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    Rang Bharti Presentation Group-2

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    Poonam Dalal
    Rang Bharti is a leading decorative paint company in India with 40% market share. It operates a plant in Gomia that produces resins, emulsions, and various paint types including distemper, water based, and solvent based paints. The plant faces challenges in meeting production targets across its product lines due to complexities from increased product variety and constraints in manufacturing capacity and cycle times. Opportunities exist to reduce inventory, streamline processes, increase shifts and throughput to better meet customer demand.

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    Rang Bharti Presentation Group-2

    Uploaded by

    Poonam Dalal
    94 views18 pages
    Rang Bharti is a leading decorative paint company in India with 40% market share. It operates a plant in Gomia that produces resins, emulsions, and various paint types including distemper, water based, and solvent based paints. The plant faces challenges in meeting production targets across its product lines due to complexities from increased product variety and constraints in manufacturing capacity and cycle times. Opportunities exist to reduce inventory, streamline processes, increase shifts and throughput to better meet customer demand.

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    Rang Bharti is a leading decorative paint company in India with 40% market share. It operates a plant in Gomia that produces resins, emulsions, and various paint types including distemper, water based, and solvent based paints. The plant faces challenges in meeting production targets across its product lines due to complexities from increased product variety and constraints in manufacturing capacity and cycle times. Opportunities exist to reduce inventory, streamline processes, increase shifts and throughput to better meet customer demand.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    94 views18 pages

    Rang Bharti Presentation Group-2

    Uploaded by

    Poonam Dalal
    Rang Bharti is a leading decorative paint company in India with 40% market share. It operates a plant in Gomia that produces resins, emulsions, and various paint types including distemper, water based, and solvent based paints. The plant faces challenges in meeting production targets across its product lines due to complexities from increased product variety and constraints in manufacturing capacity and cycle times. Opportunities exist to reduce inventory, streamline processes, increase shifts and throughput to better meet customer demand.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 18

    Rang Bharti

    Gomia Plant

    Case Analysis by Group 2

    INTRODUCTION
    Rang Bharati was a leader in Decorative domestic paint
    with 40 % of market share

    Company produced around 5000 SKUs

    Company set up Gomia plant in 1981 with capacity of


    28000 MT which was upgraded to 40000 MT

    Gomia plant was also producing Resins


    Key ingredients of various paints

    and Emulsions

    CHALLENGE
    Voice of Managing Director We will continuously upgrade our

    manufacturing and R&D capabilities so that we can continue


    to provide paint for every surface

    Worry of Plant Manager Was Gomia plant competitive?? Manufacturing operation has become more complex due to

    increase in product variety.

    PRODUCT PROFILE
    Distempe r Water Based Paint Solvent Based Paint

    KSD

    KAD

    GSE

    KPS

    BulB ul

    Primer

    RP

    REX

    Super b

    SD

    NSA P

    PROCESS FLOW : GOMIA PLANT


    Resin House Resin Storage

    Raw Material Warehouse Paint Block Finished Goods Warehouse

    Solvent Storage

    Packing Material Stores

    RESIN HOUSE
    Raw Materials Oil Penta & Other additives Total Grades 19 nos

    4 grades Caters 90% of SB paints


    15 grades Caters 10% of Production Plan SB paint 18400 KL per year Resin required - 12867 KL per year Monthly production plan 1073.3 KL

    RESIN HOUSE
    Nos 6 Capacity 60 MT Time 24-36 Hrs Nos 9 Capacity 269 KL Time 4 Hrs Nos 2 (23 plate) Nos 5 (11 Plate) Time 6 Hrs/ 8 Hrs Nos 31 Cap 5180 KL

    RM

    Reactor

    Cooler

    Blender

    Filter

    Storag e

    Cycle time 24 - 36 hrs (considered 36 hrs for calculation) Throughput time 48 hrs Wt. average production rate of reactors 18.95 * 6 = 113.7 KL / batch Batches possible/ month 20 batch Asking rate of production/ month 9 batch

    RESIN HOUSE
    No constraints to meet target production Inventory of 300 KL costing Rs 90 Lacs can be reduced Variable reactor operation time can be reduced by training to operators

    DISTEMPER LINE
    Raw Materials Liquid Ingredients Water, Dispersing Agent, Surfactant, thickener etc Powder Ingredients Tinter or Coloring agent etc Total Grades 2 Production Plan Distemper paint 14000 KL per year Monthly Requirement 1167 KL

    DISTEMPER LINE
    Charging Time -0.5 Hr Liquid Ingredient Emulsion Inspection Time 1 Hr

    Powder Ingredient Charging Time -0.5 Hr

    PUG MILL

    Storag e

    Holding Tanks Nos - 12 Total Capacity 26 KL

    Nos - 6 Total Capacity 13 MT Processing Time 2 Hr

    Cycle time 4 hrs Throughput time 8 hrs

    PACKING M/C

    Nos - 7 Packing Time 4 Hrs

    Production rate - 13 KL / batch


    Batches possible/ month 119 batch Asking rate of production/ month 90 batch

    DISTEMPER LINE
    No constraints to meet target production Cycle time for 29 batch i.e. 116 Hrs/ month to be utilized for grade c/o including cleaning 29 changeover are possible, considering holding vessel cleaning is parallel to Pug mill cleaning / charging

    WATER BASED PAINT LINE


    Total Grades 5

    Product Shade Batches - 60


    Production Plan WB paint 5600 KL per year Monthly Requirement 466 KL

    WATER BASED PAINT LINE


    Raw Material TSD
    Twin Shaft Dispenser

    Approval Time - 8 Hrs

    Storag e

    Holding Tanks Nos - 12 Total Capacity 62 KL

    3 No. for Bazaar Paints 2 No. for Premium Super Paint

    Total Capacity 2 KL/ TSD


    Processing Time 6 hrs

    Cycle time 14 hrs Throughput time 22 hrs Production rate - 10 KL / batch Batches possible/ month 34 batch Asking rate of production/ month 47 batch
    PACKING M/C

    Packing Time 4 - 8 Hrs Nos - 5

    WATER BASED PAINT LINE


    Production with Current constraints of days of working is 73% of target, without any grade changeover Target can be met by working 357 day a year with 3 shifts with available grade changeover time of 60 hrs per month i.e. for 15 grade changeover. Time taken for approval of batch to be reduced Additional TSD to be added to avoid waiting time of 8 hrs

    SOLVENT BASED PAINT PLANT


    Total Grades 4

    Color Stream - 5
    Production Plan SB paint 18400 KL per year Monthly Requirement 1534 KL

    SOLVENT BASED PAINT LINE


    Raw Material

    Nos - 44 Capacity 374KL Flow Rate 10 Lt/Min Processing Time 3.3 Hr

    Total 5 independent sets for each color


    Storage

    TSD
    Twin Shaft Dispenser

    Sand Mill
    Nos - 8 No. Each dedicated for color Stream

    Final Mixer

    Nos 5 Capacity 2 KL/ TSD

    Nos 10 Capacity 20 KL

    Processing Time 6 hrs

    Flow Rate 3.5 Lt/Min


    Processing time 9.5 Hrs

    Approval Time - 8 Hrs Adjustment Time 8 Hrs

    Cycle time 6 hrs Throughput time 96 hrs Production rate - 10 KL / batch Batches possible/ month 79 batch Asking rate of production/ month 153 batch
    PACKING M/C
    Nos 9 Time - 4 8 Hrs

    SOLVENT BASED PAINT PLANT


    Production with Current constraints of days of working is 52% of target, without any grade changeover 77 % of Target can be met by working 357 day a year with 3 shifts No of holding tank & Sand mill need to be increased to meet target Total throughput time need to be reduced by possible reduction in

    approval time

    Thank You

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