Final Surya Report

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LM THAPAR SCHOOL OF MANAGEMENT

Report on Product and

Process designSurya Polyvin Ltd. Patiala.

Submitted by: Group 4

Laxmi suri Manveen kaur

Parvinder singh Palak Bhatia

Rupesh Shahi Ramandeep Sharma

Monika Goyal.



DECLARATION

We group members Rupesh Shahi, Ramandeep Sharma, Parvinder Singh, Manveen Kaur,

Laxmi Suri, Monica Goyal and Palak Bhatia studying at L.M Thapar School of Management,

hereby declare that this project ³product and process design at Surya Polyvin

Ltd.´ submitted by us to the Department of Management, Thapar University in partial fulfillment

of the requirements of MBA project is a bonafide work carried out by us, under the guidance and

supervision of Mr. Gaurav Goyal , faculty guide. This project or any part thereof has not been

previously submitted for any degree/diploma/certificate of any University/ institution elsewhere.

Date: 9-04-11

Place: PATIALA



ACKNOWLEDGEMENT

We would like to express our heartfelt gratitude to Mr. Gaurav Goyal (Assistant Professor,

LMTSOM) for providing us the much necessary encouragement to take up this project.

We indebted to Mr. Gaurav Goyal, faculty, LM Thapar School of Management, for his

unfailing support throughout the project work. With his mentorship we could excel in our

undertaking. He has shown us the way to excel in our work, enhance and stretch our

capabilities to the fullest.

We also extend our gratitude and thanks to all the respondents without whom this project

would not have been a success.

Thank You

Place: Patiala

Date: 9-04-11



Table of Contents

Introduction to PVC ........................................................................................................................... 6

History of PVC................................................................................................................................ 6

ABOUT SURYA PIPES .......................................................................................................................... 8

Reason behind shifting to Patiala ................................................................................................... 8

Product design................................................................................................................................... 8

THE PRODUCT DESIGN PROCESS .................................................................................................... 9

Idea Development...................................................................................................................... 9

Product Screening.................................................................................................................... 10

Preliminary Design and Testing ................................................................................................ 11

Final Design ............................................................................................................................. 11

SURYA Polyvinyl pipes...................................................................................................................... 11

IDEA DEVELOPMENT: ................................................................................................................... 11

SOURCES: CUSTOMERS AND SUPPLIERS........................................................................................... 12

Cooling process ............................................................................................................................... 13

Socketing......................................................................................................................................... 13

Testing and Inspection..................................................................................................................... 13

Pipe Extrusion.................................................................................................................................. 16

Process design in surya pipe ............................................................................................................ 20

PROCESS SELECTION .................................................................................................................... 20

Repetitive Operations.............................................................................................................. 20

Types of processes used in repetition operation .............................................................................. 22

DESIGNING PROCESSES.................................................................................................................... 23

Process flow chart of surya pipe ltd. ................................................................................................ 25

Summary of flow chart................................................................................................................ 25

Advantages of PVC........................................................................................................................... 26

Chemical resistance ..................................................................................................................... 26

Toughness ................................................................................................................................... 27

Cost ............................................................................................................................................. 27

Disadvantages of PVC ...................................................................................................................... 28

Temperature................................................................................................................................ 28



Introduction to PVC

Polyvinyl chloride, commonly abbreviated PVC, is a thermoplastic polymer. It is

a vinyl polymer constructed of repeating vinyl groups (ethenyls) having one of

their hydrogens replaced with a chloride group. Polyvinyl chloride is the third

most widely produced plastic, after polyethylene and polypropylene.

It can be made softer and more flexible by the addition of plasticizers, the most

widely used being phthalates. In this form, it is used in clothing and upholstery,

and to make flexible hoses and tubing, flooring, to roofing membranes, and

electrical cable insulation. It is also commonly used in figurines and in inflatableproducts such as waterbeds, pool toys, and inflatable structures.

History of PVC

PVC was accidentally discovered at least twice in the 19th century, first in 1835

by Henri Victor Regnault and in 1872 by Eugen Baumann. On both occasions the

polymer appeared as a white solid inside flasks of vinyl chloride that had been left

exposed to sunlight. In the early 20th century the Russian chemist Ivan

Ostromislensky and Fritz Klatte of the German chemical company Griesheim-

Elektron both attempted to use PVC (polyvinyl chloride) in commercial products,

but difficulties in processing the rigid, sometimes brittle polymer blocked their

efforts. Waldo Semon and the B.F. Goodrich Company developed a method in

1926 to plasticize PVC by blending it with various additives. The result was a more

flexible and more easily processed material that soon achieved widespread

commercial use.

USES

PVC's intrinsic properties make it suitable for a wide variety of use:-

Household sewerage pipes

Pipe applications where corrosion would limit the use of metal.



Cabling applications as a wire insulator. It is also used to make vinyl

records.

PVC has become widely used in clothing, to either create a leather-

like material or at times simply for the effect of PVC.

Material for window and door frames.



ABOUT SURYA PIPES

� Started in SAMANA in 1990 with three machines in number.

� Shifted to Patiala in 2010.

� In Patiala they takeover Jain Polyvinyl which was already having three

machines.

Now they are having total 10 machines and they stop the plant which they had in

Samana for reducing complexity and other logistics problems.

Reason behind shifting to Patiala

� Lack of Space in SAMANA.

� Sales Problem: Because of high demand and supply low in 1990s of PVC

pipes.

� Marketing is not so effective there.

� They want to increase their Turnover as well as they want to expand their

business too.

� Now they are having 5000 Square feet i.e. 5 plots each of 1000 square feet.

Product design

In this report we will learn about product design and process design of PVC PIPES

INDUSTRY. Product design is the process of deciding on the unique characteristics

and features of the companys product. We will also learn about process

selection, which is the development of the process necessary to produce the

designed product. Product design and process selection decisions are typically



made together. A company can have a highly innovative design for its product,

but if it has not determined how to make the product in a cost effective way, the

product will stay a design forever.

The examples like Pizza Hut and Alza Corporation illustrates product design thatmeets customer needs, although challenging can have a large impact on a

companys success. In fact, product design is so important that leading edge

companies routinely invest in product designs well into the future. For example,

Daimler Chrysler has been conducting research to design intelligent technologies

for their vehicles that would have pedestrian and street sign recognition systems.

This type of innovative product design can give a company a significant

competitive advantage.

PRODUCT DESIGN

Product design defines a products characteristics, such as its appearance, the

materials it is made of, its dimensions and tolerances, and its performance

standards.

TH

E PRODUCT DESIGN PROCESS

Idea Development

All product designs begin with an idea. The idea might come from a product

manager who spends time with customers and has a sense of what customers

want, from an engineer with a flair for inventions, or from anyone else in the

company. To remain competitive, companies must be innovative and bring out

new products regularly. In some industries, the cycle of new product

development is predictable. We see this in auto industry, where new car models

come out every year, or the retail industry, where new fashion is designed for

every season. In other industries, new product releases are less predictable but

just as important. The Body Shop, retailer of plant-based skin care products,

periodically comes up with new ideas for its product lines. The timing often has to



do with the market for a product, and whether sales are declining or continuing to

grow.

Product Screening

After a product idea has been developed it is evaluated to determine its likelihood

of success. This is called product screening. The companys product screening

team evaluates the product design idea according to the needs of the major

business functions. In their evaluation, executives from each function area may

explore issues such as the following:

Operations What are the production needs of the proposed new product and

how do they match our existing resources? Will we need new facilities and

equipment? Do we have the labour skills to make the product? Can the material

for production be readily obtained?

Marketing What is the potential size of the market for the proposed new

product?

How much effort will be needed to develop a market for the product and what isthe long-term product potential?

Finance The production of a new product is a financial investment like any other.

What are the proposed new products financial potential, cost, and return on

investment?



Preliminary Design and Testing

Once a product idea has passed the screening stage, it is time to begin preliminary

design and testing. At this stage, design engineers translate general performance

specifications into technical specifications. Prototypes are built and tested.Changes are made based on test results, and the process of revising, rebuilding a

prototype, and testing continues. For service companies this may entail testing

the offering on a small scale and working with customers to refine the service

offering. Fast-food restaurants are known for this type of testing, where a new

menu item may be tested in only one particular geographic area. Product

refinement can be time consuming, and there may be a desire on the part of the

company to hurry through this phase to rush the product to market. However,

rushing creates the risk that all the bugs have not been worked out, which canprove very costly.

Final Design

Following extensive design testing the product moves to the final design stage.

This is where final product specifications are drawn up. The final specifications are

then translated into specific processing instructions to manufacture the product,which include selecting equipment, outlining jobs that need to be performed,

identifying specific materials needed and suppliers that will be used, and all the

other aspects of organizing the process of product production.

SURYA Polyvinyl pipes

IDEA DEVELOPMENT:

� They have a heavy weight and high transportation costs;

� They are difficult to install and maintain;

� It is difficult to implement diversions after their installation;



� Manufacturing the pipes requires high precision;

� They are subject to leakage under high water pressures.

SOURCES: CUSTOMERS AND SUPPLIERS

THE COMPANY SAW A HUGE DEMAND OF PVC PIPES BECAUSE OF ITS light

weight, high strength, and low reactivity make it particularly well-suited to this

purpose.

Cooling plant

Cooling Plant plays a vital role in production of PVC Pipe. Because after coming

out from the heating zone it is required to cool the pipe immediately.

For that water is required which is reused in the plant and that is possible with

the help of cooling plant. Water used in the Extruder is transferred to Cooling

Plant where it passes from many stages of sedimentation and come in contact of

atmosphere and water gets cooled.

Again this water can be used in the process of PVC pipe Production. Pool in which

water is collected is clean after every two months by changing water and cleaning

the walls of Pool.



Cooling process

When pipes come out of extruder, the cold water is put on the pipes to cool

them. Now the water is recycled. The water is collected in the pool and from

there water is pumped up through motor. There are different layers in the coolingtank and sedimentation of water is done. Then this water is again used for the

same process.

Socketing

For widening the end of the PVC pipes and forming Coupler (joint) at the both

ends of pipes a process is done called Socketing. Socketing techniques make work

easy of fitting or joining two pipes.

Long pipes can be formed by ordering the required size or by forming sockets at

the ends of pipe and make possible to join two or more pipes and form long pipe

of required length.

Socketing Process

The very first step is to dip the pipe in hot calcium chloride (CaCl2) and boiling

water for some time until the ends of pipe get weak and can be given any desiredshapes. Just after moulding the ends of pipe cold water is poured on the ends of

PVC pipes and made it cool and hard.

Testing and Inspection

1. Q ualification Testing

y PVC extrusion compound Cell Classification Test

y Gasket Join Design Testing

y Toxicological Testing

y Long Term Hydrostatic strength Testing

y Joint Performance Testing

y Lap-shear Testing



2. Q uality Control Testing

� Workmanship Inspection

� Marking Inspection

� Dimension Measurement

� Product Packaging Inspection

� Q uick Burst Test

3. Assurance Testing

� Sustained Pressure Test

� Hydrostatic Proof Testing

1. Q ualification Testing: - Q ualification testing is performed on piping products

and on the materials from which they are produced to ensure that the finished

products meet the requirements of applicable specifications.

PVC extrusion compound cell classification test: This qualification

test, as defined in ASTM D1784, is required and performed to

establish primary and mechanical and chemical properties of the PVC

material from which the finished pipe products are produced.

Gasket joint design testing: One option for testing joint design is to

perform pressure tests to verify that joint assemblies qualify for a

hydrostatic design basic category.

Toxicological testing: This qualification test is performed to verify

that metals and chemical cannot be extracted by water in qualities

termed toxic, carcinogenic, teratogenic, which produces adverse

physiological effects in human.

Long term hydrostatic strength testing: This test is required and

performed to establish the maximum allowable design stress in the

wall of PVC pipe in the circumferential orientation as a result of

internal pressure applied continuously with the high level of certainty

that failure of pipe cannot occur.



Joint performance testing: This test is performed to verify a leak free

design of a specified pipe joint that will maintain a proper connection

and seal.

Lap shear testing: This test is used to verify that fabricated-fitting

solvent-cementing procedures result in minimum average lap-

strength.

2. Q uality Control Testing: - Q uality control testing is performed on

specimens of PVC piping products as they are manufactured to ensure that

the products comply with applicable standards.

Workmanship inspection: Inspection is conducted to ensure that PVC

pipe product is homogeneous throughout from voids, cracks, and

other effects and uniform in colour, density and other physical

properties.

Marking inspection: Inspection verifies proper marking of the pipe as

required in the applicable product standards.

Dimensions measurement: Measurement of dimensions on regular

and systematic basis is essential. Failure to meet dimensional

requirements may render the product unsatisfactory regardless of

success in other inspections and tests.

Product packaging inspection: The finish package of PVC pipes

prepared for shipment to customer is inspected to ensure correct

pipe quantity and adequate protection of the pipe.

Q uick burst test: The PVC pipe sample is pressurised to burst within

the test time period of 60 to 70 sec. Burst pressure measured must

not be less than minimum the burst pressure requirements.



2. Assurance Testing:- Assurance testing is performed at the completion of the

manufacturing process to ensure the finished products consistently and

reliably satisfy the requirements of applicable standards.

Sustained pressure test: Fabricated fittings shall not fail, balloon,

burst or weep at the applicable sustained pressure when tested for

1000 hr.

Hydrostatic proof test: This test is required in the manufacture of

PVC pipe. In this test every coupling of PVC is proves tested for a

minimum dwell time of 5 sec.

Pipe Extrusion

The essential aspects of a solid wall PE pipe manufacturing facility are presented

in Figure 1. This section will describe the production of solid wall pipe from raw

material handling, extrusion, sizing, cooling, printing, and cutting, through

finished product handling. Details concerning profile wall pipe are also discussed

in the appropriate sections.

Raw Materials Description

The quality of the starting resin material is closely monitored at the resin

manufacturing site. As discussed in the chapter on test methods and codes in this

handbook, a battery of tests is used to ensure that the resin is of prime quality. A

certification sheet is sent to the pipe and fitting manufacturer documenting

important physical properties such as melt index, density, ESCR (environmental

stress crack resistance), SCG (slow crack growth), stabilizer tests, amongst others.

The resin supplier and pipe manufacturer may agree upon additional tests to be

conducted.



Extrusion Line

The raw material, usually referred to as PE compound, is typically supplied to the

pipe producer as non-pigmented pellets. PE pellets are stabilized for both heat

and UV protection. Usually, color pigment is added to the pipe at the producers

facility. The most common colors are black and yellow. The choice of color will

depend upon the intended application and the requirements of the pipe

purchaser. Carbon black is the most common pigment used for water, industrial,

sewer and above-ground uses. Yellow is reserved exclusively for natural gas

applications, although black with yellow stripes is also permitted for this

application. Other colors are used for telecommunications and other specialty

markets.



Extrusion Basics

The function of the extruder is to heat, melt, mix, and convey the material to the

die, where it is shaped into a pipe. The extruder screw design is critical to the

performance of the extruder and the quality of the pipe. The mixing sections of the screw are important for producing a homogeneous mix when extruding

blends.

COOLING AFTER EXTRUSION PROCESS AT SURYA POLYVIN LTD.

Cooling

For either the vacuum or pressure sizing technique, the pipe must be cool enough

so that it maintains its circularity before it exits the cooling tank. Various methods

of cooling are utilized to remove the residual heat out of the PE pipe. Depending

upon the pipe size, the system may use either total immersion or spray cooling.

Spray cooling is usually applied to large diameter pipe where total immersion

would be inconvenient. Smaller diameter pipe is usually immersed in a water

bath. Cooling water temperatures are typically in the optimum range of 40° to



50°F (4° to 10°C). The total length of the cooling baths must be adequate to cool

the pipe below 160°F (71°C) in order to withstand subsequent handling

operations.

Pullers

The puller must provide the necessary force to pull the pipe through the entire

cooling operation. It also maintains the proper wall thickness control by providing

a constant pulling rate. The rate at which the pipe is pulled, in combination with

the extruder screw speed, determines the wall thickness of the finished pipe.

Increasing the puller speed at a constant screw speed reduces the wall thickness,

while reducing the puller speed at the same screw speed increases the wall

thickness.

PULLERS OF EXTRUSION MACHINE AT SURYA POLYVIN LTD.



Process design in surya pipe

The activity of determining the workflow, equipment needs, and implementation

requirements for a particular process. Process design typically uses a number of

tools including flowcharting, process simulation software, and scale models.

PROCESS SELECTION

For every company to meet their demand and supply chain they have to follow

some processes .

All processes can be grouped into two broad categories: intermittent operationsand repetitive operations. These two categories differ in almost every way. Once

we understand these differences we can easily identify organizations based on

the category of process they use.

In surya polyvin Ltd. the process they use comes under repetitive operation.

Repetitive OperationsRepetitive operations are used to produce one or a few standardized products in

high volume. Examples are a typical assembly line, cafeteria, or automatic car

wash. Resources are organized in a line flow to efficiently accommodate

production of the product.

Note that in this environment it is possible to arrange resources in a line because

there is only one type of product. This is directly the opposite of what we find

with intermittent operations.

To efficiently produce a large volume of one type of product these operations

tend to be capital intensive rather than labor intensive. An example is mass

production operations, which usually have much invested in their facilities and



equipment to provide a high degree of product consistency. Often these facilities

rely on automation and technology to improve efficiency and increase output

rather than on labor skill. The volume produced is usually based on a forecast of

future demands rather than on direct customer orders.

The most common differences between intermittent and repetitive operations

relate to two dimensions:

(1) The amount of product volume produced.

(2) The degree of product standardization.

DECISION REPETITIVE OPERATION

� Product variety medium

� Degree of standardization High

� Organization of resources Line flow to accommodate processing

needs

� Path of products through Line flow

Facility

� Factor driving production Forecast of future demands

� Critical resource Capital-intensive(equipment

important) automation

� Type of equipment Specialized

� Degree of automation High

� Throughput time Shorter

� Work-in-process Less

inventory



Types of processes used in repetition operation

1.Line processes are designed to produce a large volume of a standardized

product for mass production. They are also known as flow shops, flow lines, or

assembly lines. With line processes the product that is produced is made in high

volume with little or no customization. Think of a typical assembly line that

produces everything from cars, computers, television sets, shoes, candy bars,

even food items.

2.Continuous processes operate continually to produce a very high volume of a

fully standardized product. Examples include oil refineries, water treatment

plants, and certain paint facilities. The products produced by continuous

processes are usually in continual rather than discrete units, such as liquid or gas.

They usually have a single input and a limited number of outputs. Also, these

facilities are usually highly capital intensive and automated.

But if we consider for the surya polyvin Ltd. it is a type of line process but

continuos for 24*7 as they produce pipes in very high volume through out the

year .



DESIGNING PROCESSES

Now that we know about different types of processes, lets look at a technique

that can help with process design.

Process flow analysis

This is a technique used for evaluating a process in terms of the sequence of steps

from inputs to outputs with the goal of improving its design. One of the most

important tools in process flow analysis is a process flowchart.

process flowchart



This is used for viewing the sequence of steps involved in producing the product,

and the flow of the product through the process. It is useful for seeing the totality

of the operation and for identifying potential problem areas. There are some

symbol to show the process flow chart.

T T TI

TI

T

I TI



Process flow chart of Surya Polyvin Ltd.

Summary of flow chart

No. Of operations =6

Transportation =2

Inspection =3

Storage =2



Advantages of PVC

PVC (polyvinyl chloride) pipes are in widespread use in a number of industries,

ranging from residential plumbing to complex water treatment systems. Because

of the material properties of PVC pipes, they are highly valuable as a thermo-

resistant structure, fire retardant fabric, and as a high quality water conduit in

many construction applications. PVC pipes are superior to most other modern

materials due to environmental friendliness, chemical resistance, inherent

toughness, heat resistance, and being electrically non-conductive/non-corrosive.

PVC is very useful for making pipes that are secure connections between other

pipes (reducing leakage), maintaining quality in water, and reducing the potential

for injury in construction applications.

Environmentally friendly

y PVC pipes are environmentally friendly due to the source of the raw

material used to make PVC resin. Salt, quite literally abundant everywhere

in the world, is used to create the resin that makes up PVC pipes. Salt is

unlikely to ever diminish as a natural resource. Because PVC pipes last fordecades, it is going to cost less in the long run to recycle.

Chemical resistance

y Acids do not harm PVC piping. Acids produce electrochemical reactions in

other materials, but PVC pipes are non-conductive (on the inside and the

exterior of the PVC pipe). Because of the resistance of PVC pipes to

chemicals, the PVC pipe is used broadly in agricultural farming, where the

pipes are exposed to destructive soils, fertilizers, and chemicals (such as

pesticides).



Toughness

y The PVC pipe is resistant to fracturing. This is due in part to its flexibility,

and partially due to its light weight. PVC pipe isn't heavy enough to shatterif it is dropped, making PVC pipes safer on construction sites than metal

pipes

Water quality

y Better water quality is achieved by running water through PVC pipes. PVC

pipes do not corrode, so there will never be any alterations to the purity inthe water.

Heat

y PVC piping is ideal for thermal resisting applications because the material of

PVC is highly resistant to thermal conductivity. PVC is made into highly

proficient insulation pipes.

Strength and Durability

y PVC is surprisingly strong and durable, especially considering its relative low

weight. This makes this material suitable for all types of long-term

application, including domestic water and deep underground piping

systems.

Cost

y PVC piping costs only fraction as much as alternate products. These lower

material costs are coupled with lower installation costs because of

increased productivity, the product's low weight and cheaper

transportation expenses.



Disadvantages of PVC

PVC (polyvinyl chloride) pipe is a type of piping often used in plumbing

applications. Despite the many benefits of PVC pipes, this type of piping has

several disadvantages associated with it.

Temperature

PVC pipes are self-insulating and capable of handling very high-

temperature water. However, PVC pipes are not very flame resistant;

they are subject to melting at temperatures of only a few hundred

degrees.

Size

PVC pipes are only available in a small number of sizes. PVC pipes for

plumbing can typically be purchased in sizes only ranging from ½ to

12 inches. PVC pipe joints can be very bulky, which restricts them

from use in tight places.

Weight

According to Builder's Web source, PVC pipes are very lightweight

which can be both an advantage and a disadvantage. Because they

are so lightweight, PVC pipes are more prone to cracking when they

are dropped or stepped on. Compared with other types of plumbing

pipes, such as copper, PVC pipes are more susceptible to crackingduring an earthquake.



Facts

Some people claim that water drawn through PVC pipes can come

out with a slight plastic taste. PVC pipes require a curing period of 24

hours before they can be pressurized with water. Because it is soeasy to install, some contractors employ unskilled labour to install

PVC piping. This can lead to improper or careless installation.



References

1. Metters, R., K. King-Metters, and M. Pullman. Successful Service Operations

Management, Thompson South-Western, 2003.

2. http://en.wikipedia.org/wiki/Polyvinyl_chloride

3. http://www.yilimachinery.com/product/429-pvc-pipe-production-line---

f0a0/.

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