Shree Ram Fibres

8/8/2019 Shree Ram Fibres

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SHREE RAM FIBRES

INTRODUCTION

Shree Ram Fibres is an excellent factory that is situated in the Industrial Area

outside Gwalior city and is the prime manufacturer of tyre cord in the country .

The students visited the factory premises on the date 12-03-2010. The

students were warmly welcomed by the staff of S.R.F. After that w e were

taken to the seminar room where we were briefed about the company which

was followed by lunch. Later we were taken on an extensive tour of the factory

premises.

BRIEFINGThe factory is a part of D.C.M. group who has been a pioneer in the Indian

Industries .The founder of the group was Shree Shreeram and was succeeded

by his sons who headed different businesses. One of the businesses that the

company deals in is Technical Textile Business (T.T.B.). The company have 5

plants for this purpose with some acquired on foreign land recently.

The Gwalior plant which we visited was built in October 1990 by CEAT limited

in technical collaboration with Toray Industries. In February 1996, the companywas acquired by S.R.F. from CEAT limited. In March 1997, there was first time

inclusion of TQM process in the company. In April 2001, introduction of

process based organization structure began. In April 2002, introduction of

structured annual planning, 8 step problem solving technique was developed.

In October 2004, Deming Prize (a prestigious Japanese award for Industrial

excellence) was awarded to the company.

We were also told that SRF has now become the 2

nd

largest tyre cord fabricmanufacturer in the world and its major customers across the world are J.K.

Tyres, Apollo, CEAT etc.

The Factory Premises has also taken measure to counter

the environmental effects. For this purpose a Bio Gas Plant was set up which

generates bio gas from canteen waste.


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Finally we were told about the safety rules which we had to follow inside the

Premises.

Safety Rules

DOs

1. Walk between the yellow line2. Use Personal Protective equipments3. Follow instruction of guide4. In case of any trouble, please take help of guide.

DONT

1. Cigarettes, match box, gas lighters ,Cameras are not allowed2. Smoking is prohibited.3. Touching the machines may be danger, please avoid4. Please dont touch the displays

We were also told about the different processes which are carried out in the

company like TQM, PDCA, PSP, SDCA . Kaizen and QCC solve problems of

workplace.

NURSERY OF VERMICULTURE UNIT

In this tapeworm shit is used as fertilizers. It is better fertilizer than chemical

fertilizer. On an average 100 Australian tapeworms are released in an area of 1

sq foot.

PROCESS OF PREPARING PIT

First a pit of 750mm is dug. The bottom layer is of wooden fodder and above

that there is a layer of dry cow dung and after that comes a layer of dry leaves.

Then comes the layer of soil and final top layer of dry leaves. It should be

noted that each layer is of 150mm each. It should be noted that we should be

adding water at regular intervals because tapeworm need water to stay alive.


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APPLICATION OF FERTILIZERS

1. Kitchen2. Nursery3. Farming

COMPOSITION

1. 5 times of Nitrogen 2. 7 times of P2O53. 11 times of Potash 4. All these contents are soluble in water and readily available to Plants.

ADVANTAGES

1. Gummy substance in tapeworm makes hard soil fertile, aerial andporous

2. Save us from diseases which are caused by the chemical fertilizers. It takes 60 days for the vermi-compost to get ready.

POLYMERIZATION DEPARTMENT

Here we were told to follow safety procedure strictly, as it was the first and

foremost point of TQM. The main output of this department is nylon chips. The

raw material used is caprolactum. The caprolactum is first melted at 80C and

stored in a storage tank where it is mixed with demineralised water to make it

viscous from where extraction is done .From there solid state polymerization is

done. This is done to increase Relative Viscosity (RV). Oil application is done to

remove static charge.

Raw Material is supplied by Gujarat State Fertilizers. This whole state process

above is actually controlled by Programma ble Logical Controller (PLC).


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At the time we were at the department an accident occurred. The 8 parallel

cords which were being produced inside the department, one of them was

broken so the photocell which was below it gave signal to the PLC and siren

blew.

YARN CHEESE

The final output of this facility is yarn cheese which contains about 306

filaments of nylon 6 fibres. Before entering this unit we were told about the 5S

(Seiri, Seiton, Seiso, Seihetzu, Shitsuke) system that the company follows

during manufacturing. It has 5 zone heaters at 270C, 280C, 280C, 290C, 270C.

There are Dornier Machines for making yarn cheese fibre. Cooling of fibre is

done by air blown from below at 15C

TWISTING

Here mixing of two cords is done so as to increase the strength of yarn cheese

fibre to about 18 kg/cm. Belt and pulley is used to provide load for twisting.

LOOM

In this region actually the main task of producing Nylon tyre cord fabric is

produced. This is all done by Dornier looms .The loom combines the fibres by

wrap and wept in straight and transversal direction.

UTILITY DEPARTMENT

This department provides for all the air at various pressure whether it is

normal air or compressed air as well as demineralised water to different parts

of the manufacturing utility.

PTRO (Plateand Tube Reverse osmosis)


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Waste water or effluent is treated by reverse osmosis so that to reduce the

pollutant content in water to about certain level. This is done because if the

untreated water is released in atmosphere it could cause several

environmental problems. Also the water could be reused again for the

manufacturing purpose.

The water is collected in a large storage tank built outside from there the

water is passed through sand filter which removes particles upto 50 microns .

So mostly all the suspended particle is left behind. After that it is passed

through the Cardtrid filter which removes impurities upto 10 microns.

Then comes the reverse osmosis process. In this a no of filter papers are

arranged in a cylinder and this further reduces the impurity. Later on

oxygenation is done to kill microbes.

BOILERS

In this we use furnace oil as fuel. The primary oil for heating is diotherm oil and

the secondary oil for heating is sandotherm oil. The heat generated is sent

where this heat energy is required in the manufacturing complex.

ELECTRICITY

The captive power plant meets 90% of electricity requirement and rest is

supplied by state power corporation (MPCL). T here were huge 33KV

transformers to regulate power supply at 440V.

The most interesting part of the factory for mechanical students was the

backup power generation unit where huge inline diesel engines were there.

There were 5 diesel engines each with 6 cylinders and each one could generate

2.3 MW of power. These engines previously used to run on diesel but later on

they were converted to run on furnace oil too. Thus the starting of these

engines is done by diesel fuel and later on by furnace fuel is used.

The fuel consumption rate is about 350 lt. /hr. At the instant we were there,

fortunately an engine was being opened up so we were able to get a close look

at the engine. So we were given a small briefing about the engine by the chief


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engineer himself. The piston was 380mm in diameter and the length of the

stroke was 480 mm. The total requirement of the plant was 11.5 MW.

Shree Ram Fibres

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