A REPORT ON THE WINTER INTERNSHIP AT APOLLO TYRES, PERAMBRA, CHALAKKUDY

SUBMITTED BY KRISHNAKUMAR.E ROLL NO 717 MBA PART 1 DEPARTMENT OF MANAGEMENT STUDIES GOA UNIVERSITY

INTRODUCTION:APOLLO TYRES is ranked 18th in the global tyre industry. It has maintained leadership position in the commercial vehicles tyre segment which generates 70% of the turnover in the Indian Tyre Industry ($3.2BILLION), in terms of value. VISION: A LEADER IN THE INDIAN TYRE INDUSTRY AND A SIGNIFICANT GLOBAL PLAYER, PROVIDING CUSTOMER DELIGHT AND ENHANCING SHAREHOLDER VALUE. PERAMBRA PLANT-IN FOCUS:APOLLO TYRES, PERAMBRA is the largest truck tyre plant in India. It is known as The Mother Plant. It became operational in the year 1977. This plant has received ISO 9001 Quality Certification.

THE BIAS TYRE MANUFACTURING PROCESS:The pneumatic tyre is a composite structure made out of rubber compounds, textile and wire materials. It has basic components, viz. Tread and Sidewall (made out of rubber compounds) and Carcass (made out of rubber compounds, textile and wire materials). The Carcass has components Plies, Bead, Chafer, Flipper etc. The process of tyre manufacturing involves mixing of various rubber compounds, dipping of fabric, preparation of various components, assembling the components to form the green tyre and curing the Green tyre to the final shape. The entire production system has been broadly divided in to 3 sections, viz. Div. A, Div. B, Div. C. The various steps of manufacturing are described below.
FABRIC DIPPING FABRIC CALENDARING PLY CUTTING SQUEEGE APPLICATION

RAW MATERIAL STORES

COMPOUND MIXING

TYRE BUILDING

TYRE CURING

FINAL FINISH INSPECTION

EXTRUSION BEAD PREPARATION

FGS

CEMENT MIXING

PROCESSES UNDER DIV. A:MIXING:All polymers are mixed with filler, process oil and other chemicals to give different grades of rubber compounds in the 4 Banbury Mixers. 2 Banbury mixers are meant for mixing the Master Batches. The other 2 are for mixing the Final Batches. In the Master Batch, the rubber is mixed with carbon, process oil and other chemicals. In the final batch, the master batch rubber is again mixed with sulphur and other vulcanizing compounds to enhance its cross-linking property at the time of curing. 205 final batches are prepared in one eight-hour shift. I master batch corresponds to 1.52 final batches. Hence, only 134 master batches needed to be prepared in 1 eight-hour shift. 1 ready to use batch will be obtained after mixing 2.52 batches (1 master batch and 1.52 final batches). 2 minutes are taken for mixing one batch. Therefore, 5 minutes are taken for obtaining 1 ready-to-use batch weighing 80 kg. Approx. 2 truck tyres can be made out of this 1 batch (1 truck tyre weighs 57kg, 85% of which form the rubber compounds). The mixed batch is the dropped on a batch-off mill to make it in to sheet form. Each type of rubber compound is specifically compounded for tyre performance. The different chemicals to be mixed are given particular codes. Detailed process specifications encompassing the temperature and pressure to be maintained, quantities and codes of different chemicals to be mixed , speed of mixing(60 rpm for master batch and 40 rpm for final batch) etc are available with the operators. After forming in to sheets a small piece of rubber compound is cut off from each batch and taken to lab for examining whether different chemicals have been distributed uniformly. Only after getting the approval, it is sent to extruders, calendaring unit etc. FABRIC DIPPING:The Nylon fabric is treated with latex, resorcinol, formaldehyde etc. , heated, stretched and cooled to increase its adhesiveness with the rubber compounds. It operates continuously for all the 3 shifts.13000 metres are dipped in an eight-hour shift. Nearly 18 m. is required for 1 truck tyre. The line speed for the dipping unit is 30 yards/minute for the truck tyre. Different nylon cords are required for the manufacture of different tyre types. Each type of nylon fabric requires to be coated with a specific amount of latex. After dipping, the fabric is wrapped and packed in

polyethylene in order to prevent the absorption of moisture from the atmosphere and stacked in the near by storage area. CALENDARING:The dipped fabric is then fed in to 4-roll calendar to apply rubber compounds on both sides. The advantage of using 4-roll calendar is that both the sides of the fabric can be coated simultaneously and that too with different rubber compounds. The agreed output with the trade union in an 8-hour shift is 55 rolls (23800 metres). The calendared fabric is then wound in cotton liners to prevent sticking. The line speed is 60 yards/minute for truck tyres. DUAL EXTRUDER:Components like sidewalls, treads are prepared using extrusion technique. The dual extruder consists of 2 separate set of mills on which 2 different types of compounds are broken down, heated and fed to 2 different screws. The 2 compounds are then extruded together in a common head. With the help of a performer and final dies, these emerge in to predetermined shape. The advantage of using dual extruder is that rubber compounds of completely different compositions can be extruded. It takes 15-20 minutes for the rubber compounds to be formed into a tread. The line speed for the truck tyre is 40 feet per minute. The output is 5 truck treads per minute. In the case of sidewalls, the output is 1500 sidewalls in eight hours. The dual extruder is considered as the bottleneck in Div. A. 1 tread and pair of sidewalls is required for 1 truck tyre. The output for dual extruder is 1920 equivalents. Each type of tyre is assigned a factor. The no. of treads prepared (which corresponds to no. of tyres) multiplied by the factor gives the output in equivalents. The sum of the output of the different tyres will be equal to 1920 equivalents in eight hours. The line speed is 38 FPM for treads and 16FPM for sidewalls. SQUEEGE APPLICATION:The calendared fabric is further applied with a layer of rubber compounds using 3-roll calendar. The output is 192 rolls per eight hours. The fabric required for 6 tyres can be obtained from 1 roll. 3 such machines are there. PREPARATION OF CHAFERS, BREAKERS AND FLIPPERS:The rubber compounds required for the above components, mixed in the Banbury is fed to the corresponding machines. 6150 breakers are obtained in an 8-hour shift. 152 rolls of chafers and flippers each are obtained in eight hours. The components required for 18 tyres are obtained per roll. PROCESSES UNDER DIVISION B:BIAS CUTTING:Bias cutters are used for cutting calendared fabrics to specified widths and angles known as plies. Eight plies are required for 1 truck tyre. The width depends upon the type of tyre and the angle of the cut depends on the type of tyre services required. 25 seconds are required to cut eight plies. 6 bias cutters are there. Therefore, plies for 6 tyres are obtained in 25 seconds. From a roll of 430 metres, we will get ply required for 40 truck tyres. BEAD WINDING, FLIPPING AND APEXING:The function of beads in a tyre is to anchor it while mounting the rim of vehicles. The bead wire is coated with rubber compound in a T-head extruder and wound in to coils of required dimension. The coiled beads are further applied with rubber and calendared fabrics of appropriate dimensions. 4 beads are required for a tyre. 5100 beads are prepared in 8 hours in 4 machines. TYRE BUILDING:Tyre Building Machine (TBM) has a turret for holding a no. of plies, breakers, chafer rolls besides tread applying conveyor. According to the size of the tyre to be built, specified building drum is mounted on the shaft (which can rotated at different speeds and in both directions) of TBM. The fabric layers and bead wires are applied to the drum, which are compressed together. After building the cord carcass on the drum, the tread, sidewalls and chafers are applied. The Green Tyres thus formed are removed from the drum by collapsing the same. PROCESSES UNDER DIV. C:-

TYRE CURING:The Green Tyre is prepared for vulcanization by the application of lubricants on the inner and outer surfaces for better moulding, awling (the sidewalls are pierced with the needles to release the trapped air) and punching. The Bagomatic Curing Press consists of a thin synthetic cured

bladder positioned in the centre of the bottom half of the mould over which the green tyres are placed. The steam pressure is applied in to the bladder and it is increased till the green tyre takes the complete shape of the mould when the press is closed. Curing media like hot water, steam etc are passed through the bladder while the outer surface of the mould is heated by the steam. The internal pressure is critical for the purpose of obtaining good moulding effects. The heat to be applied to the different locations of tyre compounds has to be as per specifications. Less temperature will result in under cure condition and more temperature will result in deterioration of rubber compounds. Afterwards, the tyre is taken out, mounted on a specially designed rim and inflated to required pressure, while it is still hot. This is to prevent the loss of shape when it is suddenly brought to room temperature after relieving the pressure. The tyre is cooled under inflation (for almost double the time taken for curing). This is known as Post Cure Inflation (PCI). The truck tyre takes 43 minutes for curing and 80 minutes for PCI. The no. of PCI presses are double the no. of curing presses. 48 cavities are there for truck tyres. 10 tyres are cured per cavity in eight hours. The achieved capacity is 92 metric tons per shift which consists of other tyres also. INSPECTION AND WAREHOUSING:The cured tyre is then trimmed off flashes, inspected and warehoused. THE HR DEPARTMENT Human Resources and Administration Department facilitates the smooth working of the organization. It is divided in to 3 sections namely 1) Industrial Relation 2) Security 3) Administration. Among the three sections, Industrial Relation is the biggest section having 3 sub-sections looking in to arrival and departure, welfare and safety of the employees. ORGANIZATIONAL STRUCTURE OF HR DEPT.:-

HEAD-HR AND ADMINISTRATION

MANAGERPERSONNEL AND IR

GENERAL MANAGERSECURITY

MANAGERADMINISTRATION

EXECUTIVE

EXECUTIVE

ASSO. MANAGER WELFARE

ASSO. MANAGER TIME OFFICE

ASSO. MANAGER SAFETY

EXECUTIVE

EXECUTIVE

EXECUTIVE

1) PERSONNEL AND IR:a) Recruitment:-

Recruitment is done through advertisement in newspapers. A good opportunity is given to the child of the worker. This increases the loyalty of the employees family towards the company. They are called for the interview and the chief executive take final decision. Selection Procedure;Management Staff- 1) Technical- Fresh Graduate Engineers from all the streams with 70% marks throughout the period of education. 2) Non-technical- Candidates holding degrees like CA/ICWA/MSW/MBA/MA (PM) Criteria for Selection: a) Consistency in Academic Performance b) Performance in GD c) Performance in Personal Interview. Induction Plan:Blue Collar Workers-2 days. Management Staff-15 days. Employee Children Skill Development Scheme: 1 year training is given to children of interested employees in production processes. The minimum qualification required is a pass in 10th STD. b) Training:The organization provides training for both managers and workers. Training programs for managers consist of both internal and external programs. The workers have internal programs only. The training systems include a) Need Identification b) Validation of Needs c) Annual Training Plan d) Selection and Preparation e) Fix Training Program f) Training Impact Assessment Areas Covered:1) For Management Staff: - a) Conceptual b) Functional c) Cross-functional d) Behavioural 2) For Workers:- a) Systems b) Technical aspects c) Work Culture d) Specialized Training For Trade Unions c) Industrial Relations:-

MUTUAL TRUST

UNDERSTANDING

TEAM WORK

A good industrial relation exists in the organization. The management and employees jointly find the solutions for the problems. There exists a good relation between employees. There are 4 main trade unions recognized by the company 1) Apollo Tyres Staff and Worker Union. 2) Apollo Tyres Employees Union. 3) Apollo Tyres Mazdoor Sangh. 4) Apollo Tyres Workers Movement. The trade unions which get at least 20% vote of total strength of employees are recognized by the management. The management has introduced a Long Term Settlement Plan which is nothing, but a collective bargaining agreement. The decisions are taken jointly by the trade union and the management. d) Welfare:The company runs a subsidized canteen on contract basis. Rest rooms with locker and washing facility, arts and sports club, well-maintained library are other facilities provided. Proper transportation facilities are given to all the employees from different destinations. All employees drawing a salary less than Rs. 10000 are covered under group accident policy and Mediclaim policy. Taking health aspects of employees working in night shifts in to consideration, 200 ml are given to them for every night shift. 3 soaps each are given to employees in the production dept. for cleanliness. Different Welfare Schemes:For Management Staff

1) Group Hospitalization Scheme: - a) Executives 20000/person. b) Middle Level Managers40000/ person. c) Senior Level Managers- 60000/person. The premium is completely met by the employees. It is meant for a 4-member family. 2) Group Personal Accident Policy. 3) 2-wheeler Loan Scheme: - 40% of the amount required is provided by the company. 4) Car Loan Scheme: - 40% of the amount is provided by the company. It is only meant for employees who are asst. managers and above. For Workers 1) Group Personal Accident Policy: - 100% premium is paid by the company. The total amount for which the employee is insured corresponds to 48 months of his salary. 2) Mediclaim: - 50% of the premium is met by the company and the rest by the employees. 6member family is covered under the insurance. Under this scheme each member can get Rs. 40,000 per year to meet the hospital expenses. 3) Housing Loans at Subsidized Interests: - 50% of the amount required is provided by the company. 4) 2-wheeler Loans at Subsidized Interests: - 70% of the amount required is provided by the company. 5) Free Periodical Medical Check-ups. 6) Co-operative society to provide financial assistance. 7) Bonuses in the range of Rs.12000-18000 are given if the annual average production > 90%, depending upon the attendance of the respective employees. 8) Gratuity can be received at the successful completion of 5 continuous years in the company. 9) Employees P.F. and Family Pension Scheme: - The contribution of employees towards P.F. and F.P.S. is 12% of the monthly salary. 10) E.S.I.:- Employees receiving salary less than Rs. 6500 will be covered under scheme. Employee contribution is 4.75% of his salary. e) Time Office:It is concerned with registering the time in and out of the workers and the purpose lies in the maintenance of discipline in attendance, calculation of wages for time-workers etc. different registers are kept for different shifts for the effective functioning. Apart from it, a punching system is also maintained. Each employee has to punch his badge in the electronic punching system maintained, both at the times of arrival and departure. Attendance is cross-checked with the attendance report of the workman and the attendance registers maintained at various sections for staff and managerial persons. Performance reports are maintained in each section. These are done with a view to reduce the absenteeism in employees. A leave book is maintained and it contains leave credited, leave balance, leave awaited. The daily attendance report is verified by the supervisor, shift engineer, shift superintendent and dept. head. Working Hours A-Shift- 6AM TO 2PM. B-Shift-2PM TO 10PM. C-Shift-10PM TO 6AM. D-Shift-9AM TO 5PM. f) Safety:The organization follows all the provisions under the Factories Act 1948. The plant is wellequipped with safety machines like fire extinguishers at reachable points and directions and training are given for operating the same. Safety directions are placed at noticeable points in and around the plant premises. Those who work in production unit are given masks, safety gowns and shoes. Here, a separate safety book is given to each employee, which prescribes certain procedures and rules to avoid accidents. The company follows the policy of SHE. S- SAFETY ASPECTS H- HEALTH The company has . Full Time Doctor. . Ambulance. . Dispensary. . Periodical Medical Checkups. E- ECOFRIENDLY SURROUNDINGS AND POLLUTION FREE WORK PRACTICES g) Security:-

Major Functions 1) Monitor and control all inward and outward movement of vehicles, material and personnel. 2) Deployment of contract workforce to various departments for routine as well as project works. 3) Maintain the database of the entire indirect workforce. 4) Ensure higher degree of liaison with police, local administration, fire force and govt. authorities. 5) Upkeep of Environment Management system including housekeeping of the plant. 6) Keeping strict vigilance, gathering and assimilating intelligence in a unionized environment. h) Other Administrative Activities:1)Performance Appraisal:1) Employees development review in the period of Mar-Apr. 2) Three Tier Systems in which the performance is evaluated by the employee himself, his immediate boss and bosss boss. 3) Helps in setting individual/ term goals. 4) Rated in respect of the achievements. 5) Mid year review of the goals. 6) Personal attributes are considered. 2)Absenteeism Management:a) System:1) Daily Follow Up. 2) If the employees are absent for 3 days consecutively, they are asked to meet HR manager before going to the workplace. After 6 days, they are not allowed to work. After 10 days, HR officials visit employees at the home and counsel them. b) Task Force:12 task forces are set up for 116 members. Each constitutes 1 HR official and 1 line personnel. A no. of employees showed remarkable improvement in their attendance after task forces were setup. 3) Salary Payment:1) Supervisors will have to open an account with the South Indian Bank and intimate the account no. to the accounting dept. which in turn will remit the salary in the bank. 2) For technical and service staff, the salary is paid on the last working day of the month. 3) For engg. and prodn. workmen, the salary is paid on the 7th working day of the next month. i) Other Relevant Information:1) There are 5 national holidays and 8 festival holidays given in a year. 2) The employees are given 1 day off after 48 hours of work. 3) The retirement age is 58 years. 4) The pay scale is revised annually in consultation with trade unions. 5) The employees can take 1 day leave after 20 consecutive days of work. 6) 3 categories of leave that the employees get are 1) sick leave 2) casual leave 3) privilege leave. 7) Promotion for management staff is purely based on performance. For workmen, it is based on seniority. THE STORES DEPARTMENT RAW MATERIALS STORES(RMS):PROCESS: - Receipt, handling, storage, packaging, forwarding and delivery of material to internal and external customers with proper documentation to meet their requirements. PURPOSE: - To supply right material in right time to produce right quality product without any interruption. ACTIVITY DESCRIPTION:- 1) Upon the receipt of raw materials, the documents related to transporter and supply are verified to ensure the authenticity. 2) Identification of the supply with full details of material code, date of receipt, suppliers name and truck reg.no. will be carried out and it will be transferred to pre-decided location. 3) Upon receipt of raw materials, GR will be prepared. 4) Based on GR, quality assurance will collect the samples as per the predetermined frequency and approve the materials, if the results are conforming to the requirements.

5) The materials, if rejected from lab will be sent back to supplier and all the accepted material will be accounted in the inventory. 6) Issue of raw materials will be carried out to internal (mixing centres, extruders etc) and external (other units of Apollo) customers based on their requests. Various Raw Materials Used:1) Polymers: - Natural and synthetic rubbers. 2) Fillers, carbon black, reinforcing clays. 3) Process oil. 4) Curing agents/sulphur. 5) Accelerators/activators. 6) Antioxidants/antiozonents. 7) Ret ardors. 8) Peptizers. 9) Fabrics. 10) Bead wire spools. 11) Solvents for cements and solutions. 12) Miscellaneous items like paints, colours, scrap flakes etc. RECEIPT OF RAW MATERIALS:Verification of Documents at Security Gate: - Serial No., suppliers name, description of the item, receipt quantity, receipt No. and date, truck reg. No., date and time of arrival and departure must be noted down. Weighing:- Security will inform the RMS about the arrival of the vehicles at the gate. The security officer and a representative from RMS will record the weight of the truck jointly. The weigh slip will indicate the following; - Serial No., Date and Time of Receipt, Suppliers Name, Gross Weight with Materials. After recording the above details in the computerized weighing balance, the vehicles are directed to the respective unloading bay. Both security and RMS personnel will sign on the weigh slip. One copy is sent to RMS along with delivery challan and second copy will be retained by security dept. Verification of Documents at RMS:- The receipt in charge will verify the documents to ascertain the no. of packages, materials code and the weight. Discrepancy, if any, will be reported orally to the officer concerned before unloading. He in turn will take apt decision. The dispatch documents include:- Delivery Challan, Invoice, Sales Tax Papers, Packing List & Duplicate Copy of Invoice for Transporter of Invoice for availing MODVAT credit. If any of these are not received, the consignment will not be downloaded. ENGINEERING GOODS STORES (EGS):EGS is responsible for storing the necessary spare parts and components required for the smooth functioning of the plant. The inventory management is based on an economic order quantity, re-order level and safety stock. Another system followed in engineering stores is Vendor Maintain Inventory. In VMI, the raw materials are stored in large quantities and the payment is made only for consumed items. At present, the total no. of item codes in the stores is 38500 out of which 23500 are spares (vary with machine, make and model) and 15000 are consumables (bearings belts etc.). It is decided to 1) Identify common equipments by same make and model. 2) Assign uniform codes to equipments make and model wise which is common across the plants. 3) Assign respective plant spares with codes of equipments. FINISHED GOODS STORES (FGS):All the finished goods after final inspection are kept at the transferring area in each shift. The staff of final finishing will prepare a finished goods transfer notes in triplicate which will be countersigned by the staff of FGS. After verification, these will be serially numbered and have the following details: - Material code, Description, Quantity. The original copy will be issued to Central Excise Wing after entering the details in stock statement. The duplicate will be given back to production dept. as their file copy. The triplicate will be issued to Production Planning Dept. 1 staff; each from PD and FGS will separately verify the quantity, size, ply rating of the finished goods and compare with the entry in the transfer note. The finished goods for dispatch kept at the transferring area will be removed to the loading bay and the remaining will be removed to the stores after packing these. FGS has the function of receiving, storing and dispatching as per Supply Chain requirements, and communicating daily stock levels.

QUALITY ASSESSMENT:The basic purpose of Plant Quality Assessment is to 1) Establish universal scale of comparison for manufacturing excellence among various tyre manufacturing units of the Apollo Group. 2) Identify improvement opportunities in manufacturing at system level ensuring strong foundation for World Class Manufacturing. 3) Prioritize improvement opportunities based on their impact on overall performance of the organization. 11 FOCUS AREAS ARE 1) OPERATIONS 2) MAINTENANCE & INSTRUMENTATION 3) HOUSEKEEPING 4) EMPLOYEE SKILLS AND SATISFACTION 5) RAW MATERIALS 6) MATERIAL HANDLING AND LAYOUT 7) QUALITY MANAGEMENT 8) SAFETY, HYGIENE & POLLUTION CONTROL 9) VISUAL MANAGEMENT 10) FG DESPATCH 11) CUSTOMER FOCUS. 13 CELLS UNDER ASSESSMENT 1) RMS 2) DIPPING 3) CALENDARING 4) MIXING 5) EXTRUDING 6) BIAS CUTTING 7) BEAD WINDING 8) TYRE BUILDING 9) TYRE CURING 10) FINAL FINISH 11) FGS 12) ENGG. 13) HR. Each of these cells is having almost 100 parameters to be assessed. Scoring methodology:All parameters are graded in to 5 levels. Score 1:- Existence of system as documented policy (slips or logbooks) with demonstrable support ensuring execution. The score is given based on the fact that the knowledge of system exists within the assessed area. Score 2:- System is followed at many places, which covers about 50% or more of applicable areas. This score is given based on the fact that the system is developing in the assessed area and it is consistently followed. Score 3:- Roles and responsibilities for various aspects of systems are clarified and communicated across. This score is given based on the fact that the triple roles in the system (customer, supplier and processor of information, product or services) are clear to all the concerned employees. Score 4:- Gaps in performance and controls are identified and corrective actions are taken resulting in to improved efficiency of system. The identified gaps are sealed permanently and there is minimal chance of recurrence. The score is given based on the fact that over a period of time, system is made more efficient (less cost, better quality, consistency, timely operations etc.). Score 5:- Continuous improvement in performance parameters (effectiveness of the system) is seen over last few years. All important performance parameters are measured. The score is given based on the fact that system has contributed towards significant business benefits and/or customer satisfaction.

SCORE 1

SCORE 2 START YES YES

BASIC AWARENE SS OF SYSTEM AMONG KEY EMPLOYE ES

N O

SIGNS OF SYSTEMS AT VARIOUS PLACES CAN BE SEEN

N O

MOST EMPLOYE ES AT SHOP FLOOR AWARE OF THE SYSTEM

NO YES SCORE 0

NO

ROLES OF EMPLOY EES ARE CLEAR AND KNOWN

YES

NO SCORE 3

GAPS IN EFFICI ENCY IDENTI FIED/R EMOV ED

YES

NO SCORE 4

SIGNIF ICANT IMPRO VEMEN T IN EFFEC TIVEN ESS

YES

SCORE 5

ANNEXURES:-

m achine utilization-fabric dipping

94 92 90 88 86 84 82 80 78 76 91 87.4 83.9 91 92.1 88.4 82.5 91.9

200607

target 200708

Apr07

M ay07

Jun07

Jul-07

Aug07

Sep07

Series1

machine utilization-four roll calendar

120 100 80 60 40 20 0 2006- target Apr- May- Jun07 2007- 07 07 07 08 Series1 Jul07 Aug- Sep07 07 % 94.2 96 92.7 94.3 90.8 91.1

87.4

79.7

machine utilization-two roll calendar

120 100 80 % 60 40 20 0 2006- target 07 200708 Apr07 May07 Jun07 Jul07 Aug07 Sep07 96.6 99 74.4 81.3 98.5 96.9 96.4

95.5

tyre curing-utilization
98 96 94 92 90 88 86 84 82 80 78 97 93 92.61 93.83 94.4 92.2 93.65

85.13

2006- target 07 200708

Apr07

May07

Jun07

Jul-07

Aug07

Sep07

machine utilization-dual extruder

100 95 90 85 80 75 2006- target 07 200708 Apr07 May07 Jun- Jul-07 Aug07 07 Sep07 96.4 95.9

94 87.4 83.6

94.8

94.5

94.9

machine utilzation-bias cutters

100 98 96 94 92 90 88 86 84 97.8 97.81 97.25

96.08

96

96.85

96.76

88.86

2006- target 07 200708

Apr07

May07

Jun07

Jul07

Aug07

Sep07

m achine utilization- m ixing

100 95 90 % 85 80 75 70 2006- target 07 200708 Apr07 May07 Jun07 Jul07 Aug07 Sep07 90.2 92 87.1 81.8 94.1 95.7 89.6 90.5

pareto chart- downtime analysis- four roll calendar

4.5 4 3.5 3 2.5 2 1.5 1 0.5 0
el ay s ot he rd

4
88.87 98.1 2

5 4.62

37 .03

el ec t

pm ric al de m la at y er ia ls sh or t

ab se nt ee i

ec h

de la ys

sm

1.9

1.9 72.21 1.8

120 99.97 100 80 60 40 0.2 20 0

downtim analysis- dual extruder e

2.5 2 1.5 1 0.5 0
el ay s pm el ay d d ec h
2 .5 8 7 5 .4 12

2 1.6 1.3 69.99 1.2 0.9

8 .1 73

120
10 0

100 80 60 40 20

te e

at er ia ls h

ot he r

ab

se n

or ta ge

is m