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Summer Internship Project Report
On
ENHANCING “DESIGN DEVELOPMENT AND QUALITY
ASSURANCE” OF PRODUCTS OF AJANTA
By
Snehasis Bose 2011/02/DFT/39/K
B.Sc FT – Designing Specialization
Class of 2014
Under the Supervision of
Mr. Kailash Tripati
Footwear In-Charge
Footwear Design and Development Institute, Kolkata
In Partial Fulfillment of the Requirements for the Degree of
Bachelor of Footwear Technology – Designing Specialization
At
FOOTWEAR DESIGN & DEVELOPMENT INSTITUTE Inside Kolkata Leather Complex (Gate No. 3)
Mouza: Karaidanga, J.L No: 32 -35, Gangapur, Near Banatala,
P.S: Kolkata, District: South 24-Parganas, West Bengal - 743 502
Year – 2013
DECLARATION
Title of Project Report - Enhancing “Design Development and Quality
Assurance” of Ajanta Products
………………………………………………………………………………………
I declare
(a) That the work presented for assessment in this Summer Internship Report
is my own, that it has not previously been presented for another
assessment and that my debts (for words, data, arguments and ideas) have
been appropriately acknowledged
(b) That the work conforms to the guidelines for presentation and style set out
in the relevant documentation.
Date: …………… Snehasis Bose
2011/02/DFT/39/K
B.Sc FT – Designing, Class of 2014
CERTIFICATE
I Kailash Tripati hereby certify that Snehasis Bose student of Bachelors
of Footwear Technology at Footwear Design and Development Institute,
Kolkata, West Bengal has completed the Project Report on ―Enhancing
“Design Development and Quality Assurance” of Ajanta products, under
my guidance.
Mr. Kailash Tripati
Head of the Department - Footwear
Senior Faculty Member – FDDI
ACKNOWLEDGEMENT
Perseverance, inspiration and motivation have played a great role in the success of
any venture. It would be incomplete to submit this report without acknowledging
the people behind this endeavor and without whose support I wouldn’t have able
to achieve this. It gives me immense pleasure to express my gratitude to everyone
who shared with me their precious time and effort during the project.
First of all, I thank Ajanta – Banik Rubber Industries Pvt. Ltd. for granting me the
permission to work with the esteem organization. I am also thankful to:
Mr. Sugata Dey (Manufacturing and Operation – DGM) my industry guide, for
his patience and guidance, encouragement and for sharing his expertise in writing
this feasibility study.
Then to Mr. Kailas Tripati and Mr. Ramesh Sahoo my faculty guide for giving
their valuable time and precious knowledge for guidance of this project.
Then to Mr. Anjan Chatterjee (Designer) who assisted and taught us how to make
a feasibility study.
I thank to all the Laboratory members of Ajanta - Banik Rubber Industries Pvt.
Ltd. They guided and helped me in all possible ways they could, at every stage of
the report. I would also like to thank all the Managers, Assist. Managers,
Supervisors and staff of Banik Rubber Industries Pvt. Ltd. Who provided us all
the relevant information and their kind support on the basis of which this report
and my summer intern ship has been prepared.
Finally I thank my college Footwear Design and Development Institute, Kolkata
for having given me this opportunity to put to practice, the theoretical knowledge
that I imparted from the program.
Snehasis Bose
Footwear Design and Development Institute
Kolkata – WB
WEEKLY SCHEDULE
WEEK I (ONE)
Day 1 Monday, 1
st July Reporting to Ajanta’s Head Office, A.J.C
Bose Road for joining as a I internship
Candidate.
Day 2 Tuesday, 2nd July Reporting to Ajanta’s main factory – Abakash
Unit, Pagladanga and met Mr. S.S. Jha.
Day 3 Wednesday, 3rd July Started working with Mr. Anjan as a
designing team worker.
Day 4 Thursday, 4th July Duplicated some production patterns for the
need of production.
Day 5 Friday, 5th July Duplicated some production patterns for the
need of production.
Day 6 Saturday, 6th July Duplicated some production patterns for the
need of production.
Day 7 Sunday, 7th July HOLI DAY
WEEK II (TWO)
Day 8 Monday, 8th July Designing new
sample footwear.
Gathering production
knowledge in EVA
Dept.
Day 9 Tuesday, 9th July Designing new
sample footwear.
Gathering production
knowledge in EVA
Dept.
Day 10 Wednesday, 10th July Designing new
sample footwear.
Gathering production
knowledge in EVA
Dept.
Day 11 Thursday, 11th July Designing new
sample footwear.
Understanding the
various compounds
and machine’s used.
Day 12 Friday, 12th July Absent Absent
Day 13 Saturday, 13th July Designing new
sample footwear.
Understanding the
whole production
planning, process and
the finishing process
Day 14 Sunday, 14th July HOLI DAY HOLI DAY
WEEK III (THREE)
Day 15 Monday, 15th July Gathering production
knowledge in PVC
Department.
Designing Men’s
Sandals (Synthetic
Upper with PU
Bottom)
Day 16 Tuesday, 16th July Gathering production
knowledge in PVC
Department.
Designing Men’s
Sandals (Synthetic
Upper with PU
Bottom)
Day 17 Wednesday, 17th July Gathering production
knowledge in PVC
Department.
Designing Men’s
Sandals (Synthetic
Upper with PU
Bottom)
Day 18 Thursday, 18th July Gathering production
knowledge in PVC
Department.
Designing Men’s
Sandals (Synthetic
Upper with PU
Bottom)
Day 19 Friday, 19th July Gathering
Information from the
in house Testing Lab.
Designing Men’s
Sandals (Synthetic
Upper with PU
Bottom)
Day 20 Saturday, 20th July Gathering
Information from the
in house Testing Lab.
Designing Men’s
Sandals (Synthetic
Upper with PU
Bottom)
Day 21 Sunday, 21st July HOLI DAY HOLI DAY
WEEK IV (FOUR)
Day 22 Monday, 15th July Gathering production
knowledge in PU
Department.
Designing Ladies
Sandals with PU
Construction.
Day 23 Tuesday, 16th July Gathering production
knowledge in PU
Department.
Designing Ladies
Sandals with PU
Construction.
Day 24 Wednesday, 17th July Knowing the
Packaging and
Dispatch process.
Designing Ladies
Sandals with PU
Construction.
Day 25 Thursday, 18th July Identifying all the
compounds used in
all the chemical
process and making a
note upon it with the
ratio of mixture and
process.
Designing Ladies
Sandals with PU
Construction.
Day 26 Friday, 19th July Gathering the
Management
strategies and Human
Resource Process of
Ajanta.
Designing Ladies
Sandals with PU
Construction.
Day 27 Saturday, 20th July Understanding the
costing theory of a
product made.
Designing Ladies
Sandals with PU
Construction.
In a whole it was a life time opportunity for me to gather the whole information
from the starting to the end means from the idea to the designing and from the
design itself to the real hand product. Really it was a amazing experience where I
got to know about the various kind of construction used in these days with a large
variety of upper material with lots of accessories and the bottoming was also
amazing.
Rather than the production, I understood the various departments working there
and their importance. Every department was related to another means everyone is
connected in a long chain brother.
Ajanta is one of the leading footwear brands in all over INDIA. They are playing
a huge role like they are proving the best quality footwear to the Indian consumers
in a very nominal cost so that everyone can afford the product.
There were various departments like the Costing Department, Accounts
Department, Testing Lab, HR Department, Technical Department, Planning
Department, Machine Department, Store Department, Chemical Department,
Security Department, Designing Department, Product Development Department,
Packing Department, Dispatch Department, Machine Department, Audit
Department, Quality Department and some other Departments.
I understood that every Department is playing their individual role which is very
important to run the production in the factory. Every individual department is
individually playing their role with reference to the other Departments which
clearly means a TEAM WORK.
Being a student of Footwear Technology specialized in Footwear Designing I laid
the main emphasis on the various construction of footwear and the designing
basics and the kind of material used in making. Ajanta is mainly famous for its
open footwear segment.
The various constructions are…
Stuck on Construction
PU Construction
PVC
EVA
This internship report will be life time valuable for me as it contain the various
researches done by me while working there as a internship candidate.
It was really a great opportunity for me to understand the whole process in front
of the eyes even practically. Thanks to Ajanta for giving me the opportunity to
pursue this internship.
TABLE OF CONTENTS
Ajanta – Banik Rubber Industries Pvt. Ltd
Products of Ajanta
Significance of the Study
Stuck on Construction
PU Pouring Construction
PVC Injection Construction
EVA Injection Construction
Few samples made by myself while interning
Company Profile
Internship Activities
An Assessment of the Internship
Conclusions of the Report
AJANTA - Banik Rubber Industries (India) Pvt. Ltd:
The journey began in 1956. This was the year, when Late Sri Rabindranath Banik
established a Hawai manufacturing factory at Madhyamgram, a small, sleepy
town in West Bengal. Since then, Ajanta has traversed a long journey, harnessing
traditional skill and workmanship with state of the art technology, to set
benchmarks in foot care solutions.
From the very beginning the emphasis had been on “superior quality products at
value for money”. Ajanta has lived up to the trust of the people throughout the
journey expanding its portfolio and diversifying its product range, adding delight
by exceeding expectations of the customers.
Today the repertoire of products includes all conceivable footwear and related
accessories for people across different cross sections of the society. High quality
products from casual wear to formal wear using a wide range of materials like
rubber, PU, EVA, PVC, canvas and leather.
From sourcing to finishing, each shoe is manufactured entirely in the company’s
own factories using expert resources and in- house R&D. The enormous
production capacity of over million pairs of footwear per day is complemented
with a strong distribution network of dealers, stockists, retail showrooms and
exclusive outlets. The company’s extensive reach covers interiors of entire West
Bengal, almost all of North Eastern states, which include Assam, Tripura,
Meghalaya, Nagaland and Mizoram, besides Bihar, Jharkhand, Orissa,
Chhattisgarh, M.P. Rajasthan and Karnataka.
Ajanta is one of the leader brands in Eastern India. It is the No.1 brand in Hawai
and School Shoes in West Bengal.
These days Ajanta has introduced a number of brands like …
PRODUCTS OF AJANTA
MEN'S SANDAL
We are involved in offering a designer collection of men's sandals. Creatively
designed and developed, these sandals are available in variety of attractive
designs and styles. We provide our men's sandal in attractive colors and
creative designs.
Stylish Men's Sandal
Men's Leather Sandal
PRODUCTS OF AJANTA
MEN'S FOOTWEAR
Counted as one of the prominent manufacturer, distributor, retailer, exporter,
trader and supplier, we are involved in offering a unique range of Men's
Footwear. These are extensively demanded by style lovers, owing to excellent
finish, stylish appeal and durability.
PRODUCTS OF AJANTA
MEN'S SLIPPERS
We excel in offering a designer collection of Men's Slippers. These are widely
applauded for unique designs, durability and high comfort level. Demands of
these Men's Slipper are increasing day by day, owing to skin friendly quality
and elegant designs. These are offered in various range and striking color
combinations.
PRODUCTS OF AJANTA
LADIES SANDALS
We are one-step ahead of our competitors in offering a unique range of Ladies
Sandals. Following the exact specifications of clients, we provide them in
various attractive range and models. One can also avail these sandals in
customized designs and colors as per their specific demands.
PRODUCTS OF AJANTA
LADIES FOOTWEAR
Enriched with vast industrial experience, we are involved in offering a
designer collection of Ladies Footwear. Our footwear are praised by various
fashion lovers, owing to stylish appeal and excellent finish. Besides,
manufactured from optimum quality fabrics, this footwear provides high
warmth to the wearer.
PRODUCTS OF AJANTA
LADIES SLIPPERS
We are offering a qualitative assortment of Ladies Slippers. These Ladies
Slippers are extensively admired owing to durable performance and wear &
tear resistance. Our Ladies Slipper are acclaimed for their high quality and
perfect color combinations. Customers can avail these in various exclusive
range.
PRODUCTS OF AJANTA
SCHOOL FOOTWEAR
Keeping in mind the precise demands of clients, we offer a unique range of
School Footwear. Elegantly designed our footwear are available in various
attractive designs, styles and all standard sizes.
PRODUCTS OF AJANTA
KIDS SANDAL
We are one-step ahead in manufacturing, trading and supplying a vivid array
of Kids Sandals. These sandals are exclusively designed following latest
fashion trend. With the availability in all standard sizes and striking colors,
these sandals are extensively admired by various style lovers.
PRODUCTS OF AJANTA
BATHROOM SLIPPER
We hold expertise in offering a wide range of Bathroom Slipper. These
Bathroom Slippers are offered in various varieties, designs and styles
following the specific demands of clients. Our Bathroom Slippers are
manufactured from optimum quality rubber and other raw materials
which make these durable and ensure consistent performance
PU (POLY URETHANE)
It is invented by the German chemist “Friedrich Bayer” in 1937.
Raw materials used in PU are Isocynates and Polyol. Polyol can be also known as
Polyesters and it is a reacting material.
PREPARATION OF PU:
1.) The bulk polymer products are made using mixing chambers.
2.) Polymers are exposed to various processing steps at heat 2300
C.
3.) Polymers which are formed in the reaction vessels; they are natural
white in color. Therefore colourance may be added up to change the
appearance as per the customer’s demand.
4.) Finally, the polymer is transformed into final product PU.
METHOD:
1.) To produce PU condensation reaction is performed.
2.) Polyol (Polyester) is used as a reacting agent in the production of PU.
3.) Polymers are light liquid in large stainless steel tanks.
4.) These tanks are equipped with agitators to keep the material fluid.
5.) Meaturing device is attached to the each tank so that the appropriate
amount of reactive materials can be pumped out.
6.) The reactive materials are passed through the heat chamber as they are
pumped into the pipes.
7.) From the pipes, it travels through the chambers of designed moulds.
8.) Dwell time is given as per necessary.
9.) As per that the mould chambers are carried to a freezing point of -30
C.
10.) Finally, the product PU sole is prepared.
ADVANTAGES OF PU:
1.) Sufficient, light weight.
2.) Have good oil resistance.
3.) It is much lighter than PVC.
4.) Flexible resistance is more.
5.) Durability is more.
DISADVANTAGES OF PU:
1.) Cost is very high.
2.) Poor fire and heat resistance.
3.) Cannot be recycled.
PVC (POLY VINYL CHLORIDE)
It is synthetic sole material.
1.) PVC is one of the molded plastic which makes a soling material.
2.) It is used in thermo plastic form.
3.) When ethane is heated under the pressure with chlorine gas at 3500
C
temperatures, Vinyl chloride is produced.
4.) We obtain vinyl chloride is a colorless gas and PVC is made by the
polymerization of the vinyl chloride.
5.) The vinyl chloride under a pressure of 6 bar is mixed with small
quantity of polymerization and water is added with the temperature of
800
C.
6.) After 15 hours of heating 90% of the monomer has been converted to
polymer. The solid PVC particles are left suspended in water. These
are then filtered-off and dried in rotator drier. These PVC grains are
very hard and clearly it can’t be used directly for footwear. By
compounding reaction, it gets softer and more flexible.
ADVANTAGES OF PVC:
1.) Cheapest unit sole.
2.) Oil resistance is more.
3.) Abrasion resistance is more.
DISADVANTAGES OF PVC:
1.) Poor soil resistance
2.) Less flexible resistance
3.) Less durability
EVA (ETHYL VINYL ACETATE)
1.) EVA is a random co-polymer of ethane and vinyl acetate monomers.
Its pure form is soft plastic material on temperature.
2.) EVA resins with vinyl acetate content of 15 – 28% are preferred for
footwear purpose to look better.
3.) Flexibility resilience and toughness all increases with adding vinyl
acetate.
4.) As like PVC; EVA resins are compounded with fillers, pigments
and blowing agents.
5.) Then these are blended with natural rubber and polyethene.
6.) In this polymer, Sulphur is not suitable for cross-linking agents but
peroxide will effectively cross-link with EVA.
ADVANTAGES OF EVA:
1.) By expanding it can be lower in density than other types of soling
material.
2.) Expanded EVA has good shock absorption properties.
3.) Good oil resistance.
4.) Good low temperature flex, crack resistance.
DISADVANTAGES OF EVA:
1.) Material cost is so high.
2.) Sole units must be built-up by bonding sheets together then trimming
and shaping them.
3.) Wear resistance is poor.
4.) It has poor split- tear resistance.
STUCK ON CONSTRUCTION
Ajanta group of companies also uses this process for making of some sleepers.
Stuck on construction is also very much known as cemented construction or the
compo process. Here in this process the out sole is attached with the upper along
with insole with the help of Cement or adhesive. These adhesives are very power
full in nature, these works only when it is been reactivated with the help of some
flash reactivation. These are the few samples which I have seen in the production.
FEW SAMPLES MADE BY MYSELF WHILE INTERNING
BANIK RUBBER INDUSTRIES (INDIA) PRIVATE LIMITED
Established in the year 1956 at Kolkata, Banik Rubber Industries (India) Private
Limited is engaged into manufacturing, supplying, exporting, distributing,
retailing and trading of a wide range of Footwear for all age groups. Exquisitely
designed, these products are attractive and comfortable to wear. An impeccable
range of products is offered that is quality tested and cost effective. Moreover,
reliability, durability and comfort are the distinguishing features of our products.
Attainment of complete customer satisfaction is the key behind our success and
that reflects through huge supply orders, we regularly get from our prestigious
customers. Products offered by us are available at pocket friendly prices through
easy modes of payment. We offer complete transparency in business dealings and
that has earned us huge admiration and confidence of customers. A detailed
survey of customer’s demands and requirements is conducted to offer a range of
better products that has to offer something new every time.
Ajanta have more than 100 owned retail stores throughout the country. We also
possess 6 factories as a part of our infrastructure.
Basic Information
Business Type Manufacturer
Exporter
Supplier
Distributor
Trader
Retailer
Ownership & Capital
Year of Establishment 1956
Ownership Type Private Limited Company
Trade & Market
Annual Turnover Rs. 100 - 500 Crore (or US$ 20 Mn - 100 Mn Approx.)
Team & Staff
Total Number of Employees 101 to 500 People
Statutory Profile
TIN No. / VAT No. 19200181068
Infrastructure
Ajanta’s sophisticated facilities are outfitted with all the requisite tools driven by
modern technology. Bulk orders of customers are processed with alacrity to
assure timely delivery of our products. We have installed advanced testing
facilities to ensure the delivery of quality approved products that are reliable and
cost effective. A capacious warehouse enables safe and streamlined stocking of
the finished products, setting high storage standards.
Quality
Ajanta’s sophisticated facilities are outfitted with all the requisite tools driven by
modern technology. Bulk orders of customers are processed with alacrity to
assure timely delivery of our products. We have installed advanced testing
facilities to ensure the delivery of quality approved products that are reliable and
cost effective. A capacious warehouse enables safe and streamlined stocking of
the finished products, setting high storage standards.
Banik Rubber Industries (India) Private Limited Ms. S. Banik (Director) / Mr. T. Sarkar (Export Manager)
'Ajanta House', 79/2, A. J. C. Bose Road
Kolkata - 700014, West Bengal, India
http://ajanta.biz/
INTERNSHIP ACTIVITIES
Day 1: I reported to head office of Ajanta group of companies and met the HR out
there. Then they took a formal interview of us and allotted us our work.
Day 2: Then I reported to the Ajanta’s main factory at Abakash, Pagladanga and
met Mr. S.S. Jha. He co operated with us a lot and introduced us with the various
team members working there.
Day 3: Started working as a internship candidate in the designing dept. with Mr.
Anjan who is a Designer at Ajanta.
Day 4: Got the work of duplicating patterns which will be further used in
production purpose.
Day 5 & Day 6: Continued the same work of duplicating Patterns.
Day 8 & Day 9: Started going to the production floor. First I went to the floor
where EVA Sole and shoes are being manufactured. In the second Half started
doing designing of own concept.
Day 10: Gathered information about the machines used in dept., Current
consumption, no. of workers working there, working chain procedure.
Day 11: Designing new samples of gent’s collection. And finding the various
compounds used in the EVA production.
Day 13: Understanding the various production process and management
strategies.
Day 15 & Day 16: Understanding the PVC department and along side designing
the men’s sandal with PU Bottom.
Day 19 & Day 20: Understanding the various testing methods at the testing lab.
Day 22 & Day 23: Understanding the PU dept. and designing the ladies sandal.
Day 24: Understanding the Packaging and dispatch department.
Day 26: Understanding the human resource policies and management strategies.
Day 27: Understanding the costing theory of products and MRP.
AN ASSESMENT OF THE INTERNSHIP
Before I went to do the internship I was theoretically sounded but I didn’t have
any practical knowledge. It is all for Ajanta group to companies who allowed me
to out the internship at their farm.
Theoretical knowledge is some else and practical knowledge is something else.
From the book or the classroom knowledge we can have the basic idea how it is
but in real life it’s very struggling.
I under stood how the team work plays its role for the running of a production
unit.
I under stood how the management people is handling the whole unit and
manipulating all the team members. I was really a very struggling job with lots
of challenges.
I understood the industry designing process from the very beginning to the end
means where the product is available to the normal customers.
As Ajanta is having more or less all the different types of construction I gathered
more or less knowledge of all the construction.
Even I understood the different stages of testing of a product or the material. As
the unit itself has its testing centre and expertise engineers who are always
performing their expertise work.
The planning department plays the most important role as doing production in
planning way is really very important otherwise everything is gone a mess up.
Machine department and maintenance dept. also plays a very imp role.
Special thanks to Mr. S.S. Jha who helped me a lot to understand the company
prospect, Human Resource Process and the management strategies.
Thanks to the Costing Department also who co operated with me to understand
the policies and the process to make out the costing of a product.
As Ajanta is itself a retailer and distributer so I understood how the retailing
process that how they are managing.
The most important thing which I noticed there in the factory that they laid a
huge emphasis on the packaging and finishing of the product which finally
increases the aesthetic value of the product.
Huge chemicals are used in the plant for the production of soling material. I
gathered hand full information regarding the chemicals used in there.
The security system is quite enriched there which is very important.
Punctuality and formality is practiced inside the factory very which finally brings
a touch of corporate inside the plant.
Exact accessories are being given to the labors for their safety like helmet,
globs,ets. This is quite impressive.
Even the plant has its own canteen system which is serving food time to time
finally which in turn helps the human lively hood.
Finally I will like to say that Ajanta is a company for Mankind.
CONCLUSION OF THE REPORT
As the other internship report contains a long paragraph at the conclusion part I
won’t do the same but I will like to say a few lines.
Ajanta is the company who has helped me to gather the practical knowledge by
giving me the internship permission. For the first time I saw the practical
industrial life and how does it works. It was really amazing to know all about the
industry process, I went to each and every department and tried to understand the
work. These days Ajanta is growing towards a corporate and employing lot of
peoples which in turns helping Bengal to earn revenue. I wish Ajanta good luck
for doing such a great job and I will happy to be a part of Ajanta’s team so that I
can do the same prestigious task.
