Production Process Management of Packaging in KDS Accessories Limited

In Bangladesh total about more than 50 numbers of packaging producing companies available. KDS accessories (Bangladesh) Ltd. is one of the leading packaging producing industries.

Now a days packaging sector is highly competitive. More or less all the local companies offer nearly similar quality products to the customers. But one thing that KDS group of companies (Bangladesh) Ltd. producing different types of packaging which called application based packaging.

KDS group of companies (Bangladesh) Ltd. has more than 501-1000 employees. It is one of the most important duties of the company to make an employment opportunity.

ORIGIN OF THE REPORT :

Internship program is a pre-requisite for acquiring BBA degree. Before completion of the degree, a student must, undergo the Internship program. Every student under the internship program has to prepare a report based on the project or particular matching with the Intern’s area of specialization and organizational requirement. The report writing consists of Intern’s analysis, findings and achievements. This report titled “production process management of packaging a study on KDS accessories Ltd.”

 

OBJECTIVE OF THE STUDY:

There had been some objectives set forward in doing this report so that it can be determined what tasks have to done. The objectives of the report are:

Main objective:

  • To companies with the KDS group (Bangladesh), its operation and activities, management style and attempt to realized the gap between the theoretical knowledge with the real business world.
  • Identifying inherent problems associated with the process like, machine disturb, gas problem, raw material process and kind of technician.

Auxiliary objective:

  • To analyze the opinion of employee regarding the process.
  • To analyze an organizational culture of mutually openness, trust, and mutual respect for achieving organizational goals.

PURPOSE:

The purpose of this study is to analyze the packaging producing process of KDS group (Bangladesh).and finally producing garments products.

SCOPE OF THE STUDY:

The study was boundless to the KDS accessories Ltd. due to 3 years working on packaging producing process in many companies as well as abroad.

The study inquired into the packaging producing process. It is also aimed at identifying the present problems faced by the employees due to process, and management philosophy. Attempts were made to find out the factors which need to be changed and improvised.

 

METHODOLOGY:

Research is the process of gathering, recording and analyzing critical and relevant facts about any problem in any section of the process. Research refers to the systematic method consisting of enunciating the problem, formulating a hypothesis, and collecting the facts or data.

All the information incorporated in this report has been collected from primary sources as well as secondary sources.

Primary Sources

Information collected for the specific purpose at hand.

  • Interview with the branch manager, operations manager and some other employees at Gazipur.
  • Discussion sessions with HR officials in Head Office at Dhaka.

Secondary Sources

Information that already exists somewhere, having been collected for another purpose.

  • KDS accessories Ltd. Annual Reports 2011.
  • Job description for each employee of KDS accessories Ltd, at Gazipur.
  • Performance appraisal format.
  • Performance appraisal guideline provided by the Human Resources department.

 

AN OVERVIEW OF KDS ACCESSORIES (BD) LTD.

BACKGROUND OF THE COMPANY:

KDS accessories is a Group of company. The company main based products is garments products. The company develops many sectors like apparel, banking, insurance, investment management, logistics, steel, textiles, trims and packaging etc. KDS accessories (Bangladesh) Ltd. established in Bangladesh in 1984 and started business in Bangladesh in 1988. The packaging sector established in Bangladesh in 2007 and started business in Bangladesh in 2008.

In Bangladesh total has two packaging plants. One plant is situated at Gazipur and other plant at Chittagong. Total packaging producing line is numbers. Packaging producing capacity per annum is 500 ton.

PRODUCTION PROCESS

Production:

The process and methods employed to transform tangible inputs (raw materials, semi finished goods, or subassemblies) idea that consumers will favor products that is available and highly affordable.

Production process:

Mechanical or chemical steps to create an object usually repeated to create multiple units of the same item

Production process management:

Production process management is the collection of technologies and methods used to define how products are to be manufactured.

Overall Production process:

Overall production process is a client centered, needs based companies how to be the low cost, high quality, environmentally responsible, safety conscious leader in their industry.

Management System:

A management system is the framework of process and procedures used to ensure that an organization co fulfill all tasks required to achieved its objectives.

Management strategy:

Is the concerned with managing the strategy-making process to increase the performance of a company, thereby increasing the value of the enterprise to its owners, its shareholders.

RAW MATERIALS:

  • Paper:

Paper is one of the main and most essential raw materials for packaging producing sector.  Generally 90% to 95 % of paper used for producing packaging. Normally paper comes in our country through importing from different countries like Thailand, Vietnam, Philippine, Indonesia, India etc.

  • Gum:

Gum is another one of the most essential raw materials for packaging producing sector.  Generally 3% to 5% of gum used for producing packaging. Normally gum comes in our country through importing from different countries like Thailand, Vietnam, Philippine, Indonesia, India etc.

  • PVC:

PVC is the additional ingredient of the packaging. During packaging producing time add the PVC for reducing the cost as well as increase the quality of the packaging. To add the PVC during packaging producing time is a latest technology. Generally 2% to 3% of PVC add during producing packaging. PVC comes in our country from India, Thailand and China.

  • Color:

Color is also the additional ingredient of the packaging. During packaging producing time add the color for reducing the cost of the packaging without disturbing the quality. Generally 1% to 2% of color adds during producing packaging. Color comes in our country from India and China.

Carton Machinery Printing Slotting Die-Cutter XinTian XT-X Series

Functions: International famous-brand electric parts and computer software are used in the whole machine of stable and reliable quality in the human-computer interface where zeroing can be adjusted at one time with automatic memory reposition. The whole machine baffle and key parts are

Carton Machinery XinTian XT-M Series Die-Cutter

Features: This machine is exclusive equipment for die cutting and molding, suitable for the manufacturing of colorful cartons, boxes and other package roducts of abnormal shape. It adopts the double roller pressing and urethane soft template; die cutting speed difference servo makes up to

Carton Machinery Flexo Printing Slotting Machine XinTian XT-L Series

Functions and Features: Chain feeding model with a clutch between the working table and unit creates convenient gravure registering. Motorized detachment and combination; pneumatic locking and loosening of printing units; automatic ink distribution and pneumatic brake separation orientating

Carton Machinery XinTian XT-L Series Slotting

Standard equipments: Paper feeding unit: It adopts chain feeding model controlled by step less speed regulation. Lead edge of paper feeding is equipped with elastic feeding pressure plate to ensure the bent paperboard to be smoothly sent in. Optically controlled counter presets order.

Carton Machinery XinTian XT-L Series Printing Slotting

Functions and Features: Chain feeding model can ensure that the bent board paper be smoothly sent due to the elastic pressing plate at the front of feeding system. Motorized detachment and combination; pneumatic locking and loosening of printing units; automatic ink distribution and plenum

Detailed Product Description:

Functions and features:

  • International famous brand electric parts and computer software are used in the whole machine with stable and reliable quality; human-computer interface, computer order storage, convenient operation and faster order update. (It can presort 999 orders in the computer.)
  • Complete machine baffle and important parts use tempering to decrease the metal internal force; and all parts are made by high-precision processing center and grinded by numerical -control grinder.
  • All transmission axles and rollers are made by high-quality steel, and processed through tempering and dynamic balance; plated with rigid chrome and grinded surface.
  • All transmission gears are made by 20CrMnTi alloy steel, which is grinded after heat-treatment, rigidity HRC58-62, and which is made by rubbing, 6 grade precision to maintain high topping precision after long using.
  • All transmission parts (connected with the axles and gears) adopt the hand-free connecting ring to eliminate the interval, suitable for long-term high-speed running.
  • All transmission bearings adopt strengthened model bearing, equipped with dustproof wind tight parts and the oiling, handy to maintenance, lasting for longer using.
  • The whole machine undergoes automatic spray lubrication, with intuitionistically showing facilities and double oil pipe balance system.
  • The whole machine runs with the adjustment presetting function, feeding, printing, slotting, die cutting all featuring auto- zeroing and memory automatic reposition.
  • The whole machine working interval adjustment adopts fast spanner-free adjustment and the electromagnetic brake system with the worm wheel and worm setting operates fast and conveniently.
  • The mainframe chooses control by frequency conversion, with more stable and energy-saving for start-up and running.
  • Option for the vacuum adsorption, kick feeding or leading edge feeding.

Optional equipment’s: ceramic analog roller, leading edge feeding system, remote computer diagnosis system, stacker.

  • It is a kick paper-feeding machine of vacuum adsorption, made of alloy aluminum, light and wear-resisting, with engineering plastic guide rail, equipped with several groups of rolling bearing to reduce the friction between papers so as to maintain a steady operation.
  • Left and right baffles, kick feeding, back baffle adopt electric-controlled adjustment and computer numerical-controlled adjustment.
  • Brush and the air draft deducting device can clear away the impurity from paper face to improve the printing quality.
  • The mainframe is controlled by the frequency conversion, with steady start-up and running, saving about 30% of the power.
  • Infrared photo electricity counter presets the order processing quantity.
  • One lock function for whole machine avoids damage caused by error operation (The mainframe can’t start up when every unit hasn’t been connected.)
  • Option of consecutive or skip paper feeding.
  • Air pressure type elastic feeding rubber roller can’t damage the strength of corrugated cardboard, with down feeding roller, plated and embossed with hard chrome.

Side baffle moves simultaneously with slotting unit and finishes the adjustment with trimming the side or not., saving time and effort, added with the pneumatic-flapping facilities to make more precise paper horizontal orientation and avoid waste.

Slotting Unit:

Functions of Slotting Unit:

All the carton size, height and phase are adjusted by computer in the human-computer interface, saving time and effort, improving working efficiency, able to store 999 common orders.

  • Double slotting structure and big diameter trace-pressing wheel produce best effect of box grooving and formulation.
  • Slotting tool rest, trace-pressing wheel and the horizontal moving structure of trimming knife adopts the precision lead screw, making more precise height and more accurate orientation for the upper and lower cutting so as to effectively lengthen the service life of the knife.
  • The elastic tangential cutting structure can cut off three and five layers of the cardboard without adjustment.
  • The slotting knife is made of high-quality alloy steel, grinded after heat treatment, with excellent rigidity and tenacity and long life of using.
  • Option of portable punching die holder.

Printing Unit:

Functions of Printing Unit:

All the axles and rollers are made of high-quality steel, rectified by computer dynamic balance, eliminating centrifugal force, plated with rigid chrome and grinded surface.

  • Printing phases adopt the planetary gear surface, controlled by PLC touch screen, with digital electric 360o adjustment(stopping and starting the machine both can be adjusted.)
  • Printing roller landscape orientation is controlled by touch screen, with digital electric adjustment of a scope of 20mm.
  • Ink inspecting system alarms the lack of oil and automatically stops paper feeding at the same time.
  • Plate-hanging device with whole hanging and half hanging slotting notch, foot switching controlling the clockwise and anticlockwise rolling, convenient to fixing and taking down the plate.
  • Fixed oil interval, printing pressing roller and leading roller interval are adjusted by fast spanner-free facilities with fixed electromagnetic brake.
  • Printing phase fixing adopts pneumatic brake structures, which will restrain the mainframe’s running to keep the original gear fixed position unchanged.
  • Reposition functions to memorize the printing position by computer and automatic reset after scrubbing plate.
  • Rubber roller and steel pipe surface are covered by wear-resistant rubber, specially grinded in intermediate-high grade, causing excellent working of the anilox roller.
  • Steel anilox roller with grinded steel pipe and pressing anilox and plated with rigid chrome (option of ceramic anilox roller)
  • Pneumatic plate-uplifting device functions as the anilox roller pneumatically separates with the stopping of the mainframe, automatically smoothing the oil to avoid dried oil.

Die-cutting Unit:

Functions of die cutting:

  • Die-cutter phase is adjusted through computer and digital electric control.
  • Die-cutting knife horizontal adjustment undergoes the computer and digital and electric control of a scope of ±5mm.
  • Glue roller cutting and trimming facilities include the cushion able to be used for many times and save the cost in a great deal.
  • The cushion roller’s mechanical, horizontal cam facility of a scope of ±35mm prolongs the lifespan of the die-cutting cushion.

Feeding Unit:

Functions of Feeding Unit:

  • Electric-controlled connecting and separating every unit, with alarm to secure operator by consecutive ringing during its processing.
  • It is a kick paper-feeding machine of vacuum adsorption, made of alloy aluminum, light and wear-resisting, with engineering plastic guide rail, equipped with several groups of rolling bearing to reduce the friction between papers so as to maintain a steady operation.
  • Left and right baffles, kick feeding, back baffle adopt electric-controlled adjustment and computer numerical-controlled adjustment.
  • Brush and the air draft deducting device can clear away the impurity from paper face to improve the printing quality.
  • The mainframe is controlled by the frequency conversion, with steady start-up and running, saving about 30% of the power.
  • Infrared photo electricity counter presets the order processing quantity.
  • One lock function for whole machine avoids damage caused by error operation (The mainframe can’t start up when every unit hasn’t been connected.)
  • Option of consecutive or skip paper feeding.
  • Air pressure type elastic feeding rubber roller can’t damage the strength of corrugated cardboard, with down feeding roller, plated and embossed with hard chrome.

Side baffle moves simultaneously with slotting unit and finishes the adjustment with trimming the side or not saving time and effort, added with the pneumatic-flapping facilities to make more precise paper horizontal orientation and avoid waste.

Slotting Unit:

Functions of Slotting Unit:

All the carton size, height and phase are adjusted by computer in the human-computer interface, saving time and effort, improving working efficiency, able to store 999 common orders.

  • Double slotting structure and big diameter trace-pressing wheel produce best effect of box grooving and formulation.
  • Slotting tool rest, trace-pressing wheel and the horizontal moving structure of trimming knife adopts the precision lead screw, making more precise height and more accurate orientation for the upper and lower cutting so as to effectively lengthen the service life of the knife.
  • The elastic tangential cutting structure can cut off three and five layers of the cardboard without adjustment.
  • The slotting knife is made of high-quality alloy steel, grinded after heat treatment, with excellent rigidity and tenacity and long life of using.
  • Option of portable punching die holder.

Printing Unit:

Functions of Printing Unit:

  • All the axles and rollers are made of high-quality steel, rectified by computer dynamic balance, eliminating centrifugal force, plated with rigid chrome and grinded surface.
  • Printing phases adopt the planetary gear surface, controlled by PLC touch screen, with digital electric 360o adjustment (stopping and starting the machine both can be adjusted.)
  • Printing roller landscape orientation is controlled by touch screen, with digital electric adjustment of a scope of 20mm.
  • Ink inspecting system alarms the lack of oil and automatically stops paper feeding at the same time.
  • Plate-hanging device with whole hanging and half hanging slotting notch, foot switching controlling the clockwise and anticlockwise rolling, convenient to fixing and taking down the plate.
  • Fixed oil interval, printing pressing roller and leading roller interval are adjusted by fast spanner-free facilities with fixed electromagnetic brake.
  • Printing phase fixing adopts pneumatic brake structures, which will restrain the mainframe’s running to keep the original gear fixed position unchanged.
  • Reposition functions to memorize the printing position by computer and automatic reset after scrubbing plate.
  • Rubber roller and steel pipe surface are covered by wear-resistant rubber specially grinded in intermediate-high grade, causing excellent working of the anilox roller.
  • Steel anilox roller with grinded steel pipe and pressing anilox and plated with rigid chrome. (option of ceramic anilox roller)
  • Pneumatic plate-uplifting device functions as the anilox roller pneumatically separates with the stopping of the mainframe, automatically smoothing the oil to avoid dried oil.

Die-cutting Unit:

Functions of die cutting:

Die-cutter phase is adjusted through computer and digital electric control.

Die-cutting knife horizontal adjustment undergoes the computer and digital and electric control of a scope of ±5mm.

Glue roller cutting and trimming facilities include the cushion able to be used for many times and save the cost in a great deal.

The cushion roller’s mechanical, horizontal cam facility of a scope of ±35mm prolongs the lifespan of the die-cutting cushion.

 

Findings

  • Some of the equipments are back dated and manual operation system. Required to updated and make it automation system.
  • Most of the executives reported that the performance appraisal system in KDS group of companies (Bangladesh) Ltd. Serves as a control device, it is a good mechanism to control employee. They suggest that it should continue.
  • The appraisal review guides the decision regarding salary increment to a great extent. This encourages employees to show better performance.
  • The supervising officer in-charge of appraising his/her subordinates has enough knowledge about his/her subordinate.
  • Control device in the form of performance appraisal has helped in accomplishing its objectives of providing better assurance companying service to the people.
  • Officers are getting more serious about their assigned jobs. They are also serious regarding procurement of business. This particular system helps the employees for getting additional increment or

Recommendation

  • Some equipment should upgrade by the most modern equipment.
  • Introduce automation system instead of manual operation.
  • Appraisal from the peers and customers can be introduced to check the biasness of the appraiser.
  • Management should take necessary initiatives for the employees whose promotions as well as career path are stuck.
  • Performance appraisal should be a continuing process and not once a year so management should give more effort on it.
  • Training master plan should not be only the mid level and top level employee but also the shop floor level employee.
  • An atmosphere of confidence and trust should be developed so that the supervisor and the employee may discuss matters frankly and offer suggestion, which may be beneficial for the organization and the employee. This shall reduce biases.

These changes can be introduced in a pilot basis in any one plant to see whether there is substantial change in the results from both of these formats. If the change brings out more accurate results and creates less dissatisfaction to the employees, then the changes should be implemented.

 

CONCLUSION:

Process management is a form of control, which is used for quality production and services. Process management is a key team of any manufacturing company. In a manufacturing company, plant is the heart of the organization and process management is a most appreciated part of the plant.

Performance situation in private organization has been influenced by some unwanted factors, which have plunged it into the present state of dilapidation. So it is imperative to identify the right track for performance planning of private organization so that it can deftly keep pace with the present ever-changing demand of time and surmount the present adversity.

Individuals working in an organization perform at varying levels of proficiency. Some use their skills, time and energy very effectively, some do not. Some display an abundance of initiative and seek opportunities for additional responsibilities, some do not. Decision making in many areas of human resources management depend upon the managers’ ability not only to recognize such differences in individual performance but also to accurately measure them.

The study of the report refers to the “Production Process Management of KDS Accessories Ltd. It is aimed at analyzing the existing format, identifying the present problems faced by the employees due to process, and management philosophy. Attempts were made to find out the factors which need to be changed and improvised.