PP Home Page Final Production Work Center Bill Of Materials Routing Shifts Materials List Manning Assets

Finished Products at AGI Catogery Chemical bottle Jars personal care pharma bottles Soft Drinks Hyderabad Plant Furnace-1 Flint Jars personal care pharma bottles

Flint
1 lb 1oz Bottle 100ml

Weight in Grams Amber

305 70 125 2.5 Litre 50 grm 10ml Bottle 100ml 22PP

Weight in Grams
1450 90 22.5 85

150 Ton Capcity Weight in Kgs 0.305 0.07 0.125

Weight in Kgsw/o scrap 91500 86010 21000 19740 37500 35250

Total Weight No.Of Bottles Hyderabad Plant Furnace-2 Flint Jars personal care pharma bottles 150 Ton Capcity Weight in Kgs 0.305 0.07 0.125

150000 300000

141000 282000

Weight in Kgsw/o scrap 91500 86010 21000 19740 37500 35250

Total Weight

150000

141000

No.Of Bottles 300000 282000 Whenever the requirement rises for the green Furnace 2 will be triggered untill Hyderabad Plant Furnace-2 150 Ton Capcity Amber Weight in Kgs Weight in Kgsw/o scrap Jars 0.305 91500 86010 personal care 0.07 21000 19740 pharma bottles 0.125 37500 35250

Total Weight

150000

141000

No.Of Bottles

300000

282000

Whenever the requirement rises for the green Furnace 2 will be triggered untill Hyderabad Plant Furnace-2 150 Ton Capcity Green(MTO) Weight in Kgs Weight in Kgsw/o scrap Soft drinks 0.34 150000 Total Weight 150000

No.Of Bottles 441176.5 Whenever the requirement rises for the green Furnace 2 will be triggered,untill Kolkata Plant Amber planning 300 Ton Capacity Amber Weight in Kgs
Chemical bottle 2.5 Litre Jars 50 grm Personal care 10ml Bottle Pharma 100ml 22PP 1.45 0.09 0.025 0.085

No.of Bottles Weight in Kgs 180000 261000 200000 18000 160000 4000 200000 17000 300000

w/o scrap 245340 16920 3760 15980 282000

Total Weight

Flint Jars personal care pharma bottles

Amber

Green(MTO) Chemical bottle 2.5 Litre Soft drinks

Jars 50 grm Personal care 10ml Bottle Pharma 100ml 22PP

Assuming a standard speed of 700 bpm is assumed for a bottle of 340 grams No.of Products bottles/min for 50 Tonne Batch 750 1000 850 500 850 1000 850 164474 714286 400000 34483 555556 2222222
555556

S.No 1 2 3 4 5 6 7

Material

Weight

Jars Flint 1 lb 0.304 Personal Care Oz Bottle Flint 0.07 Pharma Bottle 100ml Flint 0.125 Amber 2.5 Liter 1.45 Amber Jars 50 grams 0.09 Amber Jars Personal Care 10ml 0.0225 Amber Jars 100ml 0.09

Time to complete one batch in minutes 219 714 471 69 654 2222
654

8 9

Green Bottle Soft Drink Green Bottle Soft Drink

0.34 0.4

700 650

147059 125000

210 192

Original calculation Material Jars Flint 1 lb Personal Care Oz Bottle Flint Pharma Bottle 100ml Flint Bottle weight 0.7 0.12 0.12 Actual time Target time Bottles/min 750 1000 850 401 400 Total no. of btls 100000 150000 100000 Total time 133 150 118 Actual weight Target weight

1 2 3

1 2 3 4

Material Bottle weight Amber 2.5 Liter 1.45 Amber Jars 50 grams 0.09 Amber Jars Personal Care 10ml 0.0225 Amber Jars 100ml 0.09 Actual time Target time

Bottles/min 500 850 1000 850 312 400 88

Total no. of btls 70000 70000 90000 90000

Total time 140 82 90 106 Actual weight Target weight

Green

Weight in Grams

200ml , 330 ml

340

52.5

Time in hours for a batch 3.65 11.90 7.84 1.15 10.89 37.04 10.89 Bottl/ sec 12.5 16.7 14.2 8.3 14.2 16.7 14.2

Time/ bottle 0.08 0.06 0.07 0.12 0.07 0.06 0.07

3.50 3.21

11.7 10.8

0.09 0.09

Total weight in Kgs 70000 18000 12000 100000 100000

Total weight in Kgs 101500 6300 2025 8100 109825 100000

Work Centers for Cost center calculations

Plant1 Cleaning Machine 1 Batch House Mixing Machine Furnace 1 &2 2 Furnace 3 IS machine 4 Lehr 5 Inspection 6 Packing IS Machines-1,2,3 Annealing Electronic Bottle Inspection Auto Packing machine Process Work Center HCM-1 HMM-1 HFU-1&2 HIS-1 HLE-1 HEB-1,2,3 HAP-1,2 Plant 2 Cleaning Machine Mixing Machine Furnace3 IS Machines-1,2,3,4 Annealing EBI Packing

Assets Hyderabad Plant

Qty Batch House Mixing Machine Cleaning Machine Furnace IS Machine LEHR Inspection Packing Conveyors Pipe Lines Fork Lift 3 1 2 1 1 3 2 Lot Lot 7 200000 500000 50000000 20000000 3427446 10000000 1000000 4000000 2500000 750000 Cost per M/c

Kolkatta Plant
Qty Batch House Mixing Machine Cleaning Machine 3 1 200000 500000 Cost per M/c

Furnace IS Machine LEHR Inspection Packing Conveyors Pipe Lines Fork Lift

1 1 1 3 2 Lot Lot 7

70000000 20000000 3427446 10000000 1000000 4000000 2500000 750000

Work Center KCM-1 KMM-1 KF-1 KISM-1 KLEHR-1 KEBI-1,2,3 KAPM-1,2

Plant details
>> Plant will run in 3 shifts >> One day weekly off for employee and contract labour

Activity details
Total Cost 600000 500000 100000000 20000000 3427446 30000000 2000000 4000000 2500000 5250000 Time
INR

1 2 3

4 5 6 7 8 9

50 Tonnes processing time Cleaning of Raw 2Materials hr Mixing of raw materials 1 hr Furnace Loading 1 hr Preheating 1 hr Melting 4 hr Cleaning & assembling 0.5 hr Transfer to ISM0.5 hr Blowing/Moulding 2 hr Annealing 4 hr Inspection Online Packing 8 hrs

Furnace 3:00

Shift plan for 50 ton Batch House ISM Cleaning of RM

Total Cost 600000 500000

4:00 Furnace start time 5:00 Mixing of RM 6:00 7:00 8:00

Cleaning & assembling of ISM

70000000 20000000 3427446 30000000 2000000 4000000 2500000 5250000

9:00 Ready to transfer 10:00 11:00 12:00 13:00 14:00

Completion of ISM

BOM FOR AMBER Formula of SL.NO glass glass wt% component 1 2 3 4 5 6 7 8 9 10 BOM Formula of SL.NO glass Description component 1 2 3 4 5 6 7 8 9 10 11 12 13 14 SiO2 Na2O CaO Al2O3 K 2O MgO B2O3 Fe2O3 Na2SO4 Se TiO2 FeO Cr2O3 Cullet Sand Trona Lime Albite Orthoclase Dolomite Borax SiO2 Na2O CaO Al2O3 K 2O MgO B2O3 Fe2O3 Na2SO4 Cullet 63.2 11.4 9.5 4.75 0.95 1.9 2.9 0.095 0.38 4.9 Quantity Description for 50 ton batch Sand Trona Lime Albite Orthoclase Dolomite Borax Iron oxide Lake Salt Broken Gl Flint glass wt% 63.2 11.4 9.5 4.75 0.95 1.9 2.9 31587.5 5700 4750 2375 475 950 1450 47.5 190 2450 Green AMBER

Flint SL.NO 1 2 3 4 5 6 7 8 9 10 Formula of glass componen t SiO2 Na2O CaO Al2O3 K 2O MgO B2O3 Se TiO2 Cullet

glass wt% glass wt% 63.2 11.4 9.5 4.75 0.95 1.9 2.9 63.2 11.4 9.5 4.75 0.95 1.9 2.9 0.095 0.38

Iron oxide Lake Salt 0.38 Selenium Titanium Dioxide 0.095 Ferrous Oxide Chromite 4.9

0.095 0.38 4.9

4.9

Total

100.0

99.95

100.0

Green glass wt% 63.2 11.4 9.5 4.75 0.95 1.9 2.9 0.38 0.095 4.9 Quantity for 50 Description ton batch Sand Trona Lime Albite Orthoclase Dolomite Borax 31587.5 5700 4750 2375 475 950 1450 SL.NO 1 2 3 4 5 6 7 8 9 10 Formula of glass glass compone wt% nt 63.2 SiO2 11.4 Na2O CaO Al2O3 K 2O MgO B2O3 Cr2O3 FeO Cullet 9.5 4.75 0.95 1.9 2.9 0.38 0.095 4.9 Description Sand Trona Lime Albite Orthoclase Dolomite Borax Chromite Ferrous Oxide Broken Gl

190 Selenium 47.5 Titanium Dioxide Broken Gl 2450

Main Page Quantity for 50 ton batch 31587.5 5700 4750 2375 475 950 1450 190 47.5 2450

Flint Jars personal care pharma bottles

Amber
Chemical bottle 2.5 Litre Jars 50 grm Personal care 10ml Bottle Pharma 100ml 22PP

Green(MTO) Soft drinks

Steps in manufacturing process

Main Page

Main Page 1 2 3 50 Tonnes processing time Cleaning of Raw Materials 2 hr Mixing of raw materials 1 hr Furnace Loading 1 hr Preheating 2 hr Melting 4 hr Transfer to ISM 0.5 hr Blowing/Moulding 2 hr Annealing 4 hr Inspection Online Packing 8 hrs

4 5 6 7 8

Materials List
Raw Material SiO2 Na2O CaO Al2O3 K2O MgO B2O3 Fe2O3 Na2SO4 Se TiO2 FeO Cr2O3 Cullet 1 lb 1 Oz 100ml 2.5ltr 50grams 10ml 100ml 200ml 330 ml Finished Product(fert) Jars-Flint Personal Care-Flint Pharma-Btl-Flint Amber-Chemical btl Amber-Jars Amber-Personal Care Pharma Bottle Soft drink Green Bottle Packing Materials(hawa) Consumables Cartons LPG Containers BOPP Tape HSD Grease Water Nitrogen Saftery Gloves

Main Page

st
Engineering Items Spares and Hardwares Moulds Heaters Plungers Neck Rings Thermo Couples Vent Tubes Sensors Lehr Brg Conveyor Rollers Motor and GB Assly P.R.T Shovels Trolleys Stationery

Standard Manning Hyderabad Plant

Batch house Cleaning Machine Mixing Machine Furnace IS M/c LEHR INSPECTION PACKING Maint.Manager 1 Prod.Manager 1 Asst.Prod Manager 1 Engineers

1 1

3 3

Maintenance Summary of the above sheet (Hyd plant) Designation Prod'n manager Maint. Manager Asst.Prod. Manager Asst Maint manager Prod. Engineers Maint. Engineer Supervisors Operators Prod.contract labours Maint. Contract labour Fitters Electrician Fork lift drivers Total

AMM 1

Engineer 1

Qty 1 1 3 1 6 1 9 51 29 6 6 9 15 138

Grade

Kolkata Plant
Batch house Cleaning Machine Mixing Machine Furnace IS M/c LEHR Manager 1 Asst.Prod Manager 1 Engineers

1 1

3 3

INSPECTION PACKING Maintenance Summary of the above sheet (Kolkatta plant) Designation Qty Prod'n manager 1 Maint. Manager 1 Asst.Prod. Manager 3 Asst Maint manager 1 Prod. Engineers 6 Maint. Engineer 1 Supervisors 9 Operators 51 Prod.contract labours 41 Maint. Contract labour 6 Fitters 6 Electrician 9 Fork lift drivers 15 Total 150 Manager 1 AMM 1 Engineer 1

Grade

Manning work center wise

Hyderabad Plant Batch house Cleaning Machine Mixing Machine Furnace IS M/c LEHR INSPECTION PACKING Work center name HCM-1 HMM-1 HF-1&2 HISM-1 HLEH-1 HEBI-1,2,3 HAPM-1,2 Prod.Manager Asst.Prod Manager 1

1 1

Maintenance

Maint.Manager 1

AMM 1

Kolkatta plant

Batch house Cleaning Machine Mixing Machine Furnace IS M/c LEHR INSPECTION PACKING Maintenance

Work center name KCM-1 KMM-1 KF-1 KISM-1 KLEH-1 KEBI-1,2,3 KAPM-1,2

Prod.Manager Asst.Prod Manager 1

1 1

AMM 1

Supervisors Operators 3 6 9 12 3 3 12 Fitters 6 Electrician 9

Relievers

CL 1 1 3 3 3 6 12 Fork Lift Drivers 15

CL = Contract Labours

3 3

3 3

CL 6

Supervisors Operators 3 6 9 6 3 3

Relievers

CL 1 1 3 3 3

CL = Contract Labours

3 3

3 Fitters 6 18 Electrician 9 CL 6

6 24 Fork Lift Drivers 15

Engineers

Supervisors Operators 3 6 9 12 3 3 12

Relievers

CL 1 1 3 3 3 6 12 Fork Lift Drivers 15

3 3

3 3 3 3

Engineer 1

Fitters 6

Electrician 9

CL 6

Engineers

Supervisors Operators 3 6 9 6 3 3 18 Electrician 9

Relievers

CL 1 1 3 3 3 6 24 Fork Lift Drivers 15

3 3

3 3 3 3 Engineer 1 Fitters 6

CL 6

Assets Hyderabad Plant

Qty Batch House Mixing Machine Cleaning Machine Furnace IS Machine LEHR Inspection Packing Conveyors Pipe Lines Fork Lift Generator compressor 3 1 2 1 1 3 2 Lot Lot 7 1 3 200000 500000 30000000 20000000 3427446 10000000 1000000 4000000 2500000 750000 600000 500000 60000000 20000000 3427446 30000000 2000000 4000000 2500000 5250000 6 6 12 5 5 10 10 1 2 5 7 10 Cost per M/c Total Cost LIFE-YEARS

ts Kolkata Plant
Qty Cost per M/c Total Cost Batch House Mixing Machine Cleaning Machine Furnace IS Machine LEHR Inspection Packing Conveyors Pipe Lines Fork Lift 3 1 1 1 1 3 2 Lot Lot 7 200000 500000 50000000 20000000 3427446 10000000 1000000 4000000 2500000 750000 600000 500000 50000000 20000000 3427446 30000000 2000000 4000000 2500000 5250000

Main Page

LIFE-YEARS

6 6 12 5 5 10 10 1 2 5

Characteristics Class name SiClass NaClass CaClass AlClass Kclass MgClass Bclass FeClass NSClass SeClass TiClass FeOClass CrClass Raw material SiO2 Na2O CaO Al2O3 K 2O MgO B2O3 Fe2O3 Na2SO4 Se TiO2 FeO Cr2O3 Density Char name SiDCh NaDCh CaDCh AlDCh KDch MgDCh BDCh FeDCh NSDCh SeDCh TiDCh FeODCh CrDCh Density (g/cm3) 2.460-2.470 2.20-2.30 3.30-3.40 3.95 - 4.1 2.30-2.40 3.50-3.60 2.50-2.60 5.240-5.250 2.660-2.670 4.20-4.30 4.20-4.30 5.740-5.750 5.20-5.30 MP &BP Char name SiMBCh NaMBCh CaMBCh AlMBCh KMBch MgMBCh BMBCh FeMBCh NSMBCh SeMBCh TiMBCh FeOMBCh CrMBCh

Class name Amber Clambcb Clambja Clambpc Clambph Flint Clflja Clflpc Clflph Green Clsd200 Clsd330 SW H T D

Ch name
Chemical bottle 2.5 Litre Jars 50 grm Personal care 10ml Bottle Pharma 100ml 22PP Ambcbw Ambjaw Ambpcw Ambphw

SW 1450 90 70 85 305 70 85 340 400

Weight (g) T Min 72.5 4.5 3.5 4.25 15.25 3.5 4.25 17 20 1377.5 85.5 66.5 80.75 289.75 66.5 80.75 323 380

Max 1522.5 94.5 73.5 89.25 320.25 73.5 89.25 357 420

Jars personal care pharma bottles Soft drinks 200 ml Soft drinks 330 ml Std Weight Height Tolerance Diameter

Fljaw Flpcw Flphw Grs2w Grs3w

Melting point (deg C) 1600-1725 1130-1140 2570-2580 2070-2080 >350 2850-2860 505-515 1560-1570 880-890 215-225 1840-1850 1370-1380 2430-2440

Boiling point (deg C) 2225-2235 1945-1955 2845-2855 2970-2980 3595-3605 1855-1865 1425-1435 680-690 2965-2975 3410-3420 3995-4005

Ch name
Ambcbhd Ambjahd Ambpchd Ambphhd

H 305 96.5 88.5 115 189 88.5 115 205 250

T 6.1 1.93 1.77 2.3 3.78 1.77 2.3 4.1 5

Dimensions (mm) Min Max D 298.9 94.57 86.73 112.7 311.1 98.43 90.27 117.3 132.5 50.9 33.75 46.4 65.4 33.75 46.4 58 58

T 2.65 1.018 0.675 0.928 1.308 0.675 0.928 1.16 1.16

Min 129.85 49.882 33.075 45.472 64.092 33.075 45.472 56.84 56.84

Max 135.15 51.918 34.425 47.328 66.708 34.425 47.328 59.16 59.16

Color Amber

Flint

Fljahd Flpchd Flphhd Grs2hd Grs3hd

185.22 192.78 86.73 90.27 112.7 117.3 200.9 245 209.1 255

Green

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