Summer Internship Report

SRF Limited

We find a better way.

Submitted by: Submitted to:

RACHIT PAHUJA Mr. V.R. PATIL

Company: SRF ltd.

Location: Gwalior (Malanpur).

Topic: To study how an Industry runs and manufactures in continues way.

Project Objective: To learn how a plant operates and the industrial process.

Methodology Adopted: To observe different machinery used in the following departments:1. Polymerization(Poly)

2. Spinning

3. Textile

The company has a HR(Human Resource) department followed by Polymerization, Spinning and Textile plants.

In addition to these plants there is a utility plant as well which fulfills the utilities of the above mentioned plants.

INTRODUCTION

Established as CEAT limited, Tyre Cord Division in 1991 was set up by CEAT Tyre Group Company of “RPG Enterprises”.

In technical collaboration with “Toray industries”, Japan. Project work commenced in 1991 with an initial investment of

Rs. 350 crore. The plant has latest state of art technology with integrated

facilities of polymerization, spinning and twisting.

INDIA ABROAD

SRF Plants

GwaliorBhivadiPantnagarKashipurIndoreTrichiGummidipundiManali

Port ElizabethThailand

SRF Business Profile:

TTB: Technical Textile Business. CB: Chemical Business. PFB: Packaging Film Business. EPB: Engineering Plastic Business. P R&D: Projects R&D.

SRF AT A GLANCE

BUSINESS: A multi business manufacturing entity. PRODUCTS: Industrial Intermediates. COUNTRIES PRESENT: India, Thailand and South Africa. PLANT LOCATION: 10(Eight in India and two abroad). TURNOVER: $ 550 Million. WORK FORCE: 4000 Globally. Exporting to: 75 countries.

STUDY OF TECHNICAL TEXTILE BUSINESS

Tyre cords Coated Fabric Belting Fabric Industrial Yarn.

Global Position:

Belting Fabric: Ranked number 2 worldwide. Tyre Cord Fabric: Ranked number 2 in Nylon 6 tyre cord fabric.

USE OF SRF PRODUCTS IN AUTOMOBILE:

IN CAR:

Packaging films.

TECHNICAL TEXTILE BUSINESS (TTB)

Tyre cord Engineering plastics Refrigerants Industrial yarn

Now, let us understand different sections of this industry.The plant is divided into different sections which produces different end products.

The different sections are as follows:

1. Polymerization2. Spinning 3. Textile 4. Utility

My part of study basically focuses on understanding how an industry works.

The production of nylon 6 tyre cord is a long process and takes in several steps in different plants.SRF purchases the input raw material which is called Caprolactum.

The monomer is changed to a polymer in Poly plant and the product obtained is Nylon chips. These chips are then processed in the Spinning section and produces Industrial yarn. This yarn is then processed in

Textile plant and leads to the final product called Nylon 6 tyre cord which is produced according to the customer requirements.

The Utility plant on the other hand is useful to supply necessities of other sections which are as follows:

Nitrogen Air Chilled water.

Let us understand this process in a tabular form:

Since SRF works on customer demand ,there are four types of yarn that the company manufactres.

Caprolactum(purchased input

material)

Polymer chips(Polymerization)

Tyre Yarn(Spinning)

Tyre Cord Fabric (Textile)

These are differentiated on the basis of the term DENIER.

Let us understand what denier means:

DENIER is a unit of measurement that is used to determine fibre thickness of individual thread that is used in creation of textiles and fabrics.

It is the unit of measurement for linear mass density of fibre.IT IS THE MASS IN GRAMS PER 9000 METERS.

SRF manufactures yarn of following denier measurements according to customer reuirements:

840 1260 1680 1890

SPINNING

The process of spinning starts in following ways:

The nylon chips are sent off from the polymerization plant with nitrogen gas in the spinning plant where it is processed in following ways:

1. CTS It stands for Chip Transportation Silo.

2. ASMIt stands for Additive Special Mixture.Here the chip is fed with CuI in the following composition: 20Kg Chips with 4 grams of CuI. The basic use of CuI is to make the nylon 6 yarn strong.

3. CRS

It stands for Chip Receiver Silo. The purpose of this is to remove the impurities and make yarn pure.There are:A. CRS1(At 22.1 meters)B. CRS2(At 15 meters)C. CRS3

4. Melting Process: here the chip is fed to the EXTRUDER which achieves high temperature level from 160C to 290C in the following zones: A. ZONE1B. ZONE2C. ZONE3D. ZONE4E. ZONE 5

5. SPIN BLOCK: It has following parts: metering pump, pack assembly, yarn, yarn quenching by quench air.

6. TAKE UP: It defines the spin finish roller.

SRF has adopted JAPANESE technology in its Spinning plant.

The Spinning department has two plant set ups.One of them uses Tora and other uses TMT .

The first plant has 6 winders and the second plant has 8 winders.

Each machine has 6 GR Rolls:

GR1 GR2 GR3 GR4 GR5 GR6

The number of machines in 1st plant:

A B C D E F

The number of machines in 2nd plant:

G H I J K L M N

(All these machines have different GR rolls)

Number of winders in 1st plant: 24Number of winders in 2nd plant: 32

One time or other a defect occurs in the winder, therefore they have a MAITENANCE section as well.

The Maintenance section has three winder machines for repairing from each plant.

INDUSTRIAL YARN

To avoid the wastage of yarn, cheese winder is used.It collects used yarn from different rolls and winds it in a fresh one.

CHEESE WINDER

The next plant is TEXTILE

Textile has 72 twisters and 16 Looming machines.

Twisters are used to twist the yarn and make a thread out of it.Twist is given according to customer demand or the kind of denier they have asked for.

For example:

1. The customer JKI wants a denier as 1890/2. Thus, two yarns of 1890 are picked up and the twist is given to them.

2. The customer CIL wants 1260/3. Thus, three yarns of 1260 are picked up and are twisted together.

Textile process flow chart:

Twisting Cord conditioning Loom Crealing Weaving Packing

Accreditations by SRF from bsi. ( British Standard Institution)

Bsi. Environmental Management system. ISO 14001-2004

Bsi. Occupational Health and Safety Management System.

SAFETY MEASURES

One should wear ear plugs to avoid the noise from the machines. One should wear a helmet in the plant.

QUALITY MANAGEMENT SYSTEM

LEARNING FROM INDUSTRIAL TRAINING

Training helped in understanding how an industry works. It helped in understanding the organization of work. It helped in understanding of continues process. It helped in understanding the punctuality of workers. Since the

plant is operational 24 hours thus there are three shifts of eight hours each which are as follows: A, B and C.

It helped in understanding the work culture of industry. All people work as a team.

TOTAL QUALITY MANAGEMENT

QUALITY CONTROL CIRCLES.

KAIZEN

DAILY MANAGEMENT

5S

AUTONOMOUS MENTAINANCE