Introduction

Production/operations management is the process, which combines and transforms

various resources used in the production/operations subsystem of the organization into
value added product/services in a controlled manner as per the policies of the
organization. Therefore, it is that part of an organization, which is concerned with the
transformation of a range of inputs into the required (products/services) having the
requisite quality level.
The set of interrelated management activities, which are involved in manufacturing certain
products, is called as production management. If the same concept is extended to services
management, then the corresponding set of management activities is called as operations
management.

Historical Evolution of Production Management

For over two centuries operations and production management has been
recognized as an important factor in a country’s economic growth.
The traditional view of manufacturing management began in eighteenth century when
Adam Smith recognized the economic benefits of specialization of labor. He
recommended breaking of jobs down into subtasks and recognizes workers to
specialized tasks in which they would become highly skilled and efficient. In the early
twentieth century, F.W. Taylor implemented Smith’s theories and developed scientific
management. From then till 1930, many techniques were developed prevailing the
traditional view. Brief information about the contributions to manufacturing management
is shown in the Table 1.1.

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Date Contribution Contributor

1776 Specialization of labour in manufacturing Adam Smith

1799 Interchangeable parts, cost accounting Eli Whitney and others
1832 Division of labour by skill; assignment of jobs by skill;
basics of time study Charles Babbage
1900 Scientific management time study and work study
developed; dividing planning and doing of work Frederick W. Taylor
1900 Motion of study of jobs Frank B. Gilbreth
1901 Scheduling techniques for employees, machines jobs in
manufacturing Henry L. Gantt
1915 Economic lot sizes for inventory control F.W. Harris Elton
1927 Human relations; the Hawthorne studies Mayo
1931 Statistical inference applied to product quality: quality
control charts W.A. Shewart
1935 Statistical sampling applied to quality control: inspection
sampling plans H.F. Dodge & H.G. Roming
1940 Operations research applications in World War II P.M. Blacker and others.
1946 Digital computer John Mauchlly and
J.P. Eckert

1947 Linear programming G.B. Dantzig, Williams &

others

1950 Mathematical programming, on-linear and stochastic A. Charnes, W.W. Cooper

processes & others
1951 Commercial digital computer: large-scale computations
available. Sperry Univac
1960 Organizational behavior: continued study of people at
work L. Cummings, L. Porter
Integrating operations into overall strategy and policy, W. Skinner J. Orlicky and
1970
Computer applications to manufacturing, Scheduling and G. Wright
control, Material requirement planning (MRP) Quality and
productivity applications from Japan: robotics, CAD-CAM W.E. Deming
1980
.

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Concept Of Production
Production function is that part of an organization, which is concerned with the
transformation of a range of inputs into the required outputs (products) having the
requisite quality level.
Production is defined as “the step-by-step conversion of one form of material
into another form through chemical or mechanical process to create or enhance
the utility of the product to the user.” Thus production is a value addition process. At
each stage of processing, there will be value addition.
Edwood Buffa defines production as ‘a process by which goods and services are
created’. Some examples of production are: manufacturing custom-made products like,
boilers with a specific capacity, constructing flats, some structural fabrication works
for selected customers, etc., and manufacturing standardized products like, car, bus,
motor cycle, radio, television, etc.

3
Production system
Production system of an organization is that part, which produces products of an
organization. It is that activity whereby resources, flowing within a defined system, are
combined and transformed. In a controllers manner to add value in accordance with the
policies communicated by management. The production system has the following
characteristics:
1. Production is an organized activity, so every production system has an
Objective.
2. The system transforms the various inputs to useful outputs.
3. It does not operate in isolation from the other organization system.
4. There exists a feedback about the activities, which is essential to control and
improve system performance.

Classification of Production System

Production systems can be classified as Job Shop, Batch, Mass and Continuous
Production system.

Classification of Production System

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Job Shop Production
Job shop production are characterized by manufacturing of one or few quantity of products
designed and produced as per the specification of customers within prefixed time and cost.
The distinguishing feature of this is low volume and high variety of products.
A job shop comprises of general purpose machines arranged into different
Departments. Each job demands unique technological requirements, demands processing
On machines in a certain sequence.

Batch Production
Batch production is defined by American Production and Inventory Control Society
(APICS) “as a form of manufacturing in which the job passes through the functional
departments in lots or batches and each lot may have a different routing.” It is
characterized by the manufacture of limited number of products produced at regular
intervals and stocked awaiting sales.

Mass Production
Manufacture of discrete parts or assemblies using a continuous process are called mass
production. This production system is justified by very large volume of production. The
machines are arranged in a line or product layout. Product and process standardization exists
and all outputs follow the same path.

Continuous Production
Production facilities are arranged as per the sequence of production operations from the first
operations to the finished product. The items are made to flow through the sequence of
operations through material handling devices such as conveyors, transfer devices, etc.

Production Management
Production management is a process of planning, organizing, directing and controlling the
activities of the production function. It combines and transforms various resources used in
the production subsystem of the organization into value added product in a controlled
manner as per the policies of the organization.

5
 E.S. Buffa defines production management as, “Production management deals with
decision making related to production processes so that the resulting goods or services are
produced according to specifications, in the amount and by the schedule demanded
and out of minimum cost.”

Objectives of Production Management

1. Right Quality
The quality of product is established based upon the customers’ needs. The right quality is
not necessarily best quality. It is determined by the cost of the product and the technical
characteristics as suited to the specific requirements.
2. Right Quantity
The manufacturing organization should produce the products in right number. If they are
produced in excess of demand the capital will block up in the form of inventory and if the
quantity is produced in short of demand, leads to shortage of products

3. Right Time
Manufacturing costs are established before the product is actually manufactured. Hence, all
attempts should be made to produce the products at pre-established cost, so as to reduce the
variation between actual and the standard (pre-established) cost.
4. Right Manufacturing Cost
Timeliness of delivery is one of the important parameter to judge the effectiveness of
production department. So, the production department has to make the optimal utilization
of input resources to achieve its objective.

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IMDADI GROUP is one of the ancient business group working in the city. It was established
in 1911 and has completed a decade in 2011 as the most prominent and trust worthy business
group since of it times. The name IMDADI GROUP came from the founder IMDAD ALI
which means “TO HELP”. Being under the ruler ship of Britishers the company had to face
the tactics and treaties led by them which resulted into the downfall of the business. After
Independence the group resilience and not only gained back its position in the market but
developed up to what it is today. The group mainly dealt with hardware, paints and
construction material sectors. As the group expanded and diversified itself , they moved
towards backward and forward integration strategies by setting up different industries and
slogging up different works. After 1947 to till date IMDADI GROUP has expanded itself into
several other sectors and industries. One of the expansion was of Royal Resins industry in
2009 hinged near Tendua Village, Raipur engaged in the production of alkyd resins the
production capacity of which is 1800-2000 tons/year. Whereas the production capacity of
plant is 5000 tons/year.

Name and location ROYAL RESINS , Office- Budhapara near Sapre ground Raipur
(C.G) Work place – Govt. School Road , Near Borjhara power substation , Tendua village ,
Hirapur Raipur (C.G)

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Capacity – The production capacity of Alkyed resins is 800-1000 Tons /Year ,and the
production capacity of plant is 2000 Tons /year.

Sister concerns:

Imdadi Shop – deals in hardware and paints.

Imdadi Sons – deals in Cement and building construction materials

Jouhar & Company – deals in plaster of Paris and plywood’s

Imadadi Sons – deals in building construction material , Panchmedi naka , Raipur

Raipur Sales Combine – deals in hardware paints , Pandri , raipur

Popular Paints and Chemicals – manufacturer of paints , wallputti and distempers.

Future plans –

1) Planning to move to contruction line F.M Imdadiwala Builders

8
2) Planning to move to packing materials Imdadi Resins and containers

Land acquisition is in progress for future expansion at Tendua village in Raipur ( C.G ) To
carry on business of manufacturing, dealers, exporters and importers of alkyd , polymers ,
oils , rosins , glycerin , MTO , CNSL oils , and other products to produce different kinds of
alkyd reins used.

In different industries like PAINTS , CASTING AND MOULDING , PRINTING , to

manufacture, sell and deal in all or any of the by- product which will be obtained in the
process of manufacturing this alkyd reins a chemical products.

To set up and carry on the business to generate, trade, import and export of electricity power,
sell and deal in all or any of the by- product which will be obtained in the process of
generation of electricity power and to carry on such business in any other manner.

To acquire by purchase, lease, concession, grant, license or otherwise such land, building,
minerals, water works, plant stock in trade, stores, rights, privilege, easements and other
property as may from time to time be deemed necessary for carrying on the business of the
company and to build or to erect upon any land of the company how so ever acquired, such
manufactures workshop warehouse, offices, residences and other buildings and to erect such
machinery and construct such roadways, water courses hydraulic works.

To purchase, acquire and undertaking all or any part of the business property and liabilities of
any person of company carrying on proposing to carry any business which this company is
authorized to carry on or possessed of suitable for the purpose of the company or which can
be carried on in conjunction therewith or which is capable of being conducted so as directly
or indirectly to benefit the company.

To acquire from any person, firm or body corporate or unincorporated, whether in India or
elsewhere, technical information, know-how, processes, engineering, manufacturing and
operating data, plants, layouts and blue prints useful for designs, erection and operation of
plant required for and of the business of company and to acquire any grant or license and
other rights and benefits in the forgoing matters and things.

9
To improve, manage, cultivate, develop, exchange, let on lease, mortgage, sell, dispose of,
turn to account, grants, rights and privileges in respect of or otherwise deal in all or any part
of the properties and rights of the company on such terms as the company shall determine and
to supply power, light and heat and to lay out for building purposes, and to sell the same, and
to build on improve, let on building lease advance money to person, building or otherwise to
develop the same.

To establish branches, depot, show rooms, service centers, research bureaus with a view to
facilitate the work of the company and to expand its business.

To establish and maintain any agencies or branches in any part of the world for the sale of
any materials, articles, or things for the time being at the disposal or the company or for sale
or purchase of goods and materials required by the company or its constituents or other
purpose what so ever and to appoint managers, brokers contractors and other persons for the
purpose of the company and to discontinue and discharge them.

Introduction about alkyd resins

An alkyd is a polyester modified by the addition of fatty acids and other components. They

are derived from polyols and adicarboxylic acid or carboxylic acid anhydride. The term alkyd
is a modification of the original name "alcid", reflecting the fact that they are derived
from alcohol and organic acids.

10
The inclusion of the fatty acid confers a tendency to form flexible coating. Alkyds are used
in paints and in moulds for casting. They are the dominant resin or "binder" in most
commercial "oil-based" coatings.

Approximately 200,000 tons of alkyd resins are produced each year. The original alkyds were
compounds of glycerol and Phthalic acid sold under the name Glyptal. These were sold as
substitutes for the darker colored Copal resins, thus creating alkyd varnishes which were
much paler in color. From these, the alkyds we know today were developed.

There are two types of alkyd resins, drying (including semi drying) and nondrying. Both
types are typically produced from Dicarboxylic acids or Anhydrides, such as Phthalic
anhydride or maleic anhydride, and Polyols , such as Trimethylolpropane, Glycerine,
or Pentaerythritol. Alkyds are also used in items such as resins and paints.

Raw material

As is typical in any metallurgical process, resins manufacturing is highly sensitive to raw

material characteristics that would help obtain the rated capacity and the desired product
quality. Hence, it is essential to examine the chemical and physical characteristics of raw
materials, both individually and in combination. The basic raw materials for the production of
alkyd resin are OILS ( caster oil , soya bean oil , linseed oil ) , M.T.O , ROSINS , PTHYLIC ,

11
PENTA , GLYCRINE , XYLENE . Several tests are conducted in the company laboratory to
ascertain their suitability in a test tube. A state-of-the-art modern R&D facility has been
established along with a chemical laboratory to conduct the monitoring process.

OILS

Castor oil , linseed oil and soya oil  is a vegetable oil obtained from the castor bean ,
soya and linseed beans (technically castor seed as the castor plant, Ricinus
communes(Euphorbiaceous), is not a member of the bean family).

The common name "castor oil" probably comes from its use as a replacement for
castoreum, a perfume base made from the dried perineal glands of the beaver (castor in
Latin).

oil is a colorless to very pale yellow liquid with mild or no odor or taste. Its boiling
point is 313 °C (595 °F) and its density is 961 kg/m3.

It is a triglyceride in which approximately 90 percent of fatty acid chains are ricinoleic

acid. Oleic and linoleic acids are the other significant components.

Industry uses yearly 600-800 million pounds of castor oil and its derivatives have
applications in the manufacturing of soaps, lubricants, hydraulic and brake
fluids, paints, dyes, coatings, inks, plastics, waxes andpolishes, nylon, pharmaceuticals and
perfumes.

The uses of castor oil have changed over the years. Sixty years ago, castor oil was used for
medicinal purposes and as a general industrial lubricant. Soon after, chemical engineers
were able to produce derivatives of the oil that were of even more benefit to man.
Sulfonated (sulfated) castor oil, or Turkey Red Oil, was the first synthetic detergent after

12
ordinary soap, and other forms of the oil became important for the treatment of leather,
industrial lubricants, and other industrial uses.

Today, chemical engineers have come up with many uses of castor oil and its derivatives
such as: polyamide 11 (Nylon 11) engineering plastic, lubricating grease, coatings, inks,
sealant, aircraft lubricants, surfactants, emulsifiers, encapsulates, plastic films, plasticizer
for coatings, and components for shatterproof safety glass.

Castor oil has even made its way into cosmetics and related products due to its non
comedogenicity. Obviously, castor oil and its derivatives have become an important
commodity and is again a topic of interest to the chemical industry. 

Linseed oil is a common carrier used in oil paint. It can also be used as a painting medium,
making oil paints more fluid, transparent and glossy. It is available in varieties such as
cold pressed, alkali refined, sun bleached, sun thickened, and polymerised (stand oil). The
introduction of linseed oil was a significant advance in the technology of oil painting.

Traditional glazing putty, consisting of a paste of chalk powder and linseed oil, is a sealant

for glass windows that hardens within a few weeks of application and can then be painted
over. The utility of putty is owed to the drying properties of linseed oil.

PTHYLIC

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Phthalic acid is an aromatic dicarboxylic acid, with formula C6H4(CO2H)2. It is an isomer of isophthalic
acid and terephthalic acid. Although phthalic acid is of modest commercial importance, the closely

related derivative phthalic anhydride is a commodity chemical produced on a large scale.

It is the anhydride of phthalic acid. This colourless solid is an important industrial chemical, especially

for the large-scale production of plasticizers for plastics. In 2000, the world wide production volume of

phthalic anhydride is estimated to be about 3 232 000 tonnes per year.

Phthalic anhydride is a versatile intermediate in organic chemistry, in part because it is bifunctional
and cheaply available. It undergoes hydrolysis and alcoholysis. Hydrolysis by hot water forms ortho-
phthalic acid. This process is reversible: Phthalic anhydride re-forms upon heating the acid above 180
°C. Hydrolysis of anhydrides is not typically a reversible process.

Phthalic anhydride is a versatile intermediate in organic chemistry, in part because it is bifunctional

and cheaply available. It undergoes hydrolysis and alcoholysis. Hydrolysis by hot water forms ortho-
phthalic acid. This process is reversible: Phthalic anhydride re-forms upon heating the acid above 180
°C. Hydrolysis of anhydrides is not typically a reversible process.

However, phthalic acid is easily dehydrated to form phthalic anhydride due to the creation of a
thermodynamically favorable 5-membered ring.

ROSINS

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Rosin, also called colophony or Greek pitch (Pix græca), is a solid form of resin obtained
from pines and some other plants, mostly conifers, produced by heating fresh liquid resin to
vaporize the volatile liquid terpene components. It is semi-transparent and varies in color
from yellow to black. At room temperature rosin is brittle, but it melts at stove-top
temperatures. It chiefly consists of different resin acids, especially abietic acid

Rosin is an ingredient in printing inks, photocopying and laser printing

paper, varnishes, adhesives (glues), soap, paper sizing, soda, soldering fluxes, and sealing
wax.

Rosin can be used as a glazing agent in medicines and chewing gum. In pharmaceuticals,

rosin forms an ingredient in several plasters and ointments.

In industry, rosin is a flux used in soldering. The lead-tin solder commonly used in

electronics has about 1% rosin as a flux core helping the molten metal flow and making a
better connection by reducing the refractory solid oxide layer formed at the surface back to
metal. It is frequently seen as the burnt or clear residue around new soldering.

A mixture of pitch and rosin is used to make a surface against which glass is polished when

making optical components such as lenses.

Rosin is added in small quantities to traditional linseed oil/sand gap fillers, used in building
work.

When mixed with waxes and oils, rosin is the main ingredient of mystic smoke, a gum which,
when rubbed and suddenly stretched, appears to produce puffs of smoke from the finger tips.

15
Step By Step Description of the Manufacturing Process from raw material to finished
goods.

(1)First of the primary raw material i.e oils are put in the reactor .

16
(2) At 30 degree temperature MTO is added .

(3) At 60 degree temperature Xylene ,Glycrine , Penta is added

(4) Pthylic is added to the reactor at 180degree temperature

(5) Rosin is added after adding Pthylic

(6) Then after adding all the things temperature is raised to 270 degree
temperature.

(7) Then the temperature remain 270 till 16 - 18 hours .

(8) Then temperature is lower down at 80 degree .

(9) Viscosity check is done after the batch is completed .

(10) As per requirement of the costumer material is given.

1 st zone – 30 C
2nd zone - 60 C
3rd zone - 90 C
4th zone – 120 C
5th zone – 160 C
6th zone - 210 C
7th zone – 270 C
(11)After passing through the above stages of temperature in the reactor finally the alkyed
resin is produced.

ALKYD RESIN MANUFACTURING

Process Description

17
Alkyd resin can be manufactured by four different processes, solvent process being the main
commercial process which starts by adding all the raw materials in reaction kettle and the
agitation of the same is continued then, inert gas is spared through the spare line.

The vapor are condensed and recycled back to the kettle. The reacted mass is dropped into a
jacketed tank, containing the desired solvent. The cooled resin solution after thinning is
filtered in filter press and sludge is removed. It is lastly tested, packed and stored. 

The solvent process uses a small amount of solvent, 5-10%, in the esterfication reaction to act
as a reflux medium.

The Advantages of this process are:

 
a) Uniformity of product,
b) Increased speed of reaction
c) Lower material losses.

18
 
In the solvent process, the production of alkyds can be carried out either in a single stage or a
two stage process. Under the single stage process, the drying oil (linseed oil), polyalcohol and
phthalic anhydride are converted simultaneously. This method of alkyd preparation is not
satisfactory because of the incompatibility of the phthalic anhydride with drying oil (linseed
oil) and the difficulty of controlling the reaction to produce the desired end-products. 

In the first sage of the two stage solvent process, monoglyceride is produced from drying oil
and polyalcohol and in the second stage the monoglyceride is converted with phthalic
anhydride. This process is more satisfactory and is the one recommended for the envisaged
plant because it eliminates the problems of the first option.

RESINS –

RESINS ARE OF 3 TYPES

1) NON – DRYING

2) SEMI – DRYING

3) DRYING

NON – DRYING used in industrial products and also used in stoving enamel .
SEMI – DRYING used in all decorative enamels
DRYING also used in all decorative enamels

1) Linseed oil
2) Soybean oil
3) Castor oil

RESIN is made in 3 ways depending upon what kind of material is required by the customer .

1) Long oil solvent based

2) Medium oil solvent based
3) Short oil high aromatic

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Measures taken for the establishment of plant

a) Comprehensive testing of raw materials for the process.

 b) Preparation of project report for an investment decision.
c) Basic and detailed engineering of the reduction unit and all the auxiliaries .From raw
material preparation to storage and handling of finished products.
d) Preparation and selection of mechanical, electrical and instrumentation equipment
including refractoriness.
e) Inspection of equipment to ensure compliance of specifications and for meeting the
required standard from operational point of view.
f) Assistance in supervision of erection, start-up and commissioning.
g) Scheduling and monitoring the implementation of project with assistance in troubles
hooting during erection and commissioning.

h) Assistance in commissioning the plant and optimizing the plant operations.

i) Full performance guarantees for achieving rated capacity utilization

20
21
DETAILED INFORMATION AND CURRENT SENARIO

Alkyd resin, a complex oil-modified polyester that serves as the film-forming agent in some

paints and clear coatings. Developed in the 1920s, alkyd-based enamel paints were once one
of the most important types of surface coating.

Owing to their incorporation of volatile organic solvents and to their low durability on
exterior surfaces, they have yielded preeminence to newer polymer systems (particularly
water-based latex paints). Nevertheless, alkyds are still used in low-performance industrial
coatings and in interior paints.

The name alkyd, formed from alkyl (a chemical abbreviation for alcohol) and acid, denotes

the chemical origin of the resin, which is commonly based on a polymerization reaction
between an alcohol, such as glycerol, and a dicarboxylic acid or its anhydride—for instance,
phthalic anhydride. Glycerol and phthalic anhydride react to form the polyester glyptal. The
reaction can be represented as follows:

When unsaturated oil such as Tung oil, linseed oil, or dehydrated castor oil is added to

the ester-forming compounds, the result is a branched polyester containing fatty-acid side
groups. When such a coating agent is applied to a surface, the oil portion of the polyester

22
undergoes a cross-linking reaction in the presence of oxygen from the surrounding air as it
dries, yielding a tack-free film.

A typical alkyd paint consists of the oil-modified polyester to form the coating film, a solvent
such as hexane or mineral spirits to aid in application, metal naphthenates to catalyze the
drying reaction, and pigment to provide color and hide the coated surface.

The oil content of the formulation can vary. A long-oil alkyd contains 60 percent fatty acid
by weight; a medium-oil alkyd contains 40–60 percent fatty acid; and a short-oil alkyd
contains less than 40 percent.

The use of alkyd coatings is decreasing partly because of regulations restricting the release of
volatile organic content into the atmosphere. In order to meet such regulations, alkyds may be
made water-reducible by the addition of free acid groups to the molecules. In the presence of
a base such as ammonia, these groups allow the polymers to be solubilized in water rather
than in organic solvents.

Usually a co solvent such as 2-butoxyethanol is necessary to maintain a stable solution, and

under these conditions the ester linkages that are the basis of the alkyd polymer chain are
vulnerable to breakage by hydrolysis. In this case special monomers are often chosen to give
the chain hydrolytic stability

Within the surface-coatings industry, the name polyester, when used alone, indicates a
polyester free of natural-oil modifiers. Such polyesters are used extensively in coatings. The
polymer can have a linear structure, but it is often branched, and it is usually in a relatively
low-molecular-weight form that can be cross-linked to form a high-performance film.

23
When the polyester is synthesized in the presence of an excess of alcohol, it tends to have
hydroxyl end-groups on the molecules, and these molecules can be cross-linked through the
hydroxyl groups by reaction with isocyanine , epoxy, and melamine compounds.

Current Scenario Of Polymer Industry

Indian petrochemicals industry has seen growth of about 14-15% per annum over 2005-2010,
as per BMI, and double-digit growth is likely to stay over the medium term. It should out-
pace the global market, which is not expected to return to pre-recession levels of growth until
2012. Polymer output is set to accelerate over the next five years as capacity is expanded in
India.

By 2015, combined olefins capacity is forecast to cross 16 mln TPA, while polyolefins
capacity is set to rise above 13 mln TPA. While PVC capacity is set to stagnate, PE capacities
will grow by 80% The global economic environment in 2011 is likely to be better than 2010.
Developed economies of North America, Europe and Japan are expected to show better
performance in 2011 compared to the last three years.

South America and Russia are expected to grow well in 2011. Similarly, Middle East and
Africa are expected to show good growth. Asia Pacific region, with its large population will
continue marching towards better prosperity. This will drive growth of polymer end products.
China and India would strive to become more self reliant on feed stocks and polymers.

However, they may continue to depend upon the Middle Eastern region for commodity
polymers due to higher growth of polymer demand in the next few years. The Middle Eastern
region will continue to exploit its strength of oil and lower cost of feed stocks and invest
more in petrochemical business.

24
Contribution of Chemical Industry In Economy

Chemical industry is an integral component of the Indian economy, which contributes around
7 % of the Indian GDP. It touches our lives in several different different ways. Whether it is
thermoplastic furniture we use, or a synthetic garment we wear, or a drug we take – we are
inextricably associated to it.

The industry is integral to the development of agricultural and industrial development in

India and has key linkages with various other downstream, such as automotive, consumer
durables, engineering, food processing and more.
 
Globalization posses many challenges to the industry, which has predominantly developed in
a protected environment. With World Trade Organization assuming an increasing role in
global economics, there is an inevitable move towards an inter-linked international economy.
However, there have been cases where particular segments of the industry, such as
pharmaceuticals and biotechnology have performed exceedingly well even at the world
level. 

During 2005-06, the industry contributed 17.6% of the manufacturing sector. However the
country continues to be a net importer in 2005-06, with exports of US$ 5.95 billion and
imports of US$7.92 billion. The worth of Indian chemicals industry during 2005-06 was
US$30.59 billion, which reflected a growth of 10.23% over the previous year and a CAGR of
8.68% during the last 3 years. ·

25
Raw Material Constraints

MALEIC ANHYDRIDE

Maleic acid is an organic compound that is a Dicarboxylic acid, a molecule with

two carboxyl groups. Its chemical formula is HO2CCHCHCO2H. Maleic acid is the 
Cis - isomer of Butenedioic acid, whereas fumaric acid is the trans-isomer. It is mainly used
as a precursor to fumaric acid, and relative to its parent Maleic anhydride, Maleic acid has
few applications.

Maleic acid is a less stable molecule than fumaric acid. The difference in heat of
combustion is 22.7 kJ·mol−1. The heat of combustion is -1355 kJ/mole. Maleic acid is more
soluble in water than fumaric acid. The melting point of maleic acid (135 °C) is also much
lower than that of fumaric acid (287 °C). Both properties of maleic acid can be explained on
account of the intra molecular hydrogen bonding that takes place in maleic acid at the
expense of intermolecular interactions, and that are not possible in fumaric acid for geometric
reasons.

26
GLYCEROL

Glycerol (or glycerine, glycerin) is a simple polyol compound. It is a colorless,

odorless, viscous liquid that is widely used in pharmaceutical formulations. Glycerol has
three hydroxyl groups that are responsible for its solubility in water and its hygroscopic
nature. The glycerol backbone is central to all lipids known as triglycerides. Glycerol is
sweet-tasting and of low toxicity . Approximately 950,000 tons per annum are produced in
the USA and Europe; 350,000 tons of glycerol were produced per year in the United States
alone from 2000–2004.Production will increase as the EU directive 2003/30/EC is
implemented, which requires the replacement of 5.75% of petroleum fuels with bio
fuel across all Member States by 2010, as glycerol is a byproduct in the production of
biodiesel. It is projected that by the year 2020, production will be six times more than
demand

27
Coal and wood

Equal sordid tale is the supply of coal which is totally government controlled. Many units are
now enjoying the benefit of coal linkage system and those who are still out of the purview
will be linked with coal linkage system very soon. But the grade of the coal offered is not the
grade required by the sponge iron industry. Sponge iron requires specific characteristic of
coal – IDT of coal ash should have13000 degree C temperature, reactivity of coal – 2 cc of
CO / gm of C/Sec., Fixed Carbon to the level of 42-44%. Other features like Volatile Matter
between 26-32%, Ash 25%, Coking Index and Swelling index less than 1, etc. are required
for maximization of good quality sponge iron production. This is causing a concern for the
sponge iron industry as well as environment. The sponge iron industry is forced to use coal
with ash content over 40%, FC LESS THAN 33%

Pollution And Environmental Control.

The sponge iron industry is concerned about the problem of pollution and global warming.
Units are trying their level best to control pollution but we consider that the government must
step in to help the sponge iron units in their efforts. Approximately Rs. 600 crores has been
contributed to the exchequer on account of excise duty. We have made representation to the
government that at least 10% of the contribution should be paid back to the respective state
governments improving the environment situation. Several funds from international level are
available to minimize pollution level for the iron and steel industry. For example - foundry
industry in China or Re-rolling sector in India -Huge fund have been made available through
UNDP-GEF project fund. Efforts can generate fund from the sources for the improvement of
the environment.

28
Issues Regarding Manufacturing

One of the main problems in the chemical industry is pollution. Many of the chemicals such
as PCBs are very hard to eliminate from the environment for the same reasons that made
them optimal for their task, including chemical and temperature stability. The best solution is
not to generate hazardous chemicals in the first place, by finding better alternatives that do
not have long-term waste problems. Also these chemicals should be priced based on their
actual cost, including the cost of disposal of the chemicals themselves or any chemicals used
in production.
 
Another problem is lack of sufficient research to determine what the long term affect of
chemicals are on the human body. Since many of the chemicals we use are relatively new, the
industry has not had a chance to evaluate the long term affect of the chemicals use on the
human body. Chemicals should be rigorously tested by regulatory entities before widespread
use in the general population.

Water Supply
Many DRI plants are not supplied with adequate water which is essential for continuous
running of pollution equipments. Government may ensure proper supply of water through
PHE or other authority.

Transportation problem

Local road transport has become a menace for the DRI Industry. Transporters are forming
small association to force us to work at their terms and conditions. Interference of the
government is highly solicited. For the units located at a distance from centre, dependence on
road transport is essential but it is almost impossible to obtain road through normal process
and that too at a reasonable time.

29
Meaning of research:-

According to Clifford Woody:

“ Research is an academic activity and as such the term should be used in technical sense
According to Clifford woody research comprises defining and redefining problems
formulating hypothesis and suggested solution collecting organizing and evaluating data and
making deduction and reaching conclusion and at last carefully testing the conclusion to
determine whether they fit the define research .

The word research is used to describe a number of similar and often overlapping activities
involving a research for information. In other words research is a matter of gathering
information from varying sources usually in relation to specific purpose.

To decide research design and

application

To decide source of data collection

To decide form of data collection

To decide research design and

application

To process and analyze report

To prepare the research report

30
 1. Objective of the study:-

This step is also a research problem .problem definition is the most critical part of
the research process. Research problem definition involves specifying the
information needed by management. The main objectives of the study are:

 To analysis the work method and procedure.

 To determine the sequence of work.
 To analysis the working condition.
 To analysis true facts concerning the situation.
 To examine the critical facts.

2. Research design and application:-

Research design involves defining the research problem, determining how to
collect the data and from whom, establishing the way the data will be analyzed
estimating costs and the preparation of the research approach. For this study,
descriptive study research was selected.

3. Source of data:-
 Primary data
 Secondary data

Primary data:-

Primary data collected through survey methods for the purpose this study questionnaires are
designed and information is collected from the members of ROYAL RESINS .

31
Reason for selecting primary data:

In terms of primary data a questionnaire has been used to interview desire sample units that
give accurate and up to data information as well better to research problem.

Research instrument:

Questionnaire: a questionnaire consists of questions presented to respondents for their

answers, because of its flexibility the questionnaire is by far most common instrument used to
collect primary data.

Secondary data:

Secondary data means the data that are already available or exit in the universe i.e. they refer
to the data which have already been collected and analyzed by someone else. For this study
secondary data are collected though magzines, newspapers, booklets, broshers following are
being used for collecting secondary data.

Reason for collecting secondary data:

Secondary data can be gathered quickly and inexpensively, compared to primary data.

 Contact method: once the sampling plan has been determined, the marketing
researcher must decide how the subject should be contact.
 Mail questionnaire: The mail questionnaire is the best way to reach people who
would not give personal interviews or whose responses might be biased or distorted
by the interviewers. Mail questionnaires require simple and clearly worded questions.

 Telephone interview: telephone interviewing is the best method for gathering

information quickly; the interviewer is also able to clarify questions if respondents do
not understand them. The response rate is typically higher than in case of mailed
questionnaires.

32
 Personal interview: personal interviewing is the most versatile method. The
interviewer can ask more questions and record additional observations about the
respondent, such as dress and body language. Personal interviewing takes two forms.
In arranged interviews, respondent are conducted for an appointment, and often a
small payment or incentives is offered. Intercept interviews involve stopping people at
a shopping mall or busy street corner and requesting an interview.

4. To decide form of data collection:

For this project survey method was selected which was carried through personal
interview, because information from different persons was required.

5. To organize and collect data:

Once the researcher has formulated and development a research design including
questionnaire second thing he has to decide whether he has to collect the information
from all the targeted people. There can be two type of survey can be possible.
 Sample survey
 Census survey

“The sample taken for completion of the research was 50”

Sample:
Sample is true representation of the population by studying of sample we can predict
the behavior of the population.

Sample size:
In this research I have taken 50 samples.

Target population:
 Managers
 Employees
 Workers
 Customers

33
 6. To process and analyze data:
After the data was collected it was tabulated, analyzed and interpreted to the
conclusion reach.

Technique applied:

 Bar chart –A chart in which the length of the bar represented the amount of the
item associated with the bar.

 Pie chart- A circle divided into sections, such that each section represents the
percentage of the total area of a circle associates with one variable.

Q1. Are you aware about the manufacturing process of POLYMER

RESINS ?
34
 Particulars No. of respondents Percentage

Yes 5 90%

No 45 10%

Total 50 100%

AWARENESS ABOUT THE MAN-

UFACTURING PROCESS OF
RESINS
Yes No

10%

90%

INTERPRETATION:

This shows that the awareness about the manufacturing process of RESINS in ROYAL
RESINS are:

 90% people are not aware

 10% are aware

Q2. In how many stages does manufacturing process comes to an end?

35
 Particulars No. of respondents Percentage

5 3 6%

6 35 73%

7 0 0%

8 12 21%

Total 50 100%

STAGES OF MANUFACTURING
PROCESS
5
6%

8
21%

6
73%

INTERPRETATION:

 73% respondent says 6 stages, and 21% respondent says 8 stages, and 6% respondent
says 5 stages.

Q3. How many skilled employees are required in manufacturing process?

36
 Particulars No. of respondents Percentage

5-10 26 12%

10-15 18 46%

15-20 6 16%

More than 20 0 26%

total 50 100%

REQUIREMENT OF SKILLED EM-

PLOYEES

5 TO 10
More than 20 12%
26%

15 TO 20 10 TO 15
16% 46%

INTERPRETATION:

 46% respondent says 10 -15 employees are required and 26% Respondent says more
than 20 employees are required and 16% respondent says 15-20 employees are
required and12% respondents says 5-10 employees are required.

Q4. How much time is required to complete the production of a product?

37
 Particulars No. of respondents Percentage

16 hrs 19 22%

17 hrs 1 8%

18 hrs 21 70%

19 hrs 9 0%

Total 50 100%

REQUIERED TIME TO COMPLETE THE

PRODUCTION OF PRODUCT

6 hrs
22%

7 hrs
8%

8 hrs
70%

INTERPRETATION:

 70% respondent says it requires 8 hrs to complete the production and 22% respondent
says it requires 6 hrs to complete the production and 8% respondent says it requires 7
hrs to complete the production.

Q5. How many employees are required in a single shift?

38
 Particulars No. of respondents Percentage

Less than 20 26 52%

50-100 18 36%

100-150 6 12%

150-200 0 0%

Total 50% 100%

EMPLOYEES REQUIRED IN A SINGLE

SHIFT
52%
60%
50%
36%
40%
30%
20%
12%
10%
0%
0%
Less than 50
50 to 100
100 to 150
150 to 200

INTERPRETATION:

 52% respondent says less than 50 employees are required in a single shift and36%
respondent says 50-100 employees are required in a single shift and12% respondents
says 100-150 employees are required in a single shift.

Q6. What would you do for the safety purpose of the employees?

39
 Particulars No. of respondents Percentage

Fully automated machinery 9 18%

Medical facility 5 10%

Both 36 72%

Total 50 100%

SAFETY MEASURES FOR THE EM-

PLOYEES

80% 72%
70%
60%
50%
40%
30% 18%
20% 10%
10%
0%
Fully automated
machinery medical facility
both

INTERPRETATION:

 72% respondent says both fully automated and medical facilities are provided and
18% respondents says fully automated machinery and10% respondent says medical
facility.

Q7. How much break do you provide to your employees?

40
 Particulars No. of respondents Percentage

Less than 1 hr 9 18%

1 hr 35 70%

1-2 hrs 6 12%

More than 2 hrs 0 0%

Total 50 100%

BREAK DURATION FOR EMPLOYEES

Less than 1 hr 1 hr 1 to 2 hr More than 2 hr

12% 18%

70%

INTERPRETATION:

 70% respondents says 1 hr break is provided and18% respondent says less than 1 hr
break is provided and12% respondent says 1-2 hrs break is provided.

Q8. How much you pay to your employees who are engaged in
manufacturing process?

41
 Particulars No. of respondents Percentage

Less than 5000 32 22%

5000-10000 11 52%

10000-15000 7 14%

More than 15000 0 0%

Total 50 100%

PAY SCALE OF EMPLOYEES WHO ARE

ENGAGED IN MANUFACTURING
PROCESS
Less than 5000 5000 to 10000 10000 t0 15000 More than 15000
14%
22%

52%

INTERPRETATION:

 52% respondent says 5000-10000 and 22% respondent says less than 5000 and 14%
respondent says 10000-15000.

Q9. What would you do to utilize the scrap of the product?

42
 Particulars No. of respondent Percentage

Sell out 10 20%

Self utilization 8 16%

No use 2 4%

Both 1 & 2 30 60%

Total 50 100%

UTILIZATION OF SCRAP

60%

20%
16%

4%
Sell out
Self utilization
No use
1 & 2 both

INTERPRETATION:

 60% respondent says self utilization and sellout of scrap and 20% respondent
says sell out and 16% respondent says self utilization and 4% respondent says
no use.

Q10. Are you updated with latest technology for manufacturing process?

43
 Particulars No. of respondent Percentage

Yes 40 90%

No 10 10%

Total 50 100%

UPDATION OF LATEST TECHNOLOGY

No
10%

Yes
90%

INTERPRETATION:

90% respondent says manufacturing process is updated with latest technology and 10%
respondent says manufacturing process is not updated with latest technology.

Q11. What privilege do you provide to your customers?

44
 Particulars No. of respondents Percentage

Transportation 6 12%

Quality assurance 10 20%

Returning 0 0%

All of the above 34 68%

Total 50 100%

PRIVILEGE PROVIDED TO CUSTOMERS

Transportation Quality assurance Returning All of the above

12%

20%

68%

INTERPRETATION:

 68% respondent says all of the above privileges are provided to the customers and
20% respondent says quality assurance is provided to the customers and12%
respondent says transportation facility is provided to the customers.

FINDINGS

45
 1. Maximum respondents are aware about the manufacturing process of alkyd resins.
2. Maximum respondent says that 10-15 skilled employees are required in manufacturing
process of alkyd resins
3. According to the interpretation maximum respondent says that 18 hrs are required to
complete the production of a product
4. Maximum respondents are male candidates
5. Some employees working in single shift are illiterate were as some are literate.

LIMITATION’S

46
 1. Biasness of respondent.
2. Sample size is limited
3. Limited time of research
4. As the industries are located in far areas the transportation problem occurs.
5. Inadequate electric supply from government
6. Due to chemical industry study becomes more complicated

SUGGESTIONS

47
 1. As it is the production department so more and more safety measures are
provided to the employees.
2. Wastages should be treated and then recycle.
3. Scrap of the material should be decomposed after recycling it.
4. Proper safety measures should be taken for the employees engaged in
manufacturing process.
5. There should be a proper cooling system for the heat furnaces.

Bibliography

48
  P . Ramamurthy , ‘production and operation management’ ,new age (p) ltd.,2002

 S. Chand , ‘production and operation management’ ,first edition 1998.

 CR Kothari , ‘research and methodology-methods & techniques’, new age

international (p) ltd.,2004

 Martang Telsang ; ‘Industrial engineering and production management’

Chand. S. & Co. , 1st Jan 2006

Webliography
 www.ask.com

49
 www.scribd.com

 www.wikipedia.com

 www.google.com

 www.enil.com

50
 Questionnaire

I Ibrahim Hussain student of Disha College, I am conducting a survey on The Manufacturing

process of Alkyd Resins in Royal Resins in Raipur city so I would like to know your
perception about the same. Please co operate for the following-

Name:
Age:
Address:
Contact no.:

1. Are you aware about the manufacturing process of Polymer Resins ?

1. YES ( ) 2. NO ( )

2.In how many stages does manufacturing process comes to an end?

1. 5 ( ) 2. 6 ( )
3. 7 ( ) 4. 8 ( )

3. How many skilled employees are required in manufacturing

Process ?
1. 5-10 ( ) 2. 10-15 ( )
3.15-20 ( ) 4. More than 20 ( )

4. How much time is required to complete the production of a

Single product?
1. 6hrs ( ) 2. 7hrs ( )
3. 8hrs ( ) 4. 9hrs ( )

51
5. How many employees are required in a single shift?
1. Less than 50 ( ) 2. 50-100 ( )
3. 100-150 ( ) 4. 150-200 ( )

6. What would you do for the safety purpose of Employees?

1. Fully automated machinery ( )
2. Medical facility ( )
3. Both ( )

7. How much break do you provide to your employees?

1. Less than 1hr ( ) 2. 1hr ( )
3. 1-2hr ( ) 4. More than 2hr( )

8. How much you pay to your employees who are engaged in

Manufacturing process?
1. Less than 5000 ( ) 2. 5000-10000 ( )
3. 10000-15000 ( ) 4. More than 15000 ( )

9. What would you do to utilize the scrap of the product?

1. Sell out ( ) 2. Self utilization ( )
3. No use ( ) 4. 1&2 both ( )

10. Are you updated with latest technology for manufacturing?

Process?
1. YES ( ) 2. NO ( )

11. What privilege do you provide to your customer?

1. Transportation ( ) 2. Quality assurance ( )

2. Returning ( ) 4. All of the above ( )

52