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Acknowledgement:
First of all I would like to thank Kaygee Loparex India Pvt. Ltd. for giving me this opportunity. I would also like to thank my Project Guide and Mentor Mr. Mahesh Divate, Sr. General Manager, for always taking out time to help me and guide me. I learned lot from the discussions. Most important I learned to be patient for the work.
I would also like to thank Ms. Seema Agarwal for being a great mentor and improvising me all the time, her inputs were always to improve me and my results. I learned from her being proactive is the key for success in corporate.
I would also like to thank Mr. Tilkesh Jathan for taking out time and helping & guiding me throughout the project and especially in my second project was impossible to complete without his help.
I am also Thankful to SCMLD for providing me the knowledge which I was able to use in my work, I am also thankful to them for providing me a platform for this kind of opportunity.
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Executive summary:
This report is about my internship at Kaygee Loparex India Pvt. Ltd. covering the period of 2 months and 6 days from May to July first week..
Kaygee Loparex India Pvt. Ltd. is India’s leading Silicone Release Liner Manufacturer and is in equal joint venture with Loparex Group, the world’s largest commercial Silicone Release Liner solutions company.
Considering the wide spectrum of adhesive applications and end-user needs, Kaygee Loparex India Pvt. Ltd. Customize their Release Liners to specifically address Customer’s product requirements. Key application segments served include medical, hygiene, composites, self-adhesive tapes, label stock, graphic arts and many more
When looking for internship I had few criteria’s about it, as I already had experience in FMCG sector for 2 years I need not wanted same for my internship, I was looking forward to B to B type of business to make the learning diversified, more over I was looking for a independent project which will prove I am able to manage situations myself.
As given the opportunity, In Kaygee Loparex my job was to find out the new applications of the product in various Industry, as company needed to grow and spread its legs in different sectors, they choose me for the unknown market i.e. Decorative Laminates, for this finding I and company were at same level as far as application of product is concern. What exactly I was looking for, a higher sense of responsibility & a stand-alone job which will be done directly under decision maker.
It was decided initially that if this application proves to be positive then I need to find the potential of Industry as well as individual player, and if not then they will provide me a new project that would be my second project on Trans dermal Patch. Which are a new drug delivery system and this technology is emerging currently and application of Silicone Release Liner is known here, my job would be to find out potential clients who will be manufacturing this in India.
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SECTION-A INTRODUCTION TO THE COMPANY COMPANY PROFILE HISTROCIAL VIEW OF COMPANY COMPANY STRUCTURE PERFORMANCE PRODUCTS AND SERVICES
SECTION-B TRAINING AND DEVELOPMENT DEFINATION OBJECTIVE NATURE AND SCOPE HYPOTHESIS RESEARCH METHODOLOGY RESEARCH DESIGN SAMPLING DESIGN SAMPLING FRAME SAMPLING SIZE DATA COLLECTION RESEARCH TOOL LIMITATION
SECTION-C INTERPRETATION OF THE DATA ANALYSIS IMPLICATION OF THE RESULT CONCLUSION RECOMMENDATION
SECTION-D BIBLIOGRAPHY
Company Introduction:
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Kaygee Loparex India Pvt. Ltd. is India’s leading Release Liner Manufacturer and is in equal joint venture with Loparex, the world’s largest commercial Silicone Release Liner solutions company.
Considering the wide spectrum of adhesive applications and end-user needs, Kaygee customize their Release Liners to specifically address Customer’s product requirements. Company has won several rewards for its superior and quality products from companies like Jhonson & Jhonson.
Products & Services:
A wide range of Silicone Coated Release Liners for
Self-adhesive Labels Self-adhesive Tapes
Hologram Filmic Release Envelops & Packaging
Baby & Adult Diapers Feminine Hygiene Pads
Wound Care Patches Transdermal Patches
Surgical Wraps Body Electrodes
Roofing Sheets Bitumen Sheets
Self-adhesive Fastners Composites
Kaygee Loparex offers Release Liner solutions based on a wide variety of paper and film substrates. All Silicone types and curing methods are used to optimise the release properties of the final product.
Company profile:5
Name of the Company : Kaygee Loparex India Pvt. Ltd.
Address of the Company : B-28, Veera Industrial Estate, 6th Floor, Bhukhanwala Chambers, Off Link Road, Andheri (W), Mumbai 400 053, India.
Sector : Manufacturing (Industrial consumables).
Brief Profile of the company : Founded by Mr. Pranay Godha in year 2000 a joint venture with Loparex Group a U.S.A based group whose turnover is above $ 400 Million.Kaygee Loparex India Pvt. Ltd. has about 100 employees and a turnover of $15 million, Kaygee Loparex India Pvt. Ltd. is the leading commercial Silicone Release Liner manufacturer in India, with the facility of 2800 sq. meter, located at Silvassa, 180 km from Mumbai. It has the most modern Silicone coating and slitting machines. A state-of-the-art testing laboratory ensures that everything produced meets both in-house and customers’ quality requirements. Good Manufacturing Practices (GMP) and Total Quality Management (TQM) are rigorously followed to ensure that both production methods and product meet world standards.
Name of the Guide : Mr. Mahesh Divate.
Designation : Sr. General Manager
Mobile No : +91-9920184125
HISTROCIAL VIEW
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Loparex Group's history started at the beginning of the 20th century.
Loparex has grown from a small pulp manufacturer to a leading worldwide producer of
siliconized release liners. The company was one of the first to manufacture silicone-
coated paper. Loparex’s record of growth, market position and current global presence,
however, has come through specialization and value-added product development.
During its one hundred years of history, the company has been operating under several
different names and owners.
In 2001, Lohja Group and Rexam Release were merged, and the new company was re-
named Loparex. In 2004, Loparex Guangzhou plant in China started its operations.
Loparex acquired the former Douglas-Hanson Company in 2006 to become a stronger
supplier in the manufacture and delivery of release liner and blown film products.
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Introduction of the product:
A Release Liner is a paper or film based carrier web material, which is coated on one or two sides with Silicone, which provides a release effect against any type of a sticky material such as an adhesive. Release Liners are available in different colors, with or without printing under the Silicone or on the backside of the liner. Release is separation of the liner from a sticky material. A liner is the carrier for the release agent.
For example: Backing paper in Band-Aid, which is removed before use.
Globally there are 400-500 companies involved in making or dealing in Release Liners, broadly these are classified into three types:
1. Commercial Siliconizer: These are the Commercial coating companies, deal with a lot of different end uses of this Industry, they provide unique solutions to their customers. Generally these companies are not the makers of the finished products.
2. In-house Siliconizer: The maker of the finished product produce Release Liner and use it internally for there final product.
3. Converting, Processing and Printing: These manufacturers buy Silicone coated paper and convert it or print on it or process it according to the need of the customer/application.
Kaygee Loparex India Pvt. Ltd. is a commercial liner producer, which makes customized Silicone Release Liner based on the requirement of the customer, customization majorly depends on following criteria:
Base paper/film. Strength required in base material. Weight/thickness needed in base material. Silicone spread needed for the release. Release force needed for the application.
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Type of base material:
Base material is classified in two major type Paper & Film.
Paper base material:
Papers have lots of variety but for the Release Liners limited Kraft paper listed below are used.
1. Glassine: 60-120 GSM Used for labels, holograms, etc. Can be coated both sides.
2. SCK(Super Calendared Kraft): 60-65 GSM. Used for labels, etc. Less cost than Glassine. Only one side coated.
3. CCK(Clay Coated Kraft): 50-92 GSM. Used for envelops, label stocks. Only one side coated.
4. MGK(Machine Glazed Bleached Kraft): 30-40 GSM. Only one side coated. Print friendly. Used for hygiene, bakery, etc.
5. PEK(Poly Ethylene Kraft): 68-160 GSM. Mainly used in tapes. Generally both side coated.
Film base material:
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Plastic films in general are made by plastics extrusion process out of plastic resins and can be made out of one single type of plastic material, a blend of different plastic materials or multilayered co extrusions. Following are the types of the films.
1. LDPE(Low Density Poly Ethylene): 25-80 micron. Low heat resistant. Used for roofing application, bit amine. U.V treated Silicone coat.
2. HDPE(High Density Poly Ethylene): 25-80 micron. Low heat resistant. Roofing application. U.V treated coat.
3. BOPP(Blaxially Oriented Poly Propelene): 25-50 micron. Low heat resistant. U.V treated coat. Used for labels, etc.
4. PET Films (Polyester): 12-125 microns. High heat resistant Used for tapes, etc.
Product List
SR. NO. STANDARD UOM BASE - COLOUR COATING1 62 GSM Glassine - Yellow C1S
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2 62 GSM Glassine - Yellow C2S3 62 GSM Glassine - White C1S4 62 GSM Glassine - White C2S5 62 GSM Glassine-BLUE C1S6 80 GSM Glassine – White C1S7 80 GSM Glassine – White C2S8 88 GSM Glassine – White C2S9 90 GSM Glassine – White C1S10 90 GSM Glassine – White C2S11 120 GSM Glassine – White C1S12 120 GSM Glassine – White C1S -Tight13 160 GSM PEK-White C1S14 160 GSM PEK-White C2S15 31 GSM MGK – White C1S16 35 GSM MGK – White C1S17 39 GSM MGK – White C1S18 40 GSM MGK – White C1S19 34 GSM MGK – White C1S20 38 GSM MGK – White C1S21 52 GSM CCK – White C1S22 66 GSM CCK – White C1S23 90 GSM CCK – White C1S24 60 GSM SCK-White C1S25 62 GSM SCK-White C1S26 67 GSM SCK-White C1S27 23 Microns PET – Clear C1S28 30 Microns PET – Clear C1S29 36 Microns PET – Clear C1S30 36 Microns PET- Blue C1S31 50 Microns PET – Clear C1S32 50 Microns PET – Clear C2S33 100 Microns PET – Clear C1S34 125 Microns PET – Clear C1S35 75 Microns PET – Clear C1S36 75 Microns PET-Metallized C1S37 60 GSM Glassine-Blue C1S38 160 GSM Blue tint C1S39 6060 GSM Glassine – White C1S40 62 GSM Glassine – White C2S
Process of manufacturing:
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Machine 1
Unwind roller contains paper roll.
Solution is mixed of Silicone, cross linkers & catalyst.
Solution applied through “doctor line” to paper passed through three rollers.
Paper applied with solvent goes through 7 chamber oven with varying temperature.
At the end of oven paper passes over chiller roller.
Paper re-moisturized to regain moisture lost during baking process.
Rewinding of coated paper/film
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Product Testing:
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Machine 2
Unwind roller contains paper roll.
Solution is mixed of Silicone, cross linkers & catalyst.
Solution applied through to paper passed through 5 rollers.
Paper applied with solvent goes through 7 chamber oven with varying temperature.
At the end of oven paper passes over chiller roller.
Paper re-moisturized to regain moisture lost during baking process.
Rewinding of coated paper/film
Corona treatment to remove static & makes paper printable.
Testing of the product is done by R&D specialist at Kaygee Loparex manufacturing plant located at Silvassa.
Criteria:1. GSM Test.2. Thickness (micron).3. Release Force.
Procedure:
GSM Test:1. 10x10 cm paper weighed on sensitive weighing machine.2. 4-5 sample tested average is taken as a result.
Thickness Test:1. Tested by micron meter.2. 4-5 sample average is considered to be result.
Release Force:1. Tessa tape is used for testing, with standard size of 7” length & 2.5 cm width.2. Paper is attached to Tessa tape.3. Rolled by a 2kg roller 2 times.4. Kept for 1 day within glass sheets with weight on it.5. Tape is then attached to testing machine & released.6. Machine shows in graphical as well numerical figure of force required.7. Process is called “Finat 10 test”
Classification of Release Force:1. Easy Release: 5-25 gm.2. Medium Release: 25-70 gm.3. Tight Release: 70-150 gm.4. Can be produced beyond if needed.
INTRODUCTION15
Dr. Margaret Driscoll identifies four different concepts in defining blended learning The first
defines blended learning as meaning "to combine or mix modes of Web-based technology
(e.g., live virtual classroom, self-paced instruction, collaborative learning, streaming video,
audio, and text) to accomplish an educational goal." (Driscoll, 2002) Other authors also
define blended learning according to Driscoll’s first. For example in the introduction to "Building
Effective Blended Learning Programs", Harry Singh (2003) indicates blended learning models
“combine various delivery modes. Anecdotal evidence indicates that blended learning not only
offers more choices but also is more effective."
Dr. Driscoll’s second definition describes blended learning as meaning "to combine various
pedagogical approaches (e.g., constructivism, behaviorism, cognitivism) to produce an
optimal learning outcome with or without instructional technology." (Driscoll, 2002)
As Charles Graham points out in his introduction to the article “Blended Learning Systems:
Definition, Current Trends, and Future Directions”, both of these first two concepts “suffer from
the problem that they define BL so broadly that there encompass virtually all learning systems.”
(Bonk & Graham, 2004)
The third definition from Dr. Driscoll (2002) defines blended learning as meaning "to
combine any form of instructional technology (e.g., videotape, CD-ROM, Web-based
training, film) with face-to-face instructor-led training." (Driscoll, 2002) Most authors echo
this definition such as Gary Harriman, who indicated in his article, “What is Blended Learning”
(2004), that “blended learning combines online with face-to-face learning. The goal of blended
learning is to provide the most efficient and effective instruction experience by combining delivery
modalities." (GrayHarriman, 2004) In addition, Judith Smith in her article, “Blended Learning: An
Old Friend Gets a New Name”, defined blended learning “as a method of educating at a distance
that uses technology (high-tech, such as television and the Internet or low-tech, such as voice
mail or conference calls) combined with traditional (or, stand-up) education or training." (Smith,
2001) Simply put the Rochester Institute of Technology reported in the “Blended Learning Pilot
Project: Final Report for the Academic Year 2003–2004” that "blended learning aims to join the
best of classroom teaching and learning with the best of online teaching and learning."
(Rochester Institute, 2004) New South Wales Department of Education and Training (2005)
echoes the above authors in the article, "Blended Learning” by stating "blended learning is
learning which combines online and face-to-face approaches." (NSW, 2005) Richard Voos (2003)
also repeats this definition that blended learning is a combination of face-to-face and online
16
media while he goes on to state that blended learning also results in "seat time" being
“significantly reduced”. (Voos, 2003) Carla Garnham and Robert Kaleta (2002) identified blended
learning or hybrid courses as joining the best features of “in-class teaching with the best features
of online learning to promote active independent learning and reduce class seat time." (Garnham
and Kaleta, 2002) Alfred Rovai and Hope Jordan (Aug 2004) in the article "Blended Learning and
Sense of Community: A Comparative Analysis with Traditional and Fully Online Graduate
Courses" indicate "a blended course can lie anywhere between the continuum anchored at
opposite ends by fully face-to-face and fully online learning environments." (Rovai and Jordan,
2004) “According to Colis and Moonen (2001) blended learning is a hybrid of traditional face-to-
face and online learning so that instruction occurs both in the classroom and online, and where
the online component becomes a natural extension of traditional classroom learning." (Rovai and
Jordan, 2004) e-Learning Centre's Library defines blended learning as "a learning solution
created through a mixture of face-to-face, live e-learning, self-paced learning as well through a
mix of media – ‘the magic is in the mix!’ or ‘the beauty is in the blend!’ " (e-Learning Centre, 2005)
The Australian National Training Authority’s (2003) “Definitions of Key Terms Used in e-learning”
provides a definition of blended learning from Flexible Learning Advisory Group (2004) as
“learning methods that combine e-learning with other forms of flexible learning and more
traditional forms of learning. “
The fourth concept from Dr. Driscoll defines blended learning as meaning "to mix or
combine instructional technology with actual job tasks in order to create a harmonious
effect of learning and working." (Driscoll, 2002) This fourth definition gives an indication as to
the popularity of blended learning as part of corporate training. "Blended Learning is the latest
buzzword in corporate training. Mixing e-learning with other types of training delivery." (Bersin,
2003)
There are other authors who have defined blended learning by combining Driscoll’s first and third
concept. The Royer Center for Learning and Academic Technologies (2004) defines blended
learning as intermingling “multiple learning strategies or methods with a variety of media. In
contemporary terms, learning strategies and media typically include aspects of face-to-face
instruction and online (or distance) learning, in combination with a rich variety of learning
strategies or dimensions." (Royer, 2004) From “The Node's Guide to Blended Learning: Getting
the Most out of Your Classroom and the Internet” (2001), the Node Learning Technologies
Network defines blended learning as learning that uses “multiple strategies, methods and delivery
systems” including the “integration of multiple strategies, methods and delivery systems”.
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"Good teachers have always used a mix of strategies, methods and media to reach their
objectives–that’s not new. What is new is that today’s Internet-based tools can facilitate
communication, interaction, and collaborative learning in ways that were not possible before.
What’s also new is the relative accessibility of digital learning technologies and the ease with
which instructors can blend them with classroom resources" (Node, 2003).
Purnima Valiathan (2002) in "Blended Learning Models” also combined the Driscoll’s first and
third concepts of blended learning in stating that the term blended learning is “used to describe a
solution that combines several different delivery methods, such as collaboration software, Web-
based courses, EPSS, and knowledge management practices … to describe learning that mixes
various event-based activities, including face-to-face classrooms, live e-learning, and self-paced
learning." (Valiathan, 2002)
In defining “blended learning”, a few authors concentrate on the word blended. As defined in The
Concise Oxford Dictionary, 8th edition, to blend means to “form a harmonious compound,
become one”. (Concise Oxford Dictionary 8th edition,1990) As Peter Isackson (2002)
emphasizes, the definition of blended learning needs to focus on the "blending" of the methods
and strategies and not just the "tossing" together of the different modalities. Isackson (2002) uses
the analogy of good blending "like a good Scotch whiskey"; Royer Center (2004) offers additional
analogies of blending as "compared to gourmet coffees, wines, hybrid vehicles, and even
gasoline. Each blend offers a variety of choices that form an appealing whole." (Royer, 2004) In
connection with these analogies the Royer Center (2004) goes on to explain that blended
learning can have a variety of flavors and thus “there is no single approach for ‘how to blend’ ”,
just as there exist different recipes for one type of food dish. “Successful blended learning, like a
successful recipe, mingles a range of complementary ingredients in order to support the unique
purpose of each learning event." (Royer, 2004) Thus, as Isackson (2004) points out, “much of
what people claim to offer today as "blended learning" isn't so much blended (like a good Scotch
whisky) but "tossed" (like a salad).” There is the need to “distinguish between blended learning --
where there is a real input/output strategy and a dynamic structure -- and "tossed learning" where
the form of input alternates." (Isackson, 2002) As reported in “The Node's Guide to Blended
Learning: Getting the Most out of Your Classroom and the Internet”, "blended learning can be
many things–there is no prescription and no recipe." (Node, 2003)
Finally, as there are a number of concepts for defining blended learning, Martin Oliver and Keith
Trigwell (2005) in their article, "Can 'blended learning' Be Redeemed", are critical of using the
term at all. Oliver and Trigwell (2005) argue that the term ‘blended learning’ is “ill-defined and
inconsistently used. Whilst its popularity is increasing, its clarity is not.” Oliver and Trigwell (2005)
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state that definitions of blended learning lack “an analysis from the perspective of the learner."
Oliver and Trigwell (2005) suggest the need for a "shift away from manipulating the blend as seen
by the teacher, to an in-depth analysis of the variation in the experience of the learning of the
student in the blended learning context.Along the same line as Oliver and Trigwell's (2005)
criticism of the use of the term "blended learning", Don Morrison (2003) writes, "Personally, I’m
much more comfortable talking about the strategic use of learning delivery channels than
‘blended learning’. Every enterprise has learning delivery channels—it's a question of identifying
them and deciding which to use when." He continues by saying, "I have heard blended learning
dismissed as the Emperor's New Clothes on the basis that all learning—from infancy, through the
classroom, and into the enterprise—is blended learning." (Morrison, 2003)
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Training
Training is a planned and systematic effort to modify or develop knowledge/ skills and attitude through learning experience, to achieve effective performance in an activity or range of activities. Its purpose, in work situation, is to enable an individual to acquire abilities in order that he or she can perform adequately a given task or job.
Three Ingredient of Training
Knowledge Skills Attitudes
Need for Training
1. Job Requirements: - Employees selected for job might lack the qualifications required to perform job effectively. New and inexperienced employees require detailed instruction for effective performance of job.
2. Technological Changes: - Technology is changing very fast. Now automation and mechanization have are being increasingly applied in offices and service sector. Increasing use of fast changing techniques requires training into new technology.
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3. Organizational Viability: - In order to grow and survive onorganization must continually adopt itself to the changingenvoirment. In order to face international competition, the firmsmust upgrade their capabilities. Existing employees need refresher training to keep them abreast of new knowledge and foster the initiative and creativity of employees and help to prevent obsolescence of skills.
5. Internal Mobility: - Training becomes necessary when an employees moves from one job to another due to promotion and transfer.
Development
Development is a long term educational process utilizing systematic and organized procedures by which managerial personnel learn conceptual and theoretical knowledge for general purpose. It involves philosophical and theoretical educational concepts and it is designed for managers. It involves broader education and its purpose is long term development.
Development involves preparing the individual for a future job and growth of the individual in all respects. Development complements training because human resources can exert their full potential only when the learning process goes far beyond simple routine.
Objective of Development
1. To improve the performance of managers at all levels in their present job.
2. To sustain good performance of managers throughout their careers.
3. To ensure availability of required numbers of managers with the needed skills, so as to meet present and anticipated future needs of the organization.
4. To prevent obsolescence by exposing them to the latest concepts and techniques in their respective area of specialization.
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5. To replace elderly executive who have risen from the ranks by highly competent and academically qualified professionals.
6. To provide opportunities to executives to fulfill their career aspirations.
7. To ensure that the managerial resources of the organizations are utilized optimally.
Process of Development
1. Analysis of development needs-: First of all present and future needs of organization are ascertained. It is necessary to determine how many and what type of executives are required to meet the present and future needs. A critical analysis of organization structure in the light of future plans will Reveals what the organization needs in term of department, functions and key executive positions. Then job description and specifications are prepared for all executive positions.
2. Appraisal of present Managerial Talent-: A qualitative assessment of the existing executives is made to determine the type of executive talent available within the organization. The performance of every executive is compared with the standard expected of him. His personal traits are also analyzed to estimate his potential for development.
3. Inventory of Executive Manpower-: This inventory is prepared to obtain complete information about each executive. Data on the age, education, experience, health, test result and performance appraisal result is collected. Analysis of this result will show the strengths as well as deficiencies of executives in certain functions relative to the future needs of the organization.
4. Planning Individual Development Programmes -: Each one of us has a unique set of physical, intellectual and emotional characteristics. Therefore, development plan should be trail made for each individual. Such tailor-made programmes of development should give due attention to the interests and goals of the subordinates as well as to the training and development opportunities existing in t he organization
5.Establishing Training and Development Programmes: The human resource department prepares comprehensive and well conceived programmes.
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The department identifies development needs and may launch specific courses in fields of leadership, decision making, human relation, etc. On the basis of its recommendations, the top management nominates the executive who will participate in these programmes at the cost of the company.
6. Evaluating Development Programmes : Considerable money, time and effort are spent on executives development programmes. It is therefore; natural to find out what extent the programme objectives have been achieved. Observation of the trainee’s behaviour, rating of the training elements, opinion surveys, interviews, tests and changes in productivity, quality, cost etc. can be used to evaluate development programmes.
TRAINIG &DEVELOPMENT PLAN
Vision:1. Develop a culture of achievement with emphasis on
performance & discipline.
2. Help to improve level of productivity and quality .3. Achieve competitiveness at all level through modernization and technology up
gradation.
Step in Training process
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Who are the Trainers?
Who are the Trainees?
What methods & techniques
Who are the trainees?
They can be-:
new employees old employees unskilled employed semiskilled employed supervisors executives
Who are the trainers?
For new employeesTrainers could be immediate supervisors or co-workers.
For old employees Trainers could be member of personnel staff, outside,consultants.
For unskilled workers Trainers could be their senior.
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Implementation of program
For semi skilled workers Trainers could be specialists in other part of the company,supervisors.
For supervisors Trainers could be member of the personnel staff, outside consultants or industry associations.
For Executives Trainers could be faculty member at universities, outside consultants or specialists in other part of company.
What Methods &Techniques
Methods can be categorized in two groups-:
1. On – the –job2. Off – the –job
* For orienting new employees
We can use-
On – the – job
Orientation training Job rotation Apprentice training
Off – the – job
Lecture Simulation
* For innovations in products & services
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On – the – job Job instruction training Apprentice training Off – the – job Vestibule Lectures Special study Films Conference or discuss
Off – the – job
Simulation Programmed instruction Special study Lecture
* For safety education
On – the – job
Coaching
Off – the – job
Vestibule Lecture Films Simulation Programmed instruction
* For creative, technical & professional education
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On – the – job
Coaching Internships & assistantship
Off – the – job
Lectures Special study Role playing Simulation Programmed instruction Conference & discussion
* For sales, administrative, supervisory and management
education
On- the –job
Internship & assistantship Job rotation Coaching
Off- the – job
Lecture Special study Films Case study Conference & discussion Implementation of the training programme Deciding the location and organizing training facilities For On – the – job methods & techniques For on – the – job training we have to check the availability of the
trainers, their teaching skills and beside that we have to look that due to training on going work is not interrupted.
For this we can ask trainer for overtime or we can pay some extra buys for their involvement in training process, or for time being we can reduce their work load.
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For Off – the – job For this purpose we can send our trainers to MIT (Ranchi).Senior
executives can get best kind of training there. And for other level of trainers we can arrange for trainers on the
contract basis. Payments can be made according to our budget. Scheduling the training programme. The period of training can be from one week to few months,
depending upon the level of trainee and type of the training.
EVALUATION CRITERIA
Evaluation can be done of following criteria.
1) Reactions- trainees’ reactions to the objectives, contents and methods of training are measured. If they come to be positive then training can be considered effective.
2) Learning- The extent to which the trainers have learnt the desired knowledge & skills during the period.This can be check through a test or observation.
3) Behavior- Improvement in the job behavior reflects the extent to which learning has been applied to the job.
4) Results- Results can be terms of productivity improvement, quality improvement, cost reduction, reduction in labor turnover & absenteeism.
METHODS FOR EVALUATION
-Opinions and judgments of trainers.-By filling of evaluation form by trainers.-Using a questionnaire to know the trainers reactions.-Craving oral and written test to trainers.-Arranging structured interviews for trainees.
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-Company the performance of trainees on the job before and after training.
-Cost benefits analysis of the training programmer.
Evaluation enables an organization to monitor the training programmer and also to update or modifies in future programmes of training. The evaluation of training also provides useful data on the basis of which relevance of training and its integration with other functions of human resource management can be judges.
Module of training
ON – THE – JOB
In this method the trainee is placed on a regular job and taught the skills necessary to perform it. The trainee learns under the guidance & supervision of a supervisor or instruction. The trainee learns by observing and handling the job.
VARIOUS FORMS OF ON – THE – JOB
1. Apprenticeship Training-: In this method theoretical instruction and practical learning are provided to trainees in training institutes. The aim is to develop all round craftsmen. Generally a stipend is paid during the training period. Thus it provides skilled workforce to the industry. This type of orienting new employees and special skills training.
2. Internship & Assistantship-: This is a joint programme of training in which educational institutions and business firm cooperates. Selected candidates carry on regular studies for the prescribed period. They also work in some factory or office to acquire practical knowledge & skills. This method provides good balance between theory and practices. Mainly used in professional work like M B B S, C A, I C W A, C S etc. Good for special skills training, creative, technical, sales, admire, supervisory.
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3. Job rotation-: It involves movement or transfer of executives from one position or job to another on some planned basis. The aim is to broaden the knowledge, skills and outlook of executives. Often designed for junior executives. It may range from period of six months to two years. It facilitates interdepartmental cooperation and coordination. Infuses new concepts and ideas into elder personnel. Also reduces the boredom by providing variety of work. Mainly used for orienting new employees, introducing innovations in products & services and special skills training.
4. Coaching-: In the method superior guides and instructs the trainee as a each. The coach or counselors sets mutually agreed upon goals, suggests how to achieve these goals, periodically reviews the trainees progress and suggests changes required in behavior and performance. It involves close interaction between trainee and his boss. Mainly used for special skills training, safety education, creative, technical and professional education, sales, administrative supervisory and management education.
OFF – THE- JOB
In this method of training. The trainees are given training away from the work place. It provide suitable environment for them to learn the thong. It can be expensive but yet it gives better results. Almost every organization opt this method of training, as it dose not disturb the daily routine which is going in offices & factories and trainee can concentrate well.
VARIOUS FORMS OF OFF – THE – JOB TRAINING
-Vestibule / Simulation-: It utilizes the equipment which closely resembles the actual one used on the job. This is an attempt to create a realistic decision-making environment for the trainee. The emphasis is on the learning skills required by the job. Mainly
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used orientating new employees, innovation of new product & services and special skills training.
-Lectures-: Lectures is a verbal presentation of information by an instructor to a large audience. The lecture is presumed to possess a considerable depth of knowledge of the subject at hand. This method can be used for very large groups. Lectures can be used to introduce a subject, to reduce anxiety about upcoming training programmes or organizational changes, to present basic material that will provide a common background and to illustrate the application of rules and principles.
-Audio – Visuals-: Audio visual includes television slides, overheads, video-types and films. These can be used to provide a wide range of realistic examples of conditions and situations in the condensed period of time. This type of method of training can be used for special skills training safety education, creative, technical, professional, managerial education.
-Conference or Discussion-: A conference is a formal meeting conducted in accordance with an organized plan. Problems of common interest are discussed. A conference may be divided into small groups for intensive discussions. These small groups report back to the conference. It helps in developing conceptual knowledge, reducing dogmatism and modifying attitudes. The trainee’s activity participates and their interest in learning is maintained. This method can be mainly used for orienting new employees, product or services, for creative, technical & professional education.
=Case study-: Under this method, a real or hypothetical business problems or situations demanding solutions is presented in writing to the trainees. They are required to identify and analyzes the problem suggest and evaluate alternative courses of action and choose the most appropriate solution case study can provide stimulating discussion among participants, as well as excellent opportunities for individuals to defend their analytical and judgments abilities. The trainees become aware of managerial
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concept and processes and their application to specific situations. An ideal method to promote decision – making abilities within the constraints of limited data. This method can be mainly used for sales, administrative, supervisory and managerial education.
-Role playing-: The essence of role playing is to create a realistic situation, as in case study and then have the trainees assume the parts of specific personalities in the situations. Thus it is a method of human interaction which involves realistic behavior in an imaginary and hypothetical situation. Role playing primarily involves employer, employee relationships, hiring, firing, discussing a grievance procedure, etc. it brings change of attitude and better understanding among individuals. This can mainly used for creative. Technical and managerial education.- Programmed Instruction-: This is the method where training is offered without an intervention of a trainer. Information is provided to the trainee in blocks either in a books form of through a teaching machine. After reading each block of material the learner must answer a question about it. Feedback in the form of correct answer is provided after each response. Thus it involves-:
- Presenting questions facts, or problems to the learner.- allowing the person to respond.- provide feedback on the accuracy of their answers.- If the answers are correct, the learner proceeds to next block. If not then repeats the same.
This method is self- paced so trainees can progress through the programmers at their own speed. Material is also structured and self contained, offering much scope for practice. Individuals can be trained more economically and at the most convenient times. This method can be used for-:-Special skills training.-Safety education.-Creative, technical & professional education.-Sales, supervisory and managerial education.
-Laboratory Training-: This method is also called T- group training and sensitivity training. The purpose is to increase self awareness, develop interpersonal competence and sharpen team
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work skills. This method uses small number of trainees usually fewer than 12 in a group. Meetings have no agenda and questions deal with the ‘her and now’ of the group process. Discussions focus on why participants behave as they do, how they perceive one another and the feelings and emotions generated in interaction process. This method can be used for -: Safety educationCreative, technical & professional education.
Evaluating Training SystemFive Sets Of Objectives And Three Main
Questions
1. Evaluating Training Program
Objectives For Whom When HowTo improve the program as a whole
System and Trainer
Concurrent and end of program
Questionnaire, feedback and discussion involving trainers and administrators with participants.
To improve major components of the training program
System and Trainer
Before and After the inputs
Questionnaire and scales, feedback and discussion involving trainers and participants.
To increase the effectiveness of specific modules or sessions
Particular Trainer End of module or session
Module or session evaluation scales, checklists, feedback to participants.
2. Evaluating Training Process
Objectives For Whom When HowTo Improve the training climate System and
TrainersConcurrent
Interviews, open reviews, critical incidents,
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feedback and discussions with participants.
To improve the training methodologies
Trainers End of programQuestionnaires, interviews, discussions among trainers.
To improve the effectiveness of the trainers team
Trainers End of programDiscussions of trainer’s team and participants.
3. Evaluating the Training Program
Objectives For Whom When How
To Improve training facilities.
System Concurrent and end of program.
Questionnaire and feedback.
To Improve contextual factors.
System Concurrent and end of program.
Questionnaire and feedback.
4. Evaluating Training Outcomes/Impact
Objectives For Whom When HowTo increase learning by individual participants
Participants ConcurrentObjective tests, skills tests. Analysis of assignments.
To increase use of After 3 months Task analysis, analysis of diaries,
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learning in work performance
Work Organization
periodically thereafter
critical incidents, interviews of participants and their role sets
To contribute data to Organizational Effectiveness
Work Organization
After 3 months periodically thereafter
Unobtrusive measures of conflict, collaboration, productivity, motivation etc.
To help the organization change
Training system and work organization
Once every three or four years
In-depth action research and consultation.
5. Evaluating Post Training Factors
Objectives For Whom
When How
To maximize cost effectiveness of training
System Once every three or four years
Cost benefit analysis, human resource accounting
To ensure post training support at work
System and work organization
Once a yearQuestionnaire, interviews, feedback, discussions.
To identify helping an hindering factors
System and work organization
Once a yearQuestionnaire, interviews, feedback, discussions
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Introduction of the project:
Need of the Study:
Kaygee Loparex India Pvt. Ltd. believes in quality of their product and pricing is higher than the other players in the market & that is why company’s customer base is niche in the current Industry’s they operate, to grow is the agenda of every company but with these principle of not compromising the quality for price, Kaygee Loparex India Pvt. Ltd. decided to explore newer application of their product, if at all needed a new product design for a particular Industry.
To do so management decided these projects to find out the application of their Silicone Release Liners in various Industries like Laminate, bakery & confectionary Industry, this particular project is divided in to two parts,
Part A is specific to Decorative Laminate Industry and focuses on the application of Silicone Release Liner, & it is to be check by doing research.
Part B is dedicated to Trans Dermal Patch, which is a new drug delivery system, here application is know but companies are not known as this a new innovation in world and its emerging in India.
As the product availed by Kaygee Loparex are of premium quality so there is high probability that organized players will use it as they don’t want to loose on quality part, if at all there is an application. For Kaygee it was important that to know the Indian market scenario as the joint venture firm Loparex already supplies to these Industry.
Background Study:
For both projects a good understanding of current products & its current usage was necessary, so we started with the product knowledge. For Part A i.e. Laminate Industry a secondary research was done to know the major players and to confirm the same a field study was done on Mumbai market’s Laminate dealers and wholesalers.
With this basic understanding of the players, sample was decided as a mix of small as well as big players. Also to get an idea about the manufacturing process a visit was done to a Permali Wallace Pvt. Ltd. a manufacturer of L
Justification for Topic:
This Topic will benefit both the researcher and company explained below.
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Company’s Benefit:
For both topic company will understand the Indian market which is the home for the company, and this report will upgrade the exiting knowledge of the company in the respective Industry.
From the first part i.e. on Laminate Industry, company will understand the application which is currently unknown and if report establishes the application then it will be a new market opening for the company which may increase the business. And in second part which is finding potential Trans dermal patch manufacturers, this will help company generate genuine customer base to which company can serve in the future and can start testing the product now, as it takes longer period for R&D.
Researcher Benefit:
Researcher will be benefited with the learning to handle such project independently and application of concepts learned into a practical problem faced by the company which will enhance its ability of critical thinking and development of business.
Over all he has the opportunity to know what all things are required to develop a new product and a new market for the company, during the period this project will also develop certain skill set of the researcher.
“Part A”
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Objectives of Research: 1. To find out whether there is a need of Release Liner in the Lamination
manufacturing process.2. If at all there is an application what is the potential market for Kaygee Loparex
India Pvt. Ltd.
Questions to be verified:1. Is there any need of Release Liner in the manufacturing process of Laminates?2. If at all there is a need will Laminate manufacturers use Silicone Release Liner?3. If “No” what are the factors which will affect use of Silicone Release Liner in
Laminate manufacturing process?4. If there is an application then what is the size of the market?
Tentative list of hypothesis:1. H0: There is application of Release Liner in the manufacturing process
of Laminates.2. H0: There is significant wastage in the process due to current measure of release.3. H0: Market Size of Laminate Industry is quantifiable for Kaygee Loparex
India Pvt. Ltd. to enter into this market.
Scope of the study:
Geographical scope: There are no geographical limitations to this study as manufacturing process will be the same and is not affected by location of the manufacturing unit. But it is limited India as in our study we are considering only Indian manufacturers.
Functional scope: This study is limited to the manufacturing process of Laminate and within that Pressing process as the application is going to be in that process or will not be there at all.
Time scope: As such this study is not time bound but current manufacturing process of Laminate may change in future so considering this as criteria this study can be used 3 years hence from day of publishing.
Research design:
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The study intends to investigate the application of Silicone Release Liners in the manufacturing process of Decorative Laminate. Thus, this study will determine whether or not there is application. For this study, primary research and secondary research will be used. Moreover, the descriptive research method will be utilized. In this method, it is possible that the study would be cheap and quick. It could also suggest unanticipated hypotheses. Nonetheless, our study is to know the existing manufacturing procedure of the Laminate Industry and to find where Silicone Release Liner can replace. Thus, this study will use the descriptive approach. Primary research is conducted using questionnaire surveys which will be filled by meeting Production Head / Technical Head face to face. Here, the questionnaires will be used to collect quantitative data and the interviews will be used to provide qualitative insights into the data collected, like factors affecting the replacement of existing measure to Silicone Release Liner if at all there is a requirement of releasing agent in the process. Apparently, secondary data are based from internet directory websites for the companies’ information.
As stated above, this research will partially base its findings through both quantitative & qualitative research methods because this permits a flexible and iterative approach. During data gathering the choice and design of methods are constantly modified, based on ongoing analysis. This study will also employ qualitative research method because it will try to find and build theories that will explain the relationship of one variable with another variable through qualitative elements in research. Through this method, qualitative elements that do not have standard measures such as behavior, attitudes, opinions, and beliefs within the business domain will be analyzed.
Exploratory research design:
In order to support Research design an exploratory research is done to get the basic understanding of the research, starting with the understanding of the Release Liner what they are used for and what are their properties to avoid the misinterpretation in the research, this was done as a primary study by visiting the factory of Kaygee Loparex and seeing the manufacturing process. And also a visit was made to Permali Wallace Pvt. Ltd. for Laminate detail knowledge.
As company was looking forward for a process liner which can be used during manufacturing process initial exploratory research & input from Permali Wallace Pvt. Ltd. classified the Laminate Industry into sub parts:
Texture Decorative Laminate Decorative Laminate
Also classified manufacturing process into three types: High Pressure Laminate Low Pressure Laminate Continues Press Laminate
Detail of the manufacturing process & different types is shown below:
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Decorative Laminate manufacturing process:
As mentioned above in flow chart the pressing of Laminates can be done through three different mechanisms as follows:
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Kraft Paper & Design Paper are treated at High temperature individually.
Engrave into 8 meter long sheets
Both sent to A/C Room for build up (see image 1.1)
Build-up goes through Heating & cooling process where chemical is also applied
Then pressed at High Pressure & Temperature
Grinded to 8x4 Standard Size
1. High Pressure Lamination.
Image 1During this process multiple Laminates are pressed together at high pressure and supplied steam of about 150 degree which makes Laminate build-up become final product i.e. Decorative Laminate. Temperature may vary with different manufacturer, but has a range of 140-160 degree. This is the one part of Laminate manufacturing process it is called “Pressing Process” and this specific mechanism shown in image is High Pressure Laminating Process this is where release is needed, as shown in Image-1 the Interleave is a intermediary between two Laminates and is used to avoid joining of two Laminates.Build-up which is made in A/C Room can see in Image 1.1 below.
Image 1.1
2. Low Pressure Lamination.
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Image 2
LPL is used mainly for the texture Laminate purpose; it serves one Laminate at one time, thus has a low productivity as compared to HPL but proves to be more effective for texturing the Laminate.
As shown in image 2 the build-up goes through a pressing process individually but here a texture release paper is used on the upper part in order to give a texture to the Laminate during the process as at this stage Laminate is undergoing high temperature and can be molded, so the small texture on the release paper is imprinted on the Laminate and makes a new product all together.
Only one design can be given to the lot depending upon the roll size of the texture release paper.
3. Continuous Press Lamination.
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Image 3
This is the continuous process where temperature is high as compare to other process and the build-up is not engraved in sheets, it is in form of rolls, each component of build-up is applied in rolls which makes this process continues one.
These all details gave us the input to the precise segment to focus on for our objective. Secondly: distribution of the Laminate. It is important to understand how Laminate is sold as we don’t know if can turn into advantage of applying Silicone Release Liner during the transportation or during the storage.
Understanding the companies which operate in this Industry, though Internet can provide this information but it is not 100% reliable, so to confirm the companies who are the manufacturers in India and do not outsource their manufacturing, for the sample of this research. We have to visit the distributors and dealers to know few of the company’s manufacturing Laminates in India.
Finally: we spoke to Laminate Association to get some input about the process of manufacturing in India. And they confirmed that there is only one process followed which is High Pressure Laminate. And by this exploratory research we had the probability of the Silicone Release Liner application. This can be used in the HPL process as Interleave.
Sample Size:
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In total 9 samples were selected as Industry has 105 total units and out of which 68 are organized a sample of 9 was good for concluding.
Sample selection is done by convenient sampling under Non-random sampling method, as were interested in manufacturing process of the Decorative Laminates and with the information form Laminate association it was know that it is same throughout the manufacturers India, we decided this method which is not only convenient but also cost effective to the company.
To validate the data T-test & Correlation-Regression analysis will be used.
Utility of this study:
This study will enable company to understand use of its product in different Industry and if results are positive then this will open all new market for them, also will solve the problem of growth which was faced a new market will increase the top line of the company. Before this there was no knowledge about the topic that is why this study will prove to be a discovery for the company’s existing knowledge about the application of their product.
Data collection:
Data is collected through questionnaire; it has attracted all required quantitative data like Technical specification for the process as well as the consumption of the companies.
Questionnaire started with the classification of the manufacturer i.e. Wood Decorative Laminate, Conveyor belts and Plastic Laminate. Then classified into the process they follow for the manufacturing, & to find the need of Silicone Release Liners some direct questions were asked like
“Is there any requirement to cover your product during that process for protection/ to retain its glaze?”
“Does current measure affect your product quality?” “Is there any wastage due to current measure?”
Questionnaire also consisted of technical specification like Temperature during manufacturing process. Silicone coat preference. Width of the Laminate/release agent. Thickness of the release agent currently used. Type of release base material used.
Above information is must if we need to develop a specific product for a Laminate Customer/Industry.
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Final question was on the consumption of their current measure, this is mainly to know Industry size.
To contact the companies for the interview contact details were taken from the directory websites, after calling appointments were fixed with the concern person in the production department.
Source of data collection:
Internet was one of the major tools used in this study for the secondary research of the companies in Laminate Industry, but to narrow down the search basic understanding of the manufacturing process is to be gained from an existing client Permali Wallace Pvt. Ltd.
Interview approach is selected for collecting the primary data, as information needed is technical specification of the process; this method would be effective to acquire that information. So the data collected both the quantitative and qualitative were collected personally by visiting each sample no telephone interview was done all the interactions were face to face.
Analysis & Interpretation of Data
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Quantitative:
Company name
ProcessProtection in process
Current measure
Quality affected by CM
Wastage by CM
Coat Preference
Temperature
Width(mm)
Thickness(Micron)
Repetition
Consumption Ton/Month
Meghdev Enterprises (Royale)
High Pressure
YesBOPP Film
No 0.00%Two Side
100-150
1300 20 4 4
National Ply & Laminate
High Pressure
YesBOPP Film
No 0.00%Two Side
100-150
1300 18 2 1
Gopinath Enterprise
High Pressure
YesBOPP Film
No 0.00%One Side
150-200
1220 18 2 0.6
Salasar Laminates Pvt. Ltd.
High Pressure
YesBOPP Film
No 0.00%Two Side
100-150
1260 18 3 0.4
Atith Fibre Private Limited
High Pressure
YesBOPP Film
Yes 0.50%Two Side
100-150
1300 18 4 0.4
Rushil Decor Ltd.
High Pressure
YesBOPP Film
No 0.00%Two Side
150-200
1220 30 5 2.5
Horizons Lamkraft Pvt. Ltd.
High Pressure
YesBOPP Film
No 0.00%One Side
100-150
1250 16 0 2.5
Bloom Dekor Limited
High Pressure
YesBOPP Film
No 0.00%Two Side
100-150
1220 18 2 1.5
Durian Laminate
High Pressure
YesBOPP Film
No 0.50%One Side
100-150
1260 18 0 3
Data collected through questionnaire is complied in tabular form for analyses purpose by using Ms Excel & is analyzed by using SPSS analytical tool.
One sample T-test is applied for “consumption” & “wastage” variables individually so as to conclude the findings for the Industry on the basis of collected samples. As this method gives us the mean for the population i.e. Industry.
Correlation is done for “Thickness of Film-Repetition use of Film & Consumption of Film-Thickness of Film”; to find the relation between pair which will give the understanding of cause & effect basically to understand whether thickness of film causes the multiple uses of films & does thickness affects the consumption pattern of film.
Regression is done on the “Thickness of Film-Repetition use of Film” as they showed highly positive correlation so this will help the actual dependency of Repetitive usage on Thickness of film.
One sample T-Test on consumption:
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To know the average consumption of the total Industry, one sample T-test is used to find nearest value on the basis of sample consumption data.
One-Sample Statistics
N Mean Std. Deviation Std. Error Mean
Consumption Ton/Month 9 1.77 1.291 .430
One-Sample Test
Test Value = 2
t df Sig. (2-tailed) Mean Difference
Consumption Ton/Month -.542 8 .603 -.233
One-Sample Test
Test Value = 2
95% Confidence Interval of the Difference
Lower Upper
Consumption Ton/Month -1.23 .76
Analysis:
Our testing for average of Industry was done on 2 ton/month, now comparing sig. value with .05 level of significance(as 95% is confidence interval), as sig. value is higher than level of significance, thus we do not reject the hypothesis. Hence, mean consumption of total Industry is 2 ton/month approx. (Refer table 2 above).
Since the lower limit is negative and upper is positive, but significantly lesser value than lower limit this means average for the Industry is nearer to 2 ton/month but cannot be more than 2 ton/month.(refer table 3 above).
Which leads to potential of Industry consumption is in range 110-130 ton/month.
Correlation analysis on "Thickness of film & Repetitive use of film."
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To find out the relation of repetitive usage of BOPP film on its Thickness, correlation is done to test the relation between these two variables.
Correlations
Thickness(Micron) No of repetition
Thickness(Micron) Pearson Correlation 1 .674*
Sig. (2-tailed) .047
N 9 9
No of repetition Pearson Correlation .674* 1
Sig. (2-tailed) .047
N 9 9
*. Correlation is significant at the 0.05 level (2-tailed).
Analysis:There is a positively high Correlation (0.674) between Thickness & Repetition, which means that one has the dependency on other as result is nearer to +1, which leads us to find the regression of these two so as to know the dependency of thickness on repetition.
Regression analysis on “Thickness of film & Repetitive use of film.”
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ANOVAb
ModelSum of Squares df Mean Square F Sig.
1 Regression 10.993 1 10.993 5.817 .047a
Residual 13.229 7 1.890
Total 24.222 8
a. Predictors: (Constant), Thickness(Micron)b. Dependent Variable: No of repetition
Coefficients
Model
Unstandardized Coefficients
Standardized Coefficients
t Sig.B Std. Error Beta
1 (Constant) -3.052 2.325 -1.313 .231
Thickness(Micron) .284 .118 .674 2.412 .047
a. Dependent Variable: No of repetition
Analysis:
By getting the coefficients for the regression and calculating on that basis we can conclude that below 14 micron repetition cannot be done.
Correlations Consumption & Thickness
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Various company use different thickness of BOPP which lead to repetition use of BOPP, and to test whether or not it affects the overall consumption Correlation is done to test the relation of two variables i.e. Thickness & Consumption.
Descriptive Statistics
Mean Std. Deviation N
Consumption Ton/Month 1.77 1.291 9Thickness(Micron) 19.33 4.123 9
Correlations
Consumption Ton/Month Thickness(Micron)
Consumption Ton/Month Pearson Correlation 1 .277
Sig. (2-tailed) .470
N 9 9
Thickness(Micron) Pearson Correlation .277 1
Sig. (2-tailed) .470
N 9 9
Analysis:
There is a positive relation between these two variables but it’s not significant enough, thus we conclude consumption is affected by the thickness of the Film but not significantly.
Graph 1: Pie diagram for the response given for the wastage happening because of current measure of releasing agent.
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Analysis:
As a majority answer to the affected quality by Non-Silicon BOPP was NO, with the 88% of manufacturer said there is no quality defect due to use of BOPP film as a current measure for release, and 11% of then said yes there is a effect on quality, during the interview those who marked this as yes said, “There is a effect on quality but not significant enough”.
Graph 2: Pie diagram for the repetitive usage of BOPP film in the process.
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Analysis:
About 75% of the manufacturer use BOPP repetitively in which 33% of them use it more than 3 times, and only 22% of total do not like to repeat though it makes there process a bit costly.
One sample T-Test On percentage waste due to current release measure:
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One-Sample Statistics
N Mean Std. Deviation Std. Error Mean
Wastage by CM 9 .11% .220% .073%
One-Sample Test
Test Value = .1
t DfSig. (2-tailed)
Mean Difference
95% Confidence Interval of the Difference
Lower Upper
Wastage by CM .151 8 .884 .011% -.16% .18%
Analysis:
Our testing for average wastage of Industry was done on .1%, now comparing sig. value with .05 level of significance(as 95% is confidence interval), as sig. value is higher than level of significance, thus we do not reject the hypothesis. Hence, average wastage of total Industry is .1% approx. (Refer table 2 above).
Since the lower limit is negative and upper is positive, but upper value is significantly higher value than lower limit value, this means average wastage for the Industry is nearer to .1% but cannot be more than 0.1 %.( refer table 3 above).
Qualitative:
Every interview gave same response as in there was a application for the Release Liner but no one responded for its need as they were happy with the performance of the current measure (BOPP film), most of the Clients were eager to try Silicone Release Liner for various purpose, like texture printing for which we did not have a texture release paper, some wanted to replace it for quality purpose, but they were unaware of the cost they have to incur as it was told to them.
Major samples gave the response that it can be used if repetition is more or cost per sheet is less, or introducing a texture Release Liner will also enable to cater Laminate market but texture Laminate itself has a small market in India currently and to scale this it will take 2-3 years.
Findings and Conclusion:
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A Laminate is a material that can be constructed by uniting two or more layers of material together; the process of creating a Laminate is lamination, which in common parlance refers to the placing of something between layers of plastic and gluing them with heat and/or pressure, usually with an adhesive.
There are various type of Laminate out of which is Decorative Laminate, Decorative Laminates are produced with Kraft papers and Decorative papers with a layer of overlay on top of the Decorative paper, set before pressing them with thermo processing into high-pressure Decorative Laminates.
The country has in all 105 units, of which nearly 68 units are in the organized sector. With Laminates being used extensively in commercial and residential spaces, including flooring, furniture and artificial ceilings, Construction Sector depends on it, any price change can affect constructions cost, as on 2008 total Industry size for Laminates in India was 4000 crores. (Information taken from economic times see link below in website).
HPL is the only process used in India for Decorative Laminates, as confirmed with all visited manufacturers (see onsite information) & Indian Lamination manufacturer association. At high pressure & temperature multiple build up (see image 1.1) of Laminate are pressed to make the final product, Interleave is where BOPP film is used as an intermediary which does not allow two Laminate to join together during this process.
Layer of “Release Paper” shown in above Image-1 is used for giving texture to the Laminate, this procedure is not done anywhere in India (except Meghdev enterprise), as there is no market for texture Decorative Laminates in India currently, as it was observed during the discussions with the marketing and technical experts of the manufacturer we visited ,they are keen to develop texture Laminate in near future as, Mr. Jitendra from Meghdev enterprise(Royale Laminate) said they are manufacturing texture Decorative Laminates but very small quantity and if compared to Decorative Laminate it is negligible, for which machinery is different i.e. LPL(see image 2), he added. Mr.Jitendra is also the president of Lamination association in India. Also Mr.Janak from Durian Laminate asked for a sample of Silicone release paper to test but what Kaygee produce is plain Silicone coated release paper and for above a texture paper is coated with Silicone which is not a product of Kaygee Loparex as of now.
And without the significant demand no manufacturer is going to invest for this machinery, as Meghdev Enterprise is one of the major players in Decorative Laminates with four brands under the umbrella and enlarged portfolio know the future of Laminate market in India so as to get a first mover advantage they started this texture Decorative Laminate.
Application of Silicone Release Liners:
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Although Silicone Release Liner is applicable in the manufacturing process of Decorative Laminate as an Interleave, though there is no adhesive involved but required properties are over satisfied by Silicone Release Liner. But there lies a challenge to make it applicable in High pressing process in India.
To replace the BOPP film which is currently used for release measure in High Pressure Laminate process, there has to be some need in the process itself which can be either issue in Quality or Wastage during process by using BOPP film, report shows about 88% of them said there is no issue in the Quality of Laminate by using BOPP film, rest said “yes” but there is no significant difference in Quality or very minor error which can be managed. (Refer Graph 1)
And for the wastage data was collected for the percentage wastage from each of the sample in study, after analyzing data showed that the average wastage for the Laminate Industry is less than 0.1%, which is negligible. Same feedback was given by manufacturers during the interview. (Refer T-test on percentage wastage)
Factors restricting for application:
One of the major factor is cost, as every single component in the process of manufacturing carries a cost and in today’s context every company want it to be optimized, as Silicone Release Liner is expensive than normal BOPP film used by Laminate manufacturers & in order to reduce cost majority of manufacturer use BOPP film repetitively (refer Graph 2), this is another factor perhaps a challenge to make Silicone Release Liner more repeatable in use along with the cost of it, in order to replace BOPP film.
Our analysis has shown that repetition strongly depends on the thickness of the film (BOPP) and which cannot be done below 14 micron (refer Correlation & Regression analysis on Thickness of film & Repetitive use of film) i.e. thickness of the film.
Which in the end affects the consumption of BOPP film in the process though analysis has shown there is not much dependency of consumption on Thickness, but it has also shown a small positive relation (see Correlation analysis on Thickness of film & consumption of film) which means there is a direct relation between two, if one increases another might shows same behavior.
Analysis also showed that the average consumption of BOPP for the Industry is slightly less than 2 ton/month/customer, which shows the potential of the Industry for Silicone Release Liner, which when calculated can be in range 110-130 ton/month.(refer T-test for consumption).
Confirmation of Hypothesis:
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First H0: There is an application of Silicone Release Liner in the manufacturing process of Laminates.
With the help of exploratory research and findings application is confirmed. Hence, we do not reject the first H0. I.e. there is an application of Silicone
Release Liners in lamination manufacturing process.
Second H0: There is significant wastage in the process due to current measure of release. Analyzing wastage from samples data by using T-Test we have concluded that
there is no significant wastage in the lamination manufacturing process (see T-Test on wastage).
Hence, we reject Second H0. I.e. there is no wastage in lamination manufacturing process by current measure of release.
Third H0: Market Size of Laminate Industry is quantifiable for Kaygee Loparex to enter into this market.
By using T-Test on consumption of the current measure in lamination manufacturing process we have concluded that there is a huge market potential for company to enter which is in range of 110-130 tons per month.
Hence, we do not reject the Third H0. I.e. there is quantifiable market size for company to enter this Industry.
Recommendations:
Currently it is not recommended to enter this market but as it seems future potential market for company following are some recommendations on same.
As there are two different segments in the Laminate market, 1. Texture Laminate.2. Decorative Laminate.
For the Texture Laminate Kaygee will need new machinery and space, and seen the potential for the same is not very significant it is recommended this should be left for at least 2 years and then check with the samples again to validate its potential.For the Decorative application following are the details:
Application in process:
As observed, there is an application of Silicone Release Liner in the manufacturing process of Laminate, but currently there is no problem faced by the manufacturers by the current measure of release i.e. BOPP film, in order to enter into the Laminate Industry company needs to develop a new product which can be used more number of times then the current measure or wait for the new segment i.e. Texture Laminate to scale up in India and then make a texture based Release Liner
Factors affecting application:
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Cost & Repetition, to overcome these two barriers Kaygee Loparex either should develop a product which will match BOPP’s cost knowing company’s principle this is not recommended to make a low cost product but company can come up with a product which can be use more number of times as compare to BOPP film so as to give a cost effectiveness to Laminate manufacturer, as our analysis has shown BOPP has the limitation to repetition, it cannot be used twice if it is thickness is less than 14 micron & cost of BOPP film increases with the micron, using this as a concept Kaygee Loparex should develop a film which is below 14 micron and can be used repetitively then it may be able to tap the Laminate market.
Implementation of the recommendations:
In order to make a texture Release Liner company needs a new machinery, which will incur cost to the company and as currently there is less than 5% market for texture Laminate in whole Laminate market, company needs to wait at least for 2 years for texture Laminate to scale up in India.
For a lesser thickness product with more repetition to be developed company should make some sample products and give it for trail purpose to the Laminate manufacturers which have already been contacted as they were told for trails and they agreed on trying the new product if it can reduce their cost as well.
Outcomes of the implementation
Likely outcomes for Texture Decorative Laminate is company can be first mover in this category in India, if company does it on time. As company is already leading in India for rest of application of Release Liner because of its premium quality same can be replicate in this Industry. As Decorative Industry is huge and if texture dominates the market this will grow at large scale, which will indirectly benefit the Release Liner maker, as all texturing depends on the texture release paper.
For current trial’s outcome has half the probability, a lesser micron film may be used more than BOPP film it totally has 50% chance of happening, it can be concluded only after a few trials.
Exhibits: 57
Primary (questionnaire):
Q. Which of following you manufacture?a) Plastic Laminates. b) Wood Decorative c) Conveyor d) ----
Q. Which process do you follow?a) Low pressure b) High pressure c) Continuous press d) -----
Q. At what temperature does your product goes during manufacturing process?a) 50-100 b) 100-150 c) 150-200 d) >200
Q. Is there any requirement to cover your product during that process for protection/ to retain its glaze?a) Yes b) No
Q. What are the current measures to protect them?a) b) c) d)
Q. Does current measure affect your product quality?a) Yes b) No
Q. How does it affect your Quality standards?a) Does it sticks to product some times.b) Does adhesives come out at high pressure and stick to machine & damage next lot.c) Does the glaze of the product is not satisfied due to current measure
Q. Is there any wastage due to current measure?a) Yes b) No
Q. How much currently on an average is wasted?a)
Q. Do you also feel the requirement to cover/protect in finished product?a) Yes b) No
Q. If so please explain in detail:------------------------------------------------------------------------------------------------------------
Q. What if we provide a product to reduce your wastage, will you be interested?a) Yes b) No
Q. If yes are you willing to pay extra for a quality product?a) Yes b) No
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Q. What Type of adhesive you use?a) Hot melt b) Rubber c) Acrylic
Q. Select the preference?a) One side coated b) Two side coated.
Q. Select your current process?a) Adhesive on paper.b) Adhesive on product.c) High pressure manufacturing process.
Q. where do you need Release Liner?a) Lamination b) Storage c) Handling
Q. What technical specification of current measure?a) Temperature: I. 0-50 II. 50-100 III. 100-150 IV. 150-200 V. >200
b) Width:
c) GSM: I. 25-50 II. 50-75 III. 75-100 IV. 100-150 V. >150
d) Release force: I. 5-25 gm II. 25-70 gm III. 70-150 gm
e) Thickness:
f) Paper type: I. Glassine II. SCK III. CCK IV. MGK V. PEK
g) Film type: I. LDPE II. HDPE III. BOPP IV. CPP V. PET film
Q. How many repetitions you do/need?a) NO b) 2 c) 3
Q. What is the average number of sheets u manufacturer in a month?
Bibliography:
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Websites:
www.tradeindia.com/Seller/Construction-Real-Estate/Decorative-Laminates/dir.indiamart.com/indianexporters/plywood.htmlwww.alibaba.com/countrysearch/IN/Decorative-Laminate-supplier.htmlwww.justdial.comwww.warrenreleasepapers.sappi.com/homewww.ilma.org.in/http://epaper.timesofindia.com/Repository/ml.asp?Ref=RVRBLzIwMDgvMTIvMTIjQXIwMDIwNQ==&Mode=HTML&Locale=english-skin-custom
Books Refered:
Marketing research by Marketing management by Philip Kotler(13th edition).
Onsite information:
Interactive discussions with,
1. Mr.Pushkar, from Indian Laminate Manufacterer Association.2. Mr.Bhujang, R&D Head of Parmalle Wallce Pvt. Ltd..3. Mr.Janak (GM) & Mr. Hitesh (Production) from Durian Laminate Ltd..4. Mr.Mukesh, Director of Atith Fibre Pvt. Ltd..5. Mr.V.Narayan, Marketing head of Horizons Lamkraft Pvt. Ltd..6. Mr.Jitendra, Founder director of Meghdev Enterprise(Royale Laminate).7. Mr.Bhaven, Purchase head of Rushil Decor Pvt. Ltd..8. Mr.Jagdish, Plant head of Bloom Laminate.9. Mr.Rajan, Marketing Manager of Bloom Laminate.10. Mr.Deepak, Marketing Head of National Ply & Laminate.11. Mr.Arshad, Marketing manger of Gopinath Enterprise.12. Mr.Anil, Proprieter of Kamakhya Industries.13. Mr.Umesh, Distributor of Royale Laminate.14. Mr.Shankar, Owner of Shiv Shankar Enterprise.
"Part B”Trans Dermal Patches
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Summary:
This part of the project was to identify the pharmaceutical companies who has the capability to make Transdermal patches in India, as this technology itself is new in India non of the companies have launched product all are in the testing mode, so initialy it was known by us it would be difficult to get the precise answer of our question who all are the target companies.
Here application of Silicone Release Liner was know to the company, it is used to protect the adhesive till the time a consumer uses it.
We conducted a secondary research using internet as a tool to find out the what type of drugs can be used in the TDP so as to get close to the target and some news reports to find out which all companies are in news for same.
Introduction of TDP:
A transdermal patch is a medicated adhesive patch that is placed on the skin to deliver a specific dose of medication through the skin and into the bloodstream. This is the another type of drug delivery system which is not new but slowly emerging. An advantage of a Trans dermal drug delivery route over other types of medication delivery such as oral, topical, intravenous, intramuscular, etc. It provides a controlled release of the medication into the patient, usually through either a porous membrane covering a reservoir of medication or through body heat melting thin layers of medication embedded in the adhesive. Main advantage of this patch is patients dont have to go through pain of dialy vacination and also dont have to remember about the dosage, just need to change the patch on time. Currently these patches are popular as Nicotine Patches as in U.S.A 90% of patches sold are Nicotine, this Nicotine patche helps smokers to quit smoking with the constant supply of nicotine in body a smoker doesnot feel a need for a smoke.
Objective of Research:1. Which are companies who manufacture Trans Dermal Patches in India.2. What is the clasification of the comapanies for making TDP.
Questions to be verified: Are there companies in India who manufacture Trans Dermal Patch currently? Who all are the future prospects for TDP? On what basis Kaygee should classify the companies?
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Scope of Study:
Geographical: This study is limited to India as company needs information regarding Indian Pharma potential manufacturers.
Functional: As it is releated only to the application of Release Liner in TDP which is final product, this study has its limit to the manufacturing and R&D functions only.
Time: As TDP it selfis in Developing stage and it will take another year to be in market, this study has its validity around 3-4 years.
Research Design:
As the threat to confidential data was known to the company, we decided to go for the telephonic approch of the research, here question was only few i.e either these companies are into TDP or may come up in future or any R&D is in process for same.
Challenge is to connect to the right person in Formulation R&D department as they the one who develop products like TDP for the companies.
Exploratory Research:
Initially we did seconadary research using internet and found various segments where TDP has been or may be applicable:
Nicotine Patch: currently many companies like Pfizer, Elder, Novartis, etc are trying to enter this market as refered to Times Of India news, but some of them are looking specificly towards Nicotine patches.
Diabities Patch: there are many diabitic patients who need to take daily dosage through vacinations so companies feel that patches can solve there vacination pain problem and it would also be convenient to use.
Pain relif drug delivery system: For many of the pain relif measures TDP is used currently in U.S and other nations, which is extending towards India in recent time.
These three are the major segments for the company to cater, as application will be same for each of them but product may varry.
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We found there few drugs commanly used for TDP: Diclofenac. Fentanyl Buprenorphine Nitroglycerin scopolamine Clonidine methylphenidate Cyanocobalamin Rivastigmine Selegiline
Using these drugs as a source we found who are the manufacturers of these drugs in an assumption that these companies may come up with the TDP, so our classification of the comapnies was based on:
1. Big oragnized players in Pharmaceuticals.2. Medicine manufacturers.
Big companies were known from the news and magazine online which may be the future prospect to the company.
Sample Size:
A large sample of 30 was taken with the mix of two category of comapnies as mentioned above, this will enable us to understand what is the situation of Pharmacuetical in India. And population is big so we took large sample size.
Utility of Study:
This study will enable company to understand which all companies need to be targeted for TDP and there classification, this will also enable them to know how many companies are already in R&D stage and how many have yet to start, which will give them guidance in there planning for the new market.
Data Collection:
Data was collected through respective Formulation R&D heads of the companies mentioned by using Telephone as a medium. There are restriction in validity of data but as all informatio was collected geniunely talking to the right person in the formulation R&D of the company we can depend upon this information.
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Analysis of Data:
Total of Responses:
Analysis:
Overall 62% is the chances are there for the TDP application as only 24% of the response said there is no plan for manufacturing TDP in future as well & around 14% does not have R&D in India, and 24% are already covered by the company and R&D trials are in progress.
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Responses of Drug Manufacturers:
Analysis:
Majority of Drug manufacturers have no plans to come up with TDP, with few having the intensions about 21% of them are already been approached by company and remaining 28% will take time.
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Responses of Organized Players:
Analysis:
Only 6% of the organized players they have no intensions to make TDP & and 20% of them do not have R&D in India, few did not gave any response, some are already in R&D mode, and 20% of them will come up in near future.
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Findings and Conclusion:
As application is already known to the company, findings for this research were the companies who can maufacture Trans Dermal Patches in India, as already mentioned the details in Exploratory research final finding was the major company list and there concern persons in the Formulation R&D which would be helpful for the future trials, as very few are there whom company has already approached but major are keeping the information confidential but by this study we have already communicated all of them regarding our company so as soon as they feel a R&D trial of the product they can contact us or company can also approach after a time period.
Answers to the initial questions of the company:
1. Are there companies in India who manufacture Trans Dermal Patch currently?
There is only one company who currently manufactures TDP which is Sparsha Pharma a hyderabad based company, Kaygee Loparex is already in touch with them.
2. Who all are the future prospects for TDP?
There are many future prospects for TDP given in the data base, but it will take time for them to come in R&D stage but initial communication is done to them about Kaygee Loparex India Pvt. Ltd..
3. On what basis Kaygee should classify the companies?
First classification for companies should be organized players as they have the potential to develop such product and some of them are already in R&D stage. Secondly company can focus on the some drug manufacturers which have responded positively during this study as there is minority of these class so it is not recommended but for classification yes there are few in this segment as well.
Recommendation:
Kaygee Loparex India Pvt. Ltd. has to wait for some companies to respond as there planning for TDP is in process and they dont want to disclose any information regarding there product development, as during this study we have already gave company information to them so there is high probablility that they will revert when they need Release Liner for testing, if not we have the database of concern person we can again get in touch with them in due course. Those who have already started R&D for TDP have been given samples for trial same needs to be done with rest of the companies.
There are organized players who needs to be approached with in 6 months and the drug manufacturer will take longer time may be an year, so organized player should be on priority for the company.
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Exhibits:
Questionnaire:
Q. Are you manufacturing Trans dermal Patches Currently?a) Yes b) No Q. Do you have plans for future?a) Yes b) No
Q. Which pain relief management you are/going to use patches for?a)
Q. What type of liner you need?
a) Paper:
I. Base paper: i. Glassine ii. SCK iii. CCK iv. MGK v. PEK
II. GSM:
b) Film:
I. Base Film: i. LDPE ii. HDPE iii. BOPP iv. CPP v. PET film
II. Thickness:
Q. What Type of adhesive you use / going to use?a)
Q. What is the width required?a)
Q. What is yield per roll required?a)
Q. What is the average consumption?a)
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Bibliography:
Websites:
http://www.ipapharma.org/PTarchives.aspxhttp://www.indiamart.com/http://www.tradeindia.com/http://en.wikipedia.org/wiki/Transdermal_patch
Telephonic Conversations:
1. Ms. Rachi (R&D) from Alchem International Ltd.2. Mr. Ayur, R&D Head, Pfizer Ltd. 3. Dr. Ghoopchandani, R&D Head, Elder House Pharma Ltd.4. Mr. Vivek Gadgil, CBD Head, Elder House Pharma Ltd.5. Mr. Mohamed, R&D Head, Ranbaxy Laboratories Ltd.6. Ms. Joyeta paro, TL R&D, Biocon Pharma Ltd.7. Ms. Sumehdha, API R&D Head, Novartis India Ltd.8. Ms. Tejaswini, Formulation R&D Head. Novartis India Ltd.9. Ms. Bhagti, Director, Healthy Life Pharma Pvt. Ltd. 10. Mr. Rakesh Bhattacharjee, Proprietor, Schwitz Biotech Ltd.11. Mr. Ajit, R&D, Aurochem Laboratories (I) Pvt. Ltd.12. Mr. Nagraj, R&D, Aurochem Laboratories (I) Pvt. Ltd.13. Mr. Gurraj, API Production Head, Aurochem Laboratories (I) Pvt. Ltd.14. Mr. Dayanand, Production Head, Aurochem Laboratories (I) Pvt. Ltd.15. Mr. Chetan, R&D Head, Titan Laboratories Pvt. Ltd. 16. Dr. Dalvi, API R&D Head, Neon Laboratories Ltd. 17. Ms. Nita, Formulation FDD Head, Neon Laboratories Ltd. 18. Mr. Raj, R&D Head, Taj Pharmaceuticals Ltd.19. Mr. Sanjeev sethi, Owner, Solitaire Pharmacia Pvt. Ltd. 20. Mr. karamchandnani, Owner, Sellwell Pharmaceuticals Pvt. Ltd.21. Mr. Pratik, R&D, Rhydburg Pharmaceuticals Ltd.
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