Akshay P162
4
Mehta Virang P162
5
Shah Parth P164
5
Shah Ravi P164
6
Yadav Harsh P165
9

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 Submission Date: 25/03/2017
N.R. Institute of Business Management

Acknowledgement:
Being fortune enough to be part of N.R. Institute of Business Management, Ahmedabad, we
would like to thank Prof. Avani Patel for giving us this opportunity to carry out live project
on Gokul Overseas, as a part of the curriculum.

Lastly, we thank our group members for their constant encouragement and help without
which this project would not be possible.

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 Introduction of Gokul Overseas:

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Gokul Overseas, when launched in 1995 was only a merchant exporter. But, under the able
leadership of Balwantsinh Rajput, the company established a fully-integrated Castor
Manufacturing Facility in 2006, at Kandla. The manufacturing unit is located in the Special
Economic Zone (KASEZ), which is Indias biggest SEZ in the multi-product category.

The Gokul Overseas plant is a highly-integrated unit with modern facilities for all processes
ranging from seed crushing, solvent extraction, refining and production of castor derivatives.
The ultra-modern manufacturing units work in conjunction to produce premium-quality
products and this makes us a preferred brand amongst the quality-conscious buyers

The companys state-of-the-art technical equipment ensure best-in-class Castor Oil and its
derivatives with flakes of uniform quality. The company has a wide network to procure castor
seeds from the state of Gujarat and Rajasthan. The companys in-house storage facilities
ascertain the stability of seeds and products through controlled atmospheric conditions.

From pharmaceutical, lubricant, cosmetic, paints, paper, chemical, Inks, adhesives and many
other industries wherever applicable, Gokul Overseas is their first-choice. Hence, it is no
surprise that the company now export to buyers located in USA, Europe, Japan, China and
Thailand that are known for adhering to strict and stringent quality guidelines.

Products:

The Gokul Overseas is the most reckoned name in the castor industry offering widest
collection of castor oil products and derivatives. The company supply and
manufacture high-quality castor products and its derivatives in its manufacturing unite
by experts hands.

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 1. Castor Oil Pharmaceutical Grade:

2. Castor Oil Commercial Grade:

3. Castor Oil First Special Grade No. 1 BSS:

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 4. Castor Oil Pale Pressed Grade

5. Pharmaceutical Grade:

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 Production Process:

1. Refining:

Refining Capacity at Gokul Overseas 250 TPD

The Commercial Castor Oil is then charged to Bleacher for further purification. It
is purified by adding Bleaching Earth and Activated Carbon under vacuum and
heat. Thence the Oil is filtered with help of Pressure Leaf Filter which separates
the Carbon and Bleaching Earth that was added earlier in the process. The
Filtered Oil is light in color and is called B.S.S. Grade Castor.

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 2. Derivative Manufacturing:

Hydrogenation Plant Capacity 110 TPD

Derivative Plant Capacity 82.5 TPD

Dehydrated Castor Oil Plant Capacity 15 TPD

The capacity of Derivative Plants can be used to manufacture any of the derivatives
mentioned in the Products section. The company make custom made derivatives
specific to the requirements of the Customer.

Production Capacity:

Gokul Overseas has capacity per day 600 tons of crushing, 250 tons of refining, 300
tons of solvent extraction & 120 tons of derivatives.

Gokul Overseas has capacity per annum of 180000 tons of crushing, 75000 tons of
refining, 90000 tons of solvent extraction & 36000 tons of derivatives.

Plant Facility:

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 Crushing including Cold Pressed Grade Derivatives Unit-Controlled temperature
during flaking of derivatives results in uniform color and better whiteness of products.

Capacity per day Oil Mill-550 MT

Capacity Utilitisation Oil Mill-75%

Capacity per day Solvent Plant-300 MT

Capacity Utilitisation BSS Refinery-70%

Capacity per day HCO- 70 MT

Capacity Utilitisation HCO-70%

Packaging Facilities:

Companys products are packed in Customer-friendly bags of all sizes with H.D.P.E.
liners and barrels. The products are stored under appropriate atmospheric condition
so as to keep the chemical properties stable and ensure the product reach you in the
best condition.

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 Storage Facilities:

The company take utmost care while storing their products. The liquid products, once they
are manufactured and tested for its desired stability and combination, are stored in S.S. 304
tanks. The warehouse is well-segregated to ensure that the products are easily accessible.
Another aspect that the company take extreme care about is the packaging. The companys
packed bags are specially treated to ensure not just safety of their products during storage and
transportation but also ascertain that their products stay fresh for long.

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 Logistics Channel:

Companys well-defined logistics channel enables them to deliver their

products to the Customers across the globe on schedule. The presence of
Gokul Overseas plant at a strategic location with its proximity to Kandla port
enables them to honour the delivery schedule. The logistics team is well-
equipped to deliver orders to Customers flawlessly to various destinations via
Roadways, Railways and Sea Routes.

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 Quality Control:

Gokul Overseas has been a preferred partner across the globe and thats mainly because we
conform to stringent quality standards in manufacturing of Castor Oil and its derivatives. The
complete evaluation, optimization and testing of products takes place at every possible step to
ensure highest quality output. The companys indigenous Research and Development
department, which forms a backbone for future development and growth of the Company,
secures that the finished products conform to highest level of international quality and
Customer satisfaction.

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 Concept of Lean Manufacturing:

Lean manufacturing or lean production, often simply "lean", is a systematic method for
the elimination of waste ("Muda") within a manufacturing system. Lean also takes into
account waste created through overburden ("Muri") and waste created through unevenness in
workloads ("Mura"). Working from the perspective of the client who consumes a product or
service, "value" is any action or process that a customer would be willing to pay for.

Model of the Lean production system

Lean manufacturing makes obvious what adds value, by reducing everything else (which not
adding value). This management philosophy is derived mostly from the Toyota Production
System (TPS) and identified as "lean" only in the 1990s.lean is the set of "tools" that assist in the

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identification and steady elimination of waste. As waste is eliminated quality improves while
production time and cost are reduced

Gokul overseas purifies commercial castor oil under the refining machines. The wastage
coming out from the refining process is called lean . This will improve quality. By applying
the lean manufacturing concept the company, the company has reduced the lag time between
two processes.

Suggestions:

1. The company should make Zero Defects System. By accepting this system, the
company will reinforce that no defect is acceptable in manufacturing process. This
will increase the quality & mitigate the defect.

2. The company should adopt Kanban System. By adopting this system, the
company can reduce the over-production problem.

3. The company should recycle the wastage coming from manufacturing process.

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