CHAPTER 1

INTRODUCTION

1
 CHAPTER 1

INTRODUCTION

Manufacturing systems are considered essential by most nations for the creation and
propagation of wealth, and for improving the standard of living of its people. Estimates show
that developed countries, such as USA, Japan, Germany, and other nations in the Pan-Pacific
region, such as Taiwan, South Korea, Singapore, and Hong Kong, have a manufacturing base
comprising at least 20% of their gross domestic product which provides for at least 30% of
their traded goods. Given the extent of manufacturing activities carried out in many different
countries in the World, the design and operation of manufacturing systems assumes
tremendous importance from the perspective of making nations competitive. The ability to
compete is vital for contemporary manufacturing due to the globalization, or
internationalization, of all aspects of product manufacture (quality, product variations, labor,
technology, markets, etc.).

In the United States, the issue of designing and operating manufacturing systems that can
retain the global economic advantage is a major concern to industry leaders, academic
researchers, Congressional policymakers, and socials in the Federal Government. The Report
of the President's Commission on Industrial Competitiveness (1985), and research reports
generated by the National Academy of Engineering (1988), the National Research Council
(1990), and the National Science Foundation sponsored workshops conducted at the
University of Cincinnati (Mital et al., 1994b; Mital, 1995, 1996) demonstrate the seriousness
of this concern. Some of these reports also contrast the relative importance of advanced
technology with human resource-based technology and highlight the fact that, among
countries with a large manufacturing base, the United States no longer dominates in the
creation of new and advanced technologies.

According to Farnum (1987), the worldwide share of American advanced machine tool
production in 1987 dropped to 7.8% as compared to Japan's share of 20.5% and Germany's
share of 19.9%. Also, in advanced machine tool exports, the US share was low (4.4%)
compared to Japan (20.8%) and Germany (22.6%). Further, many countries now have the
scientific and technological infrastructure to create new technologies. What then must make a
positive difference to the United States industrial competitiveness, these reports conclude, is
the development of a skilled human resource base Benexts of training Overall, training leads

2
to acquiring new skills and/or improvements in existing skills (Carnevale and Goldstein,
1990). These, in turn, lead to two distinct economic benefits: (1) improvements in individual
choices and earnings, and (2) cost savings for the organization.

According to Carnevale and Goldstein (1990), on the average, about half of one's lifetime
earnings are driven by learning in school and on the job. People with low skills, or skills not
needed by employers, have limited choices and low earnings (Lillard and Tan, 1986).
Increasingly, we are encountering situations where people with low or unneeded skills are
unable to and employment that will maintain their standard of living, or are being forced to
accept jobs that result in a substantial lowering of their earnings. Since the skills learned on
the job complement educational experiences and lead to individuals' having more choices,
on-task training is critical. Economic benefits of training for organizations include significant
improvements in productivity (through improvements in quality, reduction in scrap and
waste, reduction in throughput time, greater flexibility to respond to needs, etc.), and a
competitive advantage of employers and the nation as a whole (e.g. Denison, 1984; Mincer,
1988; Carnevale and Goldstein, 1990).

The United States Department of Labor (1993b) has reported that formal worker training
introduced in 180 manufacturing firms in the United States increased overall productivity by
17% in 3 years when compared to industries that did not introduce any training program. The
Department of Labor also reported that another survey of 157 small manufacturers observed a
drop of 7% in scrap and an increase of 20% in the productivity of production workers. The
economic benefits of training, thus, point out the necessity of introducing formal training
programs in manufacturing industry. Moreover, the greater the complexity of technology, the
greater will be the training and human resource management needs.

The process of Machine molding mainly includes three stages: three processes of filling,
filling and holding. During the plasticizing stage of the Machine process, the screw conveys
the plasticized material forward at a certain speed. As the screw groove of the screw becomes
shallower, the material is compacted and continuously conveyed forward. The head is
continuously accumulating, waiting for the arrival of the Machine instruction, and at the same
time, the screw will continuously retreat as the back pressure of the Machine increases during
the Machine process. When the Machine is started, the screw moves forward, and the
material continuously fills the mold. At the same time, as the pressure in the mold increases,
the screw moves while injecting.

3
When the material is filled in the mold, the Machine injects the material into the mold by the
action of back pressure. With the temperature of the material continues to decrease, the
pressure in the mold cavity begins to decrease. When the injected material can be safely
molded without being damaged, the Machine mold is opened, and the product is ejected
through the mold structure. Products that can be inlaid with the mold, and then the mold is
closed for the next cycle.

The external structure and size of the Machine product are the exact structure and size of the
internal mold of the Machine, thereby replicating the mold-shaped product. Machine molded
products often have many defects, such as short shots, sprays, sags, flow marks, weld marks,
and floating fibers. These defects can be treated by subsequent processes such as spray
coating, but it will increase the corresponding cost and time. The rapid heating-and-cooling
cycle molding has become an effective solution to this problem.[34] At the same time,
controlling the parameters in the Machine molding process is one of the effective means of
manufacturing high-quality precision Machine products. At present, Machine molding
technology has been applied in many fields such as optics, medical plastics, and drug
delivery.

Machine molding technology involes multi-disciplinary backgrounds. Existing Machine

molding technology review articles mainly focus on the development and application of
Machine molding technology, such as the application of metal Machine molding in medical
equipment, and the applicability of metal Machine molding technology to the manufacture of
medical equipment. Some also report the limitations and needs for the preparation method,
the microstructure and properties of the metal matrix composite materials. There is also an
introduction to the theoretical knowledge in the Machine molding process, a comprehensive
introduction to the melting mechanism and shear mechanism during the Machine molding
process, and an analysis and introduction to a certain mixed system. In this way, there are
many articles about the Machine molding process and application, Machine molding
materials and Machine molding mechanism. The main contribution of this article is a
comprehensive introduction to the entire Machine molding process including Machine
molding equipment, Machine molding molds, Machine molding processes, Machine molding
materials and some special Machine molding technologies.

The Machine molding of composite materials and micro-Machine molding in recent years are
also introduced with detailed examples. 2. Machine molding equipment, molds and processes

4
Plastic has gradually replaced many metal materials due to its light weight, stable chemical
properties, good insulation properties, and low price, and has been widely used in high-end
industries and daily life. At present, new materials represented by polymer materials are
indispensable and have become one of the four major basic materials (steel, wood, cement).
They are widely used in agriculture, machinery, medical, aerospace, automotive, and
construction fields. The plastic industry is developing rapidly. The Machine molding process
can form a variety of complex shapes, sizes, and precise plastic products. It has the
advantages of short cycles, high efficiency, and high precision.

Introduction of Machine molding machine

Machine molding machine, also known as plastic Machine molding machine or Machine
machine, is used to add granular or powdery polymer raw materials to the Machine molding
machine barrel, melt and plasticize into polymers with good fluidity under the action of
external heating and mechanical shear the melt, followed by the plunger or screw, quickly
enters the mold cavity with a lower temperature, and is cooled and solidified to form a plastic
product consistent with the shape of the mold.[38] The Machine machine usually consists of
an Machine system, a mold clamping mechanism, a hydraulic system, an electrical control
system, a heating part and other auxiliary parts such as a cooling part and a feeding part. The
following mainly introduces the Machine system, mold clamping mechanism, hydraulic and
electrical control systems. As one of the most important components, the Machine system is
mainly composed of three parts: the plasticizing part, the Machine part and the pressure
driving part.

Its functions are as follows:

(1) Plasticizing- under the combined action of the screw and the heating ring, the material is
melted and plasticized uniformly;

(2) Machineone under the action of the screw, the plasticized material is injected into the
mold cavity at a set pressure and speed;

(3) the pressure is maintained- one molten material is injected into the cavity. Inside the
cavity, the screw stays still to replenish a part of the molten material into the cavity to
eliminate shrinkage caused by cooling, ensure product quality, and prevent material from
flowing back.

5
2.2 MACHINE MOLDING PROCESS

2.2.1 PRECISION MACHINE MOLDING

Machine molding technology can be divided into precision Machine molding and
conventional Machine molding according to processing accuracy. Precision Machine molding
has incomparable advantages over conventional Machine molding in terms of repeatability
control, parameter control, and size control. For example, Michaeli et al. conducted in-depth
research on factors affecting the precision Machine molding process of aspherical plastic
lenses, including mold design, process parameters and plastic raw materials. They used
different Machine process parameters and mold structures to perform actual Machine
experiments, and analyzed the degree of influence of process parameters and molds on the
imaging quality of aspherical plastic lenses.

The final experimental results show that compared to the mold design, the Machine molding
process parameters have a more significant impact on the imaging quality of aspherical
plastic lenses. Zhang et al. used Machine molding simulation software to optimize the design
of molds for large Machine molding products based on process monitoring and a series of
experiments and verification, successfully predicting the deficiencies of microscopic features.
The typical microfluidic chip was successfully copied using the Machine molding technology
to obtain suitable process data and simulation parameters. This method significantly
improved the accuracy of the product. The process of using simulation software to predict
and verify through experiments is shown. Young et al.] used simulation software to study the
effects of Machine molding process parameters such as melt temperature, mold temperature,
holding pressure, and holding time on the residual stress and warpage of plastic lenses. The
study found that compared with other Machine molding process parameters, the effect of the
holding pressure on the thickness direction of the plastic lens is more significant. Macías et
al. repeated Machine molding experiments and found that an improper selection of Machine
molding process parameters led to the generation of residual stress in the plastic lens, which
significantly affected the structural size of the plastic lens. The stress method prolongs the
service life of plastic lenses and increases the dimensional accuracy of plastic lenses.

The development of micron Machine molding

In recent years, the main research directions of microMachine molding technology involve
the influence of process parameters on the micro-feature replication performance, improving

6
the consistency between products, and finding the general law governing the influence of
mold cavity roughness on the micro-feature replication. Progress has been made in obtaining
the effects of mold temperature and Machine melt temperature on the accuracy of micron
Machine molded products. Xie et al. found that mold temperature and Machine speed are the
main factors affecting micron Machine welding marks. In the stage, ultrasonic vibration and
physical vapor deposition (PVD) are used to process the corresponding films after molding,
and even the strength of the thickness weld marks can be improved to greatly improve
mechanical properties. Since the viscosity and rheological behavior of polymer melts are very
different at macro and micro sizes, the study of their flow mechanism and rheological
behavior under micro conditions should be strengthened. However, the minimum capillary
diameter of capillary rheometers commonly used in experiments is 1 mm. Therefore, how to
obtain rheological data of polymer melts at the micrometer scale has become the bottleneck
of current research.

7
 CHAPTER : 2

COMPANY PROFILE

8
 CHAPTER : 2

COMPANY PROFILE

The company has a successful leadership track record of two generations of being in the same
business of machine manufacturing, which once reckoned from machining job work 30 years
back. Since then we have never looked back.

In this vying world to choose from the right machine ally for your food, dairy and
pharmaceutical processing need we humbly introduce our self as one of the business partner
ready to ―Solve your production challenges‖ by providing the custom-made machine
solutions as per your need.

With management leadership of two generations we have a track record of 30 years starting
from a small job work machining unit for different industries. We have grown to a Brand
among the packing industries and we have not only solved the precision need of each one of
our clients but we have also originated new machines creating an aseptic productions operation
along with minimizing the human involvement.
Fillpack technology, an ISO 9001-2015 certified company, has been trusted for over two
decades for its in-house manufacturing and exporting of quality packaging machinery for
industries like Dairy, Pharmaceuticals, Beverages, Cosmetics & Toiletries, Lube & Edible Oil,
Pesticides, and Food. Over the years, Fillpack has invested time and money in understanding
and developing solutions per customers' needs. As a result, Fillpack has reached and has a
presence in the market segments of Milk, Ice Cream, Juice and Pharmaceuticals.

Fillpack is an innovative leader in the processing, filling & packaging industry. Speaking about
the company, Nitin Kere, managing director, Fillpack, says, "Fillpack Technology is a pioneer
in the paneer cutting industry and one of the leading manufacturers of bottle filling machines.
We are the leading manufacturers of paneer cutting and complete turnkey basis plants for
equipment. We provide Bottle Filling Machine Solutions, Pouch Packing Solutions, Sachet
Packing Solutions, Milk, Curd, Paneer Pasteuriser, Bulk Milk Coolers, Storage Tanks,
Mixing/Heating Tanks, Paneer Cutting Solutions, Cup Filling & Sealing Machine Solutions

9
and Vacuum Packaging Machines etc. We also provide turnkey basis plants for milk, fruits and
vegetables, juices, and ice cream, among other things."

Fillpack offers a wide variety of equipment for the food and dairy industry, including paneer
cutting machine, paneer dipping tank, automatic conduction sealing machine, and vacuum
packing machine, among others.

Automatic filling linePhoto- Fillpack technology

At ANUTEC/PackEx- 2022

The Fillpack team is eager to present its products at the upcoming event ANUTEC, India's
largest international fair for food and drink technology in September 2022. Regarding the
products to be displayed, Kere says, "We will be exhibiting Cup Filling Machine, Conduction
Sealing Machine, Paneer Cutting Machine and Hopper Piston Filling Machine at ANUTEC."

Viewing the live display of such vital equipment will be a great way to educate the masses
about the machinery behind the everyday foodstuffs we consume. At the trade show, the
Fillpack team hopes to evoke curiosity among the visitors and create new connections and
genuine long-term partnerships. They wish to make the most of the opportunity and network
with professionals from various industries under one roof.

According to Kere, a trade show like ANUTEC will help them meet new customers and make
mutually beneficial and meaningful connections.

Vision and plans

The company looks forward to systematic growth of client satisfaction, employee growth, and
reaching new horizons by increasing the machinery segment. He shares the company's plans,

10
"Our ambition is to distinguish ourselves by making the most of Fillpack's competitive
advantages. We plan to increase the efficiency of production through the automation of
processing plants. We believe in improving performance through inspiring, engaging, and
developing our people." He believes that industries should go for expansion in their business to
move forward.

With its head office in Thane, Maharashtra, Fillpack Technology offers multi-disciplinary
engineering design and description services and state-of-the-art technology applications with
the help of skilled professionals to ensure quality packaging machines and dependable after-
sales services.

MILESTONE

Started in 1987 with job work for of machining and fabrication for moulding machine
industries, In 2013 we started with making machinery for food industries ( Packing / Filling /
Paneer Cutting ).We have brought innovative paneer combo (cubing) machine and we have
also introduced conduction machine which helps to seal PP retortable bottles. We have
supplied filling line and paneer processing line to different industries starting from local dairy
firm to Multinational Corporations, consuming 10 lakh litres per day

VISION

Company looks forward for a systematic grow of the clients satisfaction, employees growth
and touch new horizon by increasing the machinery segment. Our ambition is to distinguish
ourselves by making the most of Fillpack’s competitive advantages. From our customers’
perspective, we are their benchmark partner. Reliable and robust, we are ready to adapt to
their challenges by offering efficient and high-performance solutions.

INNOVATION

Together with our partners, we constantly strengthen our position as innovation leader in our
industry. At Fillpack, our track record in developing new machines has given us edge over
our competitors. We have set standard in Paneer combo cubing machine, Conduction sealing
for PP bottle machine, combination of Unsclamber and airjet machine, Leaked milk packet
cutting machine. And we are coming up with more such machines.

11
MISSION

At Fillpack, our mission is to increase the efficiency of production by automation of

processing plants. Fillpack is an innovative leader in the filling, packing and processing
industry. Our job is to improve the indigenous between man and machine. We believe that
every operation can be intensified for increasing the production solution for better output. We
believe in improving performance through inspiring, engaging and developing our people.
Personal growth is strongly supported and there are versatile opportunities for career
development.

OUR SERVICES

In this vying world to choose from the right machine ally for your food, dairy and
pharmaceutical processing need we humbly introduce our self as one of the business partner
ready to ―Solve your production challenges‖ by providing the custom-made machine solutions
as per your need.

WHAT WE OFFER

Our spectrum of products includes various machines like PP Bottle Flavoured Milk Turnkey
Project, Ghee Jar Filling Line Machines, Curd Cup Packing Machine, Paneer Equipments, Ice
Cream Equipments, Milk Processing Plants, Ghee Plant, Cold Room, Hygienic Stations, Lab
Furniture, Bulk Milk Coolers.

Advanced Technology

FILLPACK TECHNOLOGY , an ISO 9001-2015 certified company is strategically head

quartered at Thane Maharashtra India with two advanced manufacturing units with skilled
technocrats & professionals to ensure quality packaging machines & dependable after sales
services.

Expert Engineers

Fillpack offers multi-disciplinary Engineering design and description Services exploitation

intelligent and state of art technology applications. Our team includes professional engineers
having made expertise in industries like dairy farm, Food, pharmaceutical, beverages etc.

12
 AUTOMATIC AUGER FILLER MACHINE

 Sealing:Centre seal
 Pouch Size: Pouch 150mm(W)320(L)
 Range: 1 kg to 5kg.
 Servo Based, Vertical Sealing: Pneumatic
 Out-put pouches per minute: 5 to 15 pouch per min.
 Suitability: Any heat sealing films (laminates) or Alum foil based material
 Power Requirement: 5 KW.( Motor, Main Motor, Heaters etc.)

PANEER CUTTING MACHINE

 Machine Size: 1500(L)X800(W)X1650(H) in mm

 Capcity:200to [Link] Hour
 PLC: Delta, Siemens, Allen Bradley
 All blades and structural frame are of S.S.304
 Air Pressure:5 Bar

13
 LINEAR CONDUCTION SEALING MACHINE

 The machine is sturdy and compact in design and simple in operation.

 It consists of one horizontal blades frame and guided by UHMW bushes and connected to
pneumatic cylinder for up and down operation.
 Another horizontal Actuator Cylinder attached with UHMW Pusher to index Paneer
Accurately.
 CAll blades and structural frame are of S.S.304
 Poly Carbonate doors are provided for visibility of cutting material. Air Cleaning system
provided with the machine.

WEB SEALING MACHINE

 Power Consumption (KW): 22KW

 Packing dimension : 1450(L)x 550(W)x 400(H)
 Height of conveyor (mm): 850
 Dimension (LxWxH) (mm): 2500 x 800 x 1500
 Air pressure : 7.5 Kg/sqcm
 Product Packing : PP Bottle/ Glass Bottle
 Paking Speed: 4-5 Packcts Per minutes

14
 CHAPTER : 3

REVIEW OF LITERATURE

15
 REVIEW OF LITERATURE

Mr. P. Vinod, Mr. K. Vijaykumar have designed multi-cavity Machine mould with HRS and
CRS. By comparing both designs, they researched the impact of runner systems, mould
cooling and venting. Moulding analysis is carried out using ANSYS.

G. Rajendra Prasad, Dr S. Chakradhar Goud Studied dynamic characteristics like hot runner
nozzle strain using analysis in FEA.

N. Divya, Dr. S. N. Malleswara Rao, Dr. V. S. Parameswara Rao, [9] concluded in their
paper as the hot runner system accommodates the molten plastic. The runner method
determines mould component consistency and productivity. They performed structural and
thermal analysis of the mould 's original and updated designs concluding that the modified
design produces the best performance.

Rashi A. Yadav, S. V. Joshi, N. K. Kamble, Recent studies to design and determine Machine
moulding method parameters. In parameter environment for Machine moulding, several test
works were performed focused on various approaches. In the plastic Machine moulding
(PIM) industry, optimum process parameter settings are critically affected by performance,
consistency, and cost of output.

A. Demirer, Y. Soydan, Unlike the conventional runner approach, hot runner machine effects
on Machine moulding method and Machine product properties were studied. They used data
from method parameters experiments. Machine pressure and temperature change a broad
variety. For the hot runner process, Machine pressure was marginally lower for higher weight
samples. If the temperature of the process increases, shrinkage and warpage increased,
reducing with increased Machine pressure and happening at a low level where the sample
weight was high.

Gurjeet Singh, Ajay Verma Studied primary moulding conditions from design creation to
product manufacturing. They studied different factors based on processing parameters. It is
concluded that efficiency declines when channelizing efforts to improve quality. Parameters
must be optimised to ensure good quality and efficiency. Authors analysed different
responses to Machine moulding process quality based on output parameters and methods.

Mehdi Moayyedian, Kazem Abhary, the Machine moulding method implemented a new gate
geometry. It was observed that current edge gates corners create turbulence of molten plastic

16
leading to internal and external defects. New geometry was introduced to reduce injected
parts' internal and external flaws. The study's goal was to make the final piece easier
geometry, which eliminates the last part 's apparent blemish after de-gating.

[Link] Sekhar, N. Jaya Krishana Suggested design for two circular flat plate 1 mm wide.
Contribution of this research was to change the existing edge gate geometry by eliminating
rectangular edge gate corners to minimise scrap occurrence of injected bits. Smooth plastic
flow through cavities often prevents internal and exterior defects. The result reveals no shot-
filling cavities. No weld lines, meld lines or sink marks were identified with new edge gate
design. The experiment ends with an added portion of the initial edge gate step, less
noticeable than the current edge gate.

Harold Godwin, Mold Making Technology — Competition and price pressure in the Machine
moulding industry affected many manufacturers of OEMs, moulders, and moulds. The
required operating costs were due to increased resin, electricity, human capital, resulting in
profit pressure. The decision to use a hot runner was noticeable for medium and large
moulded component volumes.

Sal Benenati, Hot runner systems are so popular Machine moulds. Hot runner suppliers must
adjust part designs to satisfy more strict output and material demands, sometimes adding
complexity to products. Some techniques , for example, use moving motors to control valve
gates, some need specific heaters, and some require unique mould tolerances to function
properly. Standard convection, low shear velocity, and high viscosity-dependent effects were
studied. Lee and Lin et al. Built a multi-cavity mould runner and gating system. Use Finite
Element Theory (FEM) network. Optimal runner unit parameter used to minimise Machine
mould warp, FEM, Taguchi phase and adductive framework. Processes during mould filling,
enhancing moulding condition. Model Machine mould simulation at steady flow rate. Finite
differences method offers strong consent for methodological solutions. Different gate sizes
and locations using flow simulation have been detected for defects reduction such as weld
lines and air traps, air traps and warpage can be managed by varying process parameters. Part
flow-reducer studied using Autodesk Mould Flow tools. The mould flow analysis is used to
predict the piece's deformation and change the design accordingly.. The plastic toy building
block section is analysed; cycle time is successful for four cavities as filling and cooling time
for four cavities does not improve in single cavity configuration. The outcome indicates that
both parameters influence product consistency, Plastic Flow Simulation analyses the flow of

17
molten plastic to optimise part and mould designs, reducing possible part defects. Simulation
research was undertaken for optimum gate location. Comparing two gate positions was
achieved. Comparative analysis found the optimal gate location. Several product flaws
decrease due to improper eating. [20]. Comparative analysis of the use of different gate types
and runner system for the same job, resulting in a satisfactory reduction of moulding defects
and increased pressure in the component, which is also within limits.

Vikas B J and Chandra Kumar R [22] Optimizing scrap processing period. Manual gui plays
a key role in producing plastic components without compromising product consistency. This
paper explains gate position and size effect by repetitive analyses. Plastic flow advisor
programme prevents fill, scrap and automated degassing. Simulation analyses method
parameters including fill time, shrinkage, weld lines, pressure decrease, and air traps in
successive tests. Experimental verification for current improved gate location in the Machine
moulding method. Reduced shrinkage and ventilation, minimising defeats. Simulation
software has greatly impacted the Machine moulding industry. Cheaper simulation
simulations are an alternative to traditional factory-floor experiments. Study on developing
plastic Machine moulding method has now expanded a tonne.

18
 CHAPTER 3

RESEARCH METHODOLOGY

19
 RESEARCH METHODOLOGY

Generally research is considered as an endeavour to arrive at the answer to intellectual and

practical problem through the application of scientific methods to the knowledge universe. It
is movement from known to unknown. Research is essentially a logical and an organized
enquiry seeking facts through objective verifiable methods in order to discover the relation
among them and to refer from the board principles or laws. It is really a method of critical
thinking.

Research may be defined as a systematic and objective analysis and recording of controlled
observations that may lead to the development of generalization of principles or theories
resulting in predicting and possibly ultimate control of events.

Methodology is often used in a narrow sense to refer to methods, technology or tools

employed for the collection data as well as it’s processing. This is also used sometimes to
designate data collection to arrive at the conclusion. Infects, it describes that what should
have been done. It provides answers to some of the major questions while search like what
must be done, how it will be employed, how sources of data will be analysed to arrive at the
conclusion. For systematic research scientific approach is necessary. It is therefore essential
to follow systematic methodology to arrive at a proper conclusion.

 The procedures involved in the concept of research methodology are:-

 Collection of data.
 Analysis of data.
 Reporting.

METHODOLOGY OF ANALYSIS:-

Data which has been collected through various sources has to proceed and analysed the
accepted relevant scientific method are used for analysed processing is done by different
graphs, which clearly show the finding and half us to understand thing is more better way
different table and comparative chart also used for analysed and the most important ways was
case study and illustration.

20
ANALYSIS: The data collected has to process and analysis is done in accordance with the
acceptable relevant scientific method processing of the data covers editing loading
classification.
EDITING: Editing is a routine task it is process of examining collected data especially in
survey to detest and animate error editing endures completeness accuracy and uniformity.

CODING: It is process of assign numerical or other symbol to symbol to answer so that

response can be part in a limited number of categories.
CLASSIFICATION: The large volume of data collected for a search study has to be
reduced in homogenous gropes for getting a meaningful relationship. This is known as
classification of data. It condense data in such way that similarities and dissimilarities can
easily be apprehended, so as to facilities comparison. Classification of data collected can be
categorized as by geographical grouping chronological grouping qualitative and quantitative
groupings.

TABULATION: It is a process of summarizing row data and displaying the same in concept
from for further analysis. The tabulation can be simplified in rows and columns; it conserves
space and minimizes exploratory and descriptive statements. Tabulation facilities the process
of comparison. It assists in various statistical computations. It simplifies complex data, and
gives identify to data and reveals pattern.

GRAPHIC PRESENTATION: Graphic presentation of statistical data gives a pictorial effect.

It enables one to present data in simple, clear and effective manner. It shows what is
happening and what is likely to take place just as quickly as the age is capable of working. A
graph is a visual form of presentation. It provides an attractive and impressive view. It also
provides easy comparison of two or more phenomena.

21
PROBLEM STATEMENT

A swot up of Manufacturing Process management is undertaken in command to

identify the inventory performance and position of the company and to recognize the potency
and flaw and to assess the profitability of the company. Inventories constitute most important
part of resources of large mainstream of the companies in India.

Inventory a double edged sword is usually an asset of an organization, if not worn

correctly it will become liability. It is therefore absolutely very important to handle
inventories resourcefully and efficiently in order to overcome unnecessary investment. And
to identify the trouble/challenges concerned in the Manufacturing Management Process

22
OBECTIVES OF THE STUDY

 To study the Process of Manufacturing of Machine in Fillpack Technology.

 To study different techniques used for Manufacturing Process & Operations.
 To study the Cost Control techniques in Fillpack Technology.
 To analyze financial reports of Fillpack Technology specific with inventory
management.
 To suggest the measures for improving the inventory level.

23
DATA COLLECTION

Collection of data refers to purposive gathering of information relevant to the subject matter
under study and the methods used depend mainly on the nature, purpose and scope of the
enquiry to be undertaken, as well as on the availability of resources and time.

The data collection can be grouped under two types:-

 Primary data

 Secondary data

PRIMARY DATA:- Primary data are those which are collected for the first time. They are
original in character. They are collected by the researcher for the first time for her own use.

The source of primary data includes:

1. Direct personal investigation

2. Interview

DIRECT PERSONAL INVESTIGATION- This implies the situation where the researcher
goes into the field of study in person for the collection of required data. Also, the
investigation of this nature is normally confined to a single locality and the information
gathered is capital in nature.

INTERVIEW METHOD- Every interview has got its own balance of revaluation and has
withheld information, an interview can be effective informal verbal and non-verbal
conversation initiated for the specific purpose focus on a certain planned contained areas.

SECONDARY DATA- Secondary data are those which have already been collected by
others. When it is not possible to collect data in primary form, the researcher may take the
help of secondary data. They are thus which have already been collected for serving the
objectives other then what the researcher might have in his mind.

24
The sources of secondary data includes:-

1) Books

2) Websites

3) Journals

1. BOOKS:

A book is a collection of paper or other material with text, pictures, or both written on them,
bound together along one edge, usually with covers. In library and information science, a
book is calling a monograph to distinguish it from serial periodicals such as magazines
journals or newspapers.

2. WEBSITE:

A website may be the work of an individual, a business or other organization and is typically
dedicated to some particular topic or purpose. Any website can content s hyperlink to any
other website, so the distinction between individual sites, as perceived by the user, may
sometimes to blur.

3. JOURNALS:

A journal may publication issued at stated intervals, such as magazines or the record of the
transactions of a society, are often called journals. In academic use, a journals refers to a
serious, scholarly publication, most often peer-reviewed. The purpose of a journal is to
provide a place for the introduction a scrutiny of new research and often a forum for the
critique of existing research.

RESEARCH DESIGN

Research design is the plan for collecting the information related to the study.
Research design explains the methods that are used for collecting the information .The
research design will focus of attention on the different methods that are used for collecting of
the data. Also it will help to solve the problem. Different forms of collecting the data will be
tested in the research design. In this case, survey method is used to collect the necessary data.
In the survey method, the used to collect information from the customers, questionnaires is
used. And the detail information is collected related to the study. The question mainly focuses
the attention on the customer satisfaction to fulfill the objective of the study.

25
 CHAPTER 4

DATA ANALYSIS & INTERPRETATION

26
 DATA ANALYSIS & INTERPRETATION
Q1. Which technology is used in management at Fillpack Technology ?

Criteria Frequency Percentage

Close partnership with suppliers 10 10%
Close partnership with customers 9 9%
JIT supply 6 6%
E-procurement 8 8%
EDI 5 5%
Outsourcing 9 9%
Subcontracting 8 8%
3PL 7 7%
Plan strategically 6 6%
Manufacturing Strategy Benchmarking 7 7%
Vertical integration 5 5%
Holding safety stock 6 6%
Use of external consultants 9 9%
Other, please specify 5 5%

Close Partneship with suppliers

5 10 Close Partneship with Customers

9 JIT Supply

9 E-Procurement

6 EDI

Outsourcing
5 6
Subcontracting

3PL

7 8 Plan Strategically

Supply Chain Benchmarking

6 5 Vertical Integration

Holding safety Stock

7 9 Use of External Consultants
8
Other, Please Secify

INTERPRETATION

10% of the respondents said they manage Manufacturing Strategy Close partnership with
suppliers, 9% of the respondents said they manage Manufacturing Strategy Close partnership
with customers, 6% of the respondents said JIT supply, 9% of the respondents said they
manage Manufacturing Strategy outsourcing, 7% of the respondents said 3PL, 6% of the
respondents said holding safety stock and other said please specify.

27
Q2. How successful do you think is Fillpack Technology in managing its
Manufacturing Strategy?

Criteria Frequency Percentage

Not successful at all 6 6%
Not successful 8 8%
Somewhat successful 28 28%
Successful 40 40%
Very successful 18 18%

6
18 8
Not successful at all
Not successful
Somewhat successful
28 Successful
Very Successful
40

INTERPRETATION

As shown by the pie chart, 40% of respondent Successful think is Fillpack Technology in
managing its Manufacturing Strategy in general, 28% of respondent somewhat successful, 18%
of respondent Very successful, 8% not successful and 6% of not successful at all.

28
Q3. Does your company have a clear Manufacturing Strategy and operation strategic
plan?

Criteria Frequency Percentage

Most of the time 40 40%
Often 34 34%
Sometimes 16 16%
Rarely 6 6%
Almost never 4 4%

4
6

Most of the time

16 40 Often
Sometimes
Rarely
Almost never

34

INTERPRETATION:-

As shown by the graph, 40% of the respondents think most of the time that company have a
clear Manufacturing Strategy and operation strategic plan, 34% of the respondents think often
that company have a clear Manufacturing Strategy and operation strategic plan and 16% of the
respondents think sometimes that company have a clear Manufacturing Strategy and operation
strategic plan.

29
Q4. How satisfied are you with the current technology regarding Manufacturing
Strategy?

Criteria Frequency Percentage

Not at all 6 6%
Somewhat 12 12%
Satisfied 56 56%
Quite satisfied 24 24%
Very satisfied 12 12%

12 6
12

Not at all

24 Somewhat
Satisfied
Quite Satisfied
Very Satisfied

56

INTERPRETATION

As shown by the pie chart, 56% of respondent satisfied with the current inventory policy
regarding Manufacturing Strategy, 24% of respondent quite satisfied, 12% of respondent Very
satisfied, 12% Somewhat and 6% of respondent Not at all.

30
Q5. Is Manufacturing Strategy having all the address of the developer branches of the
company?

Criteria Frequency Percentage

Highly agree 40 40%
Agree 34 34%
Neutral 16 16%
Disagree 6 6%
Highly disagree 4 4%

4
6

Highly Agree
16 40
Agree
Neutral
Disagree
Highly Disagree

34

INTERPRETATION

In above pie graph 40% of the respondents highly agree with Manufacturing Strategy having all
the address of the developer branches of the company, 34% of the respondents agree with
Manufacturing Strategy having all the address of the developer branches of the company, 16%
of the respondents think neutral and 4% of the respondents highly disagree with Manufacturing
Strategy having all the address of the developer branches of the company.

31
Q6. Rate the working strategies of Manufacturing Strategy department on the basis of
the current programs?

Criteria Frequency Percentage

Outstanding 12 12%
Excellent 10 10%
Good 48 48%
Average 30 30%

12

30
10
Outstanding
Excellent
Good
Average

48

INTERPRETATION

As shown by the pie chart, 48% of respondent feel good working strategies of Manufacturing
Strategy department on the basis of the current programs, 30% of respondent Average, 12% of
respondent Outstanding, 10% Excellent.

32
Q7. Do you think that stages in Manufacturing Strategy Risk Management involving
in each company?

Criteria Frequency Percentage

Highly agree 42 42%
Agree 32 32%
Neutral 18 18%
Disagree 4 4%
Highly disagree 4 4%

4
4

18 Highly Agree
42 Agree
Neutral
Disagree
Highly Disagree

32

INTERPRETATION

As per shown in above pie graph 42% of the respondents highly agree that the Manufacturing
Strategy department is having sufficient transportation and capacity, 32% of the respondents
agree that the Manufacturing Strategy department is having sufficient transportation and
capacity, 18% of the respondents neutral with above statement and 4% of the respondents
disagree that the Manufacturing Strategy department is having sufficient transportation and
capacity.

33
Q8. Choose the right option, where the Manufacturing Strategy department is facing
problem in taking care of the raw material of Fillpack Technology?

Criteria Frequency Percentage

During storage 34 34%
Packaging 30 30%
Testing of packaging 14 14%
Evaluation of defective raw material 22 22%

22
During Storage
34
Packaging

Testing of Packaging
14
Evaluation of defective
raw material

30

INTERPRETATION

As shown by the pie chart, 34% of respondent feel during storage, 30% of respondent
Packaging, 14% of respondent Testing of packaging, 22% Evaluation of defective raw material.

34
Q9. Is there any case recorded by the Manufacturing Strategy department in which
the production department complained late delivery of raw materials?

Criteria Frequency Percentage

Most of the time 34 34%
Often 28 28%
Sometimes 20 20%
Rarely 8 8%
Almost never 10 10%

10

8
34 Most of the time
Often
Sometimes
20 Rarely
Almost Never

28

INTERPRETATION

34% of the respondents think most of the time that any case recorded by the Manufacturing
Strategy department in which the production department complained late delivery of raw
materials, 28% of the respondents think often that any case recorded by the Manufacturing
Strategy department in which the production department complained late delivery of raw
materials and 20% of the respondents think sometimes.

35
Q10. According to the current growth process of the Fillpack Technology, which of the
following needs much attention and progress to boost the production?

Criteria Frequency Percentage

Operational activities 40 40%
Tactical activities 35 35%
Current programming strategies 25 25%

25
Operational Activities
40
Tectical Activities

Current Programming
Strategies

35

INTERPRETATION

40% of the respondents said the current growth process of the Fillpack Technology is
operational activities needs much attention and progress to boost the production, 35% of the
respondents said the current growth process of the Fillpack Technology is tactical activities
needs much attention and progress to boost the production and 25% of the respondents said the
current growth process of the Fillpack Technology current programming strategies.

36
Q11. Are you happy with the Manufacturing Strategy of Fillpack Technology?

Criteria Frequency Percentage

Yes 78 78%
No 22 22%

22

Yes
No

78

INTERPRETATION

In above graph78% of the respondents said yes they happy with the Manufacturing Strategy of
Fillpack Technology and 22% of the respondents said they don’t happy with the Manufacturing
Strategy of Fillpack Technology.

37
Q.12) Do you know who your critical suppliers are what exposures they face for at least
one product line?

Opinion Percentage
Yes 75
No 25
Total 100

25

Yes
No

75

INTERPRETATION
From the above graph it is clear that the 75% critical suppliers are exposures and one
product line and 25% not critical suppliers are exposures and one product line.

38
Q.13) Are supplier exposures integrated in the decision to select a supplier?

Opinion Percentage
Yes 70
No 30
Total 100

30

Yes
No

70

INTERPRETATION
From the above graph it is clear that the 70% supplier exposures integrated in the
decision to select a supplier and 30% not exposures integrated decision the supplier.

39
Q.14) Rate the working strategies of Manufacturing Strategy department on the basis
of the current programs.

Opinion Percentage
Outstanding 30
Excellent 40
Good 15
Average 15

15

30

Outstanding
15 Excellent
Good
Average

40

40
 CHAPTER 5
CONCLUSIONS

41
 CONCLUSIONS

The main purpose of our study is to obtain a quality product with suitable
parameters, as well as to eliminate the factors that will increase the cost by optimizing the
parameters. When it comes to production, minimum cost - maximum quality is always more
advantageous. Plastic Machine settings were determined as optimum values and shown in
the study. The wall thickness is in the appropriate range recommended for polypropylene
material and this value is 0.9 mm. For carved furniture legs; the product was measured as
12 cm in height and 14 cm in length.

The strength and solidification of the product were better when sufficient cooling
was achieved in the mold. Water arriving at 35 °C is sent to the mold at 17 °C in the chiller
cooling group. At values below 17 °C, sweating occurs in the mold and products with
defects on the surface are formed. The total cost has been determined as approximately
13.673 ₺. Monthly expenses are specified in Table 5. This study will be helpful in future
studies in determining the average expenses of these studies and determining the appropriate
parameters for the product in the studies that will make production with the plastic Machine
molding method.

42
 CHAPTER 6

SUGGESTION

43
 SUGGESTION

 Production management focuses on carefully managing the process to produce and to

distribute products and services.
 We believe that product lines present an opportunity for increased efficiencies and
economies, more reliable and predictable and higher quality production, a more robust
relationship with a production, launching and management in current and new
markets A great deal of focus is on efficiency and effectiveness of processes
development.
 It improve the productivity and represents the relationship between top down and
bottom up approach to achieve goals.
 Therefore production development and management often include substance
measurement and analysis of all the internal activity.
 This paper will help more organizations make the attempt.
 At last we concluded that management is not only a important key but also play a vital
role in before the production and after it also.

44
 CHAPTER 7

BIBLIOGRAPHY

45
 BIBLIOGRAPHY

 Administration industrially general purveyance organization -commandment, co

ordination controlee, Paris Dunned,1966
 Journal of Operations Management 17 _1998. 23–37
 Vocationa Business: Training, Developing and Motivating People by Richard Barrett
- Business & Economics - 2003. - Page 51
 Key to the Success of a Product and Even of the Company Behind It." The Financial
Times.27February2006
 K. Shridhara baht ,K Aswathappa
 S. Anil Kumar and [Link]
 Juneau hub Juneau, First Himanshu , and Preachy Juneau. "Management ."
Management Study Guide. Web Craft Put Ltd, 2011. Web. 17 Mar201

46
ANNEXURE

47
 ANNEXURE

Q1. Which technology is used in management at Fillpack Technology?

 Close partnership with suppliers

 Close partnership with customers
 JIT supply
 E-procurement
 EDI
 Outsourcing
 Subcontracting
 3PL
 Plan strategically
 Manufacturing Strategy Benchmarking
 Vertical integration
 Holding safety stock
 Use of external consultants
 Other, please specify
Q2. How successful do you think is Fillpack Technology in managing its
Manufacturing Strategy?

 Not successful at all

 Not successful
 Somewhat successful
 Successful
 Very successful
Q3. Does your company have a clear Manufacturing Strategy and operation strategic
plan?

 Most of the time

 Often
 Sometimes
 Rarely
 Almost never

48
Q4. How satisfied are you with the current Technology regarding Manufacturing
Strategy?

 Not at all
 Somewhat
 Satisfied
 Quite satisfied
 Very satisfied
Q5. Is Manufacturing Strategy having all the address of the developer branches of the
company?

 Highly agree
 Agree
 Neutral
 Disagree
 Highly disagree
Q6. Rate the working strategies of Manufacturing Strategy department on the basis of
the current programs?

 Outstanding
 Excellent
 Good
 Average
Q7. Do you think that stages in Manufacturing Strategy Risk Management involving
in each company?

 Highly agree
 Agree
 Neutral
 Disagree
 Highly disagree
Q8. Choose the right option, where the Manufacturing Strategy department is facing
problem in taking care of the raw material of Fillpack Technology?

 During storage

49
  Packaging
 Testing of packaging
 Evaluation of defective raw material
Q9. Is there any case recorded by the Manufacturing Strategy department in which
the production department complained late delivery of raw materials?

 Most of the time

 Often
 Sometimes
 Rarely
 Almost never
Q10. According to the current growth process of the Fillpack Technology, which of the
following needs much attention and progress to boost the production?

 Operational activities
 Tactical activities
 Current programming strategies
Q11. Are you happy with the Manufacturing Strategy of Fillpack Technology?

 Yes
 No
Q.12 Do you know who your critical suppliers are what exposures they face for at least
one product line?
 Yes
 No
Q.13 Are supplier exposures integrated in the decision to select a supplier?
 Yes
 No
Q.14 Rate the working strategies of Manufacturing Strategy department on the basis
of the current programs.

 Outstanding
 Excellent
 Good
 Average

50