Winter Internship at Apollo Tyres, Chalakkudy

INTRODUCTIONINTRODUCTION

►APOLLO TYRES – A BRIEF FORAYAPOLLO TYRES – A BRIEF FORAY►1515THTH IN THE GLOBAL TYRE INDUSTRY IN THE GLOBAL TYRE INDUSTRY►LEADERSHIP IN COMMERCIAL VEHICLE LEADERSHIP IN COMMERCIAL VEHICLE

SEGMENT IN INDIA SEGMENT IN INDIA ►PERAMBRA PLANT-IN FOCUSPERAMBRA PLANT-IN FOCUS►LARGEST TRUCK TYRE PLANT IN INDIA.LARGEST TRUCK TYRE PLANT IN INDIA.

THE BIAS TYRE THE BIAS TYRE MANUFACTURING PROCESSMANUFACTURING PROCESS

1)MIXING1)MIXING►CARBON, PROCESS OIL, RUBBER, CARBON, PROCESS OIL, RUBBER,

CHEMICALS ETCCHEMICALS ETC►4 BANBURY MIXERS4 BANBURY MIXERS►MASTER BATCH AND FINAL BATCHMASTER BATCH AND FINAL BATCH►RUBBER COMPOUNDS REQD. FOR RUBBER COMPOUNDS REQD. FOR

EXTRUSION,CALENDARING,TREADS,SIEXTRUSION,CALENDARING,TREADS,SIDEWALLS, BEAD ETC.DEWALLS, BEAD ETC.

PROCESSES UNDER DIV. APROCESSES UNDER DIV. A

2) DIPPING2) DIPPING►TO INCREASE THE BONDABILITY WITH TO INCREASE THE BONDABILITY WITH

THE RUBBER COMPOUNDSTHE RUBBER COMPOUNDS►CONTINUOUS OPERATION FOR 6 DAYS- CONTINUOUS OPERATION FOR 6 DAYS-

1 DAY FOR PREVENTIVE MAINTENANCE1 DAY FOR PREVENTIVE MAINTENANCE►13000 METRES IN 8 HOURS.13000 METRES IN 8 HOURS.


3) CALENDARING3) CALENDARING►THE DIPPED FABRIC COATED WITH THE DIPPED FABRIC COATED WITH

RUBBER COMPOUNDS ON BOTH SIDES RUBBER COMPOUNDS ON BOTH SIDES SIMULTANEOUSLY.SIMULTANEOUSLY.

►23800 METRES IN 8 HOURS23800 METRES IN 8 HOURS►UNREALISED CAPACITY.UNREALISED CAPACITY.


4) EXTRUSION4) EXTRUSION►SIDEWALLS, TREADS ETC.SIDEWALLS, TREADS ETC.►2 DIFFERENT RUBBER COMPOUNDS 2 DIFFERENT RUBBER COMPOUNDS

CAN BE EXTRUDED.CAN BE EXTRUDED.►1500 SIDEWALLS IN EIGHT HOURS.2 1500 SIDEWALLS IN EIGHT HOURS.2

SIDEWALLS/TYRESIDEWALLS/TYRE►OUTPUT=1920 EQUIVALENTOUTPUT=1920 EQUIVALENT


5) SQUEEGE APPLICATION5) SQUEEGE APPLICATION►AN EXTRA COAT OF RUBBER AN EXTRA COAT OF RUBBER

COMPOUNDS APPLIED TO COMPOUNDS APPLIED TO CALENDARED FABRICCALENDARED FABRIC

►THE OUTPUT IS 192 ROLLS IN A SHIFTTHE OUTPUT IS 192 ROLLS IN A SHIFT►THE FABRIC FOR 6 TYRES OBTAINED THE FABRIC FOR 6 TYRES OBTAINED

FROM 1 ROLL.FROM 1 ROLL.


6) CHAFERS, FLIPPERS, BREAKERS6) CHAFERS, FLIPPERS, BREAKERS►6150 BREAKERS IN EIGHT HOURS6150 BREAKERS IN EIGHT HOURS►152 ROLLS OF FLIPPERS AND CHAFERS 152 ROLLS OF FLIPPERS AND CHAFERS

EACH IN 8 HOURSEACH IN 8 HOURS►COMPONENTS FOR 18 TYRES COMPONENTS FOR 18 TYRES

OBTAINED PER ROLL.OBTAINED PER ROLL.

PROCESSES UNDER DIV. BPROCESSES UNDER DIV. B

7) BIAS CUTTING7) BIAS CUTTING►8 PLIES REQUIRED PER TYRE8 PLIES REQUIRED PER TYRE►THE CALENDARED FABRIC CUT TO THE CALENDARED FABRIC CUT TO

REQUIRED WIDTH AND ANGLEREQUIRED WIDTH AND ANGLE►PLIES FOR 6 TYRES OUT IN EVERY 25 PLIES FOR 6 TYRES OUT IN EVERY 25

SECONDSSECONDS


8) BEAD WINDING, FLIPPING & APEXING8) BEAD WINDING, FLIPPING & APEXING►BEAD- TO ANCHOR THE TYRE WHILE BEAD- TO ANCHOR THE TYRE WHILE

MOUNTING THE RIM OF THE VEHICLESMOUNTING THE RIM OF THE VEHICLES►THE BEAD WIRE IS COATED WITH THE BEAD WIRE IS COATED WITH

RUBBER COMPOUNDSRUBBER COMPOUNDS►A SECOND COAT OF RUBBER A SECOND COAT OF RUBBER

COMPOUNDSCOMPOUNDS►COATED WITH CALENDARED FABRICCOATED WITH CALENDARED FABRIC


►4 BEADS REQUIRED PER TYRE.4 BEADS REQUIRED PER TYRE.►5100 BEADS IN EIGHT HOURS IN 4 5100 BEADS IN EIGHT HOURS IN 4

MACHINESMACHINES


►TYRE BUILDINGTYRE BUILDING►TREAD, SIDEWALL, 8 PLIES, CHAFERS, TREAD, SIDEWALL, 8 PLIES, CHAFERS,

BREAKERS, FLIPPERSBREAKERS, FLIPPERS►GREEN TYRE IS MADE ON A GREEN TYRE IS MADE ON A

COLLAPSIBLE, ROTATING DRUM.COLLAPSIBLE, ROTATING DRUM.

PROCESSES UNDER DIV. CPROCESSES UNDER DIV. C

►TYRE CURING AND PCITYRE CURING AND PCI►10 ROUNDS OF CURING IN 8 HOURS10 ROUNDS OF CURING IN 8 HOURS►92 METRIC TONS IN EIGHT HOURS92 METRIC TONS IN EIGHT HOURS►48 CAVITIES FOR TRUCK TYRES48 CAVITIES FOR TRUCK TYRES►43 MINUTES/TRUCK TYRE43 MINUTES/TRUCK TYRE► NO. OF PCI PRESSES= 2* NO. OF NO. OF PCI PRESSES= 2* NO. OF

CURING PRESSESCURING PRESSES

PROCESSES UNDER DIV. CPROCESSES UNDER DIV. C

►FINAL FINISH, INSPECTION AND FINAL FINISH, INSPECTION AND WAREHOUSINGWAREHOUSING

PARETO ANALYSIS- PARETO ANALYSIS- DOWNTIMEDOWNTIME

►THUMB RULE- 80% OF THE PROBLEMS THUMB RULE- 80% OF THE PROBLEMS ARE CAUSED BY THE 20% OF THE ARE CAUSED BY THE 20% OF THE REASONSREASONS

►HENCE, AFTER ANALYZING, THOSE HENCE, AFTER ANALYZING, THOSE 20% ARE ADDRESSED.20% ARE ADDRESSED.

pareto chart- downtime analysis- four roll calendar

4

1.9 1.9 1.81

0.237.03

54.62

72.21

88.8798.12 99.97

00.51

1.52

2.53

3.54

4.5

020406080100120

%

PLANT EFFICIENCIESPLANT EFFICIENCIES

►POWER CONSUMPTION (KWH/KG OF POWER CONSUMPTION (KWH/KG OF CURED TYRE)CURED TYRE)

►REPAIR AND MAINTENANCE (Rs./KG OF REPAIR AND MAINTENANCE (Rs./KG OF CURED TYRE)CURED TYRE)

►TYRE SCRAP (% OF CURED TYRE TYRE SCRAP (% OF CURED TYRE WEIGHT)WEIGHT)

►BEAD SCRAP ( SAME AS ABOVE)BEAD SCRAP ( SAME AS ABOVE)

PLANT EFFICIENCIESPLANT EFFICIENCIES

►COMPOUND SCRAP (SAME AS BEFORE)COMPOUND SCRAP (SAME AS BEFORE)►NAPHTHA CONSUMPTION (LITRES/KG NAPHTHA CONSUMPTION (LITRES/KG

OF CURED TYRE)OF CURED TYRE)

►FUEL CONSUMPTION (LITRES/KG OF FUEL CONSUMPTION (LITRES/KG OF CURED TYRE)CURED TYRE)

PLANT QUALITY ASSESSMENTPLANT QUALITY ASSESSMENT

►TO ESTABLISH A UNIVERSAL SCALE OF TO ESTABLISH A UNIVERSAL SCALE OF COMPARISON FOR MANUFACTURING COMPARISON FOR MANUFACTURING EXCELLENCE AMONG VARIOUS TYRE EXCELLENCE AMONG VARIOUS TYRE MANUFACTURING UNITS OF ATL.MANUFACTURING UNITS OF ATL.


►11 FOCUS AREAS ARE 11 FOCUS AREAS ARE ►1) OPERATIONS 1) OPERATIONS ►2) MAINTENANCE & 2) MAINTENANCE &

INSTRUMENTATIONINSTRUMENTATION►3) HOUSEKEEPING 3) HOUSEKEEPING ►4) EMPLOYEE SKILLS AND 4) EMPLOYEE SKILLS AND

SATISFACTIONSATISFACTION►5) RAW MATERIALS5) RAW MATERIALS


►6) MATERIAL HANDLING AND LAYOUT 6) MATERIAL HANDLING AND LAYOUT ►7) QUALITY MANAGEMENT7) QUALITY MANAGEMENT►8) SAFETY, HYGIENE & POLLUTION 8) SAFETY, HYGIENE & POLLUTION

CONTROL CONTROL ►9) VISUAL MANAGEMENT 9) VISUAL MANAGEMENT ►10) FG DESPATCH 10) FG DESPATCH ►11) CUSTOMER FOCUS.11) CUSTOMER FOCUS.


►13 CELLS UNDER ASSESSMENT 13 CELLS UNDER ASSESSMENT ►1) RMS 1) RMS ►2) DIPPING 2) DIPPING ►3) CALENDARING 3) CALENDARING ►4) MIXING 4) MIXING ►5) EXTRUDING 5) EXTRUDING ►6) BIAS CUTTING 6) BIAS CUTTING


►7) BEAD WINDING 7) BEAD WINDING ►8) TYRE BUILDING 8) TYRE BUILDING ►9) TYRE CURING9) TYRE CURING► 10) FINAL FINISH 10) FINAL FINISH ►11) FGS 11) FGS ►12) ENGG. 12) ENGG. ►13) HR.13) HR.


►All parameters are graded in to 5 All parameters are graded in to 5 levels.levels.

►Score 1:- Existence of system as Score 1:- Existence of system as documented policy (slips or logbooks) documented policy (slips or logbooks) with demonstrable support ensuring with demonstrable support ensuring execution. The score is given based on execution. The score is given based on the fact that the knowledge of system the fact that the knowledge of system exists within the assessed area.exists within the assessed area.


►Score 2:- System is followed at many Score 2:- System is followed at many places, which covers about 50% or places, which covers about 50% or more of applicable areas. This score is more of applicable areas. This score is given based on the fact that the given based on the fact that the system is developing in the assessed system is developing in the assessed area and it is consistently followed.area and it is consistently followed.


►Score 3:- Roles and responsibilities for Score 3:- Roles and responsibilities for various aspects of systems are various aspects of systems are clarified and communicated across. clarified and communicated across. This score is given based on the fact This score is given based on the fact that the triple roles in the system that the triple roles in the system (customer, supplier and processor of (customer, supplier and processor of information, product or services) are information, product or services) are clear to all the concerned employees.clear to all the concerned employees.


►Score 4:- Gaps in performance and Score 4:- Gaps in performance and controls are identified and corrective controls are identified and corrective actions are taken resulting in to actions are taken resulting in to improved efficiency of system. The improved efficiency of system. The score is given based on the fact that score is given based on the fact that over a period of time, system is made over a period of time, system is made more efficient (less cost, better more efficient (less cost, better quality, consistency, timely operations quality, consistency, timely operations etc.).etc.).


►Score 5:- Continuous improvement in Score 5:- Continuous improvement in performance parameters performance parameters (effectiveness of the system) is seen (effectiveness of the system) is seen over last few years. The score is given over last few years. The score is given based on the fact that system has based on the fact that system has contributed towards significant contributed towards significant business benefits and/or customer business benefits and/or customer satisfaction. satisfaction.

THE HR DEPARTMENTTHE HR DEPARTMENT

►a) Recruitmenta) Recruitment►Selection ProcedureSelection Procedure ►Criteria for SelectionCriteria for Selection ►Induction PlanInduction Plan


►b) Trainingb) Training►The training systems include The training systems include ►a) Need Identification a) Need Identification ►b) Validation of Needs b) Validation of Needs ►c) Annual Training Plan c) Annual Training Plan ►d) Selection and Preparation d) Selection and Preparation ►e) Fix Training Program e) Fix Training Program ►f) Training Impact Assessmentf) Training Impact Assessment


►c) Industrial Relationsc) Industrial Relations►The trade unions which get at least The trade unions which get at least

20% vote of total strength of 20% vote of total strength of employees are recognized employees are recognized


►4 main trade unions recognized by the 4 main trade unions recognized by the companycompany

►1) Apollo Tyres Staff and Worker 1) Apollo Tyres Staff and Worker Union.Union.

►2) Apollo Tyres Employees Union.2) Apollo Tyres Employees Union.►3) Apollo Tyres Mazdoor Sangh.3) Apollo Tyres Mazdoor Sangh.►4) Apollo Tyres Workers’ Movement.4) Apollo Tyres Workers’ Movement.


►d) Welfared) Welfare►A subsidized canteen on contract A subsidized canteen on contract

basisbasis► Rest rooms with locker and Rest rooms with locker and

washing facility washing facility ► Arts and sports club Arts and sports club ►Well-maintained libraryWell-maintained library ►Proper transportation facilities Proper transportation facilities


►For Management StaffFor Management Staff►1) Group Hospitalization Scheme: 1) Group Hospitalization Scheme:

- a) Executives – 20000/person. b) - a) Executives – 20000/person. b) Middle Level Managers- 40000/ Middle Level Managers- 40000/ person. c) Senior Level Managers- person. c) Senior Level Managers- 60000/person. The premium is 60000/person. The premium is completely met by the employees. completely met by the employees. It is meant for a 4-member family.It is meant for a 4-member family.


►2) Group Personal Accident Policy 2) Group Personal Accident Policy ►3) 2-wheeler Loan Scheme: - 40% of 3) 2-wheeler Loan Scheme: - 40% of

the amount required is provided by the amount required is provided by the company.the company.

►4) Car Loan Scheme: - 40% of the 4) Car Loan Scheme: - 40% of the amount is provided by the company. It amount is provided by the company. It is only meant for employees who are is only meant for employees who are asst. managers and above. asst. managers and above.


►For WorkersFor Workers►1) Group Personal Accident Policy: - 1) Group Personal Accident Policy: -

100% premium is paid by the 100% premium is paid by the company. The total amount for which company. The total amount for which the employee is insured corresponds the employee is insured corresponds to 48 months of his salary.to 48 months of his salary.


►2) Mediclaim: - 50% of the premium is 2) Mediclaim: - 50% of the premium is met by the company and the rest by met by the company and the rest by the employees. 6-member family is the employees. 6-member family is covered under the insurance. Under covered under the insurance. Under this scheme each member can get up this scheme each member can get up to Rs. 40,000 per year to meet the to Rs. 40,000 per year to meet the hospital expenses.hospital expenses.


►3) Housing Loans at Subsidized 3) Housing Loans at Subsidized Interests: - 50% of the amount Interests: - 50% of the amount required is provided by the company.required is provided by the company.

►4) 2-wheeler Loans at Subsidized 4) 2-wheeler Loans at Subsidized Interests: - 70% of the amount Interests: - 70% of the amount required is provided by the company.required is provided by the company.


►5) Free Periodical Medical Check-ups 5) Free Periodical Medical Check-ups ►6) Co-operative society to provide 6) Co-operative society to provide

financial assistance.financial assistance.►7) Bonuses in the range of Rs.12000-7) Bonuses in the range of Rs.12000-

18000 are given if the annual average 18000 are given if the annual average production > 90%, depending upon production > 90%, depending upon the attendance of the respective the attendance of the respective employees.employees.


►8) Gratuity can be received at the 8) Gratuity can be received at the successful completion of 5 continuous successful completion of 5 continuous years in the company.years in the company.

►9) Employees P.F. and Family Pension 9) Employees P.F. and Family Pension Scheme: - The contribution of Scheme: - The contribution of employees towards P.F. and F.P.S. is employees towards P.F. and F.P.S. is 12% of the monthly salary.12% of the monthly salary.


►10) E.S.I.:- Employees receiving salary 10) E.S.I.:- Employees receiving salary less than Rs. 8500 will be covered less than Rs. 8500 will be covered under scheme. Employee contribution under scheme. Employee contribution is 4.75% of his salary.is 4.75% of his salary.


►Time OfficeTime Office►Registering the time in and out of the Registering the time in and out of the

workers workers

►Maintenance of discipline in Maintenance of discipline in attendance attendance

►calculation of wages for time-workers calculation of wages for time-workers


►Working HoursWorking Hours►A-Shift- 6AM TO 2PM.A-Shift- 6AM TO 2PM.►B-Shift-2PM TO 10PM.B-Shift-2PM TO 10PM.►C-Shift-10PM TO 6AM.C-Shift-10PM TO 6AM.►D-Shift-9AM TO 5PMD-Shift-9AM TO 5PM


►f) Safetyf) Safety►Well-equipped with safety Well-equipped with safety

machines like fire extinguishers at machines like fire extinguishers at reachable points and directions reachable points and directions and training are given for and training are given for operating the same.operating the same.


►Those who work in production unit are Those who work in production unit are given masks, safety gowns and shoes. given masks, safety gowns and shoes.

►Safety directions are placed at Safety directions are placed at noticeable points noticeable points


►The company hasThe company has►Full Time DoctorFull Time Doctor►AmbulanceAmbulance►DispensaryDispensary►Periodical Medical Checkups Periodical Medical Checkups


►g) Securityg) Security►Monitor and control all inward and Monitor and control all inward and

outward movement of vehicles, outward movement of vehicles, material and personnel material and personnel

►Deployment of contract workforce to Deployment of contract workforce to various departments for routine as various departments for routine as well as project works.well as project works.


►Maintain the database of the entire Maintain the database of the entire indirect workforce indirect workforce

►Ensure higher degree of liaison with Ensure higher degree of liaison with police, local administration, fire force police, local administration, fire force and govt. authorities and govt. authorities

►Upkeep of Environment Management Upkeep of Environment Management system including housekeeping of the system including housekeeping of the plant.plant.

►Keeping strict vigilance, gathering and Keeping strict vigilance, gathering and assimilating intelligence in a unionized assimilating intelligence in a unionized environment. environment.


►1) There are 5 national holidays and 8 1) There are 5 national holidays and 8 festival holidays given in a year.festival holidays given in a year.

►2) The employees are given 1 day off 2) The employees are given 1 day off after 48 hours of work.after 48 hours of work.

►3) The retirement age is 58 years. 3) The retirement age is 58 years. ►4) The pay scale is revised annually in 4) The pay scale is revised annually in

consultation with trade unions.consultation with trade unions.


►5) The employees can take 1 day leave 5) The employees can take 1 day leave after 20 consecutive days of work.after 20 consecutive days of work.

►6) 3 categories of leave that the 6) 3 categories of leave that the employees get are 1) sick leave 2) employees get are 1) sick leave 2) casual leave 3) privilege leave.casual leave 3) privilege leave.

►7) Promotion for management staff is 7) Promotion for management staff is purely based on performance. For purely based on performance. For workmen, it is based on seniority.workmen, it is based on seniority.

Documents

Winter Internship at Apollo Tyres, Chalakkudy