VOLKSWAGEN SCHREIBER DYNAMIX PIAGGIO BARAMATI SUGAR INDUSTRY industrial reports

1. 1
Index
No. Name of the Industry Page no.
1. Volkswagen India Plant,
Chakan, Pune.
05 To 24
2. Schreiber Dynamix Dairy
Industries Limited,
Baramati.
25 To 34
3. Piaggio Ape Plant,
Baramati.
35 To 49
4. Shi Chatrapati Sahakari
Sakhar Karkhana,
Indapur.
50 To 60

2. 2
Volkswagen Assembly
Plant, Chakan, Pune.

3. 3
Introduction
The German automobile manufacturer headquartered in Wolfsburg,
Germany. Volkswagen is the original and top-selling marquee of the Volkswagen
Group, the biggest German automaker and the second biggest automaker in the
world.
Volkswagen means "people's car" in German Its current slogan is Das Auto
(The Car). Volkswagen India Private Limited is a subsidiary of Volkswagen Group
Sales India Private Limited that assembles, manufactures and distributes
Volkswagen vehicles in India. It was established in 2007.
Brands under Volkswagen

4. 4
History
When in 1937 the company was founded, no one could have guessed that it
would one day be Europe's largest carmaker. The purpose of the company was to
manufacture the Volkswagen car, originally referred to as the Porsche Type 60,
then the Volkswagen Type 1, and commonly called the Volkswagen Beetle.
Today Volkswagen Group sells passenger cars under the Audi, Bentley, Bugatti,
Lamborghini, Porsche, SEAT, Skoda and Volkswagen marques motorcycles under
the Ducati brand. It consists of approximately 340 subsidiary companies. The
company has operations in approximately 150 countries and operates 94
production facilities across 24 countries
.

5. 5
Mission & Vision
"Vision 2050" sets a new agenda for business: By working in co-operation
with politicians and society, the world of business can play a key part when it
comes to combating serious environmental issues and social inequality.
Volkswagen's main contribution to the project is related to sustainable mobility.
To be a world market leader in the car (sedan,hatchback,luxury) segment ,
and achieve the status of a pan global company which manufactures and markets a
wide range of high quality product to the total satisfaction of customer in the
domestic and overseas market by ensuring top Quality.
Agenda
 Plant Study
 Assembly Line Up (Production Process)
 Close View
 Question Answer Session With the Communication Executive
 Separate Walking Footpaths for visitors and Audibility headsets, note pads
provided with a dynamic guide, for the Industrial tour.

6. 6
Plant Overview
Establishment of Chakan Plant
In November 2006 an MOU was signed between the Volkswagen group &
Govt. Of Maharashtra which started the construction of the plant on April 2007 on
a 575 acre land allotted in Chakan with buildings covering about 115 thousand
square meters, which means, the total premises is 2x1kilometres
The foundation of the plant has double significance. The plant is one of the
most modern units in Volkswagen group and the opening of the plant is a major
step of Volkswagen for starting their India operation.
Infrastructure
With an investment of Rs. 3800 crores . By December 2007 the body shop, paint
shop, assembly & logistics departments were constructed. On March 2009 the
plant was inaugurated by Shri S. C. Jamir, hon‟ble governor of Maharashtra in the
presence of the Prof. Dr. Jochem Heisman, member of board of Volkswagen ag.
While the following month production process of Volkswagen model polo had
begun, this was followed by Skoda.

7. 7
A state-of-the art communication centre designed in-line with Volkswagen
group‟s international facilities was inaugurated in the plant premises. The current
plant is made in a “t” shape with area of around 9 football fields, the reason that
the plant can be extended in the future by overlapping the same design without
making changes to the current plant.
Employee Relations on Job Training

8. 8
The plant employs around 2500 employees from the ITI, they are thoroughly
trained in the profi room specially designed for the training purposes with state of
art facilities and equipments with also sample car models so that the employees
could easily be demonstrated practically such as factory automation, robotics and
applications engineering or management. Various training consisting of personal
development programs, general seminars and courses, as well as specialized
training programs geared towards the specific requirements of individual
departments.
Assembly Line
The facility operated German automaker in India that covers the entire
production process from Press Shop through Body Shop and Paint Shop to Final
Assembly.
The basic components amount to 3000 for 1 Car which are outsourced to known
companies while certain components are produced in the plant itself, while
gearbox & engine are imported from the parent plant in Germany.
Chassis Press Shop

9. 9
Body Shop
 At first the cars go through the body shop where the outer body is assembled
in different assemblies in accordance to the car models.
 Hardly any manpower is required at the time as kuka robots are used to
control the welding process. There are 80 such robots which are imported from
Germany.
 Roller part blue powder coating is applied on the body of the car so that the
metal doesn‟t catch rust or scratches.
 Diode laser brazing (dlb) welding is used to attach the roof to the body as it
improves the aesthetics of the joints.
 Safety pads are attached on pivotal areas of the car body such as the side of
the roof & the side of the door, the safety pads take up the external pressure in case
of accidents so that the passengers remain safe.
 In order to guarantee, in any circumstances, the safety of passengers,
systematic laboratory tests are performed as well as so called destructive and non-
destructive quality tests of welds, junctions and glued connections.

10. 10
Floor Panel Line:
The first thing to be produced is the floor, the basis for the car. At this stage of
production manual and automated welding operations are performed, adhesive is
applied and powder actuated fasteners are installed for casings and upholstery
Side Walls Area:
Side walls of the caddy, caddy maxi consist of internal and external body paneling.
At each side of the caddy side walls there is a robotized station for cutting with
plasma, where frames for passenger models (kombi) are cut out. Connecting of
internal and external body paneling on both sides of the side walls is carried out at
the robotized stations. In the side wall paneling area processes of welding, gluing,
spot welding and bending of inner wheel arches are carried out.
Body Shell Welding Line:
On the body shell welding line, in the process of joining the floor panel with the
side parts and roof, the final shape of the car as seen by the customer is created. On
this line, the parts are joined using point welding, gluing and welding in gaseous
atmospheres.
Final Line:
In the final process of car body production, where mudguards, bonnet, doors and
gates are mounted, the minimum tolerance of gaps must be kept. After passing the
final quality control, the car body leaves the car body construction division and is
transported using a skid system to the paint shop where it is painted in customer
chosen color.

11. 11
Paint Shop
 The paint shop is an enclosed facility where only the trained workers are
permitted an entry; the workers compulsorily need to wear the suit in which every
part of their body is covered.
 A primer coat is applied on the body so that no corrosion takes place with a
guarantee of a decade.
 The car body is submerged in huge tanks where the first protective layer of
paint is applied in order to ensure protection against corrosion.
 The next process is coarse and fine sealing of all welds and places where
sheet metal is joined together.
 In the next stage, four robots apply a protective layer on the bottom of the
car body, which protects the chassis against the atmospheric influences. Most of
the painting lines are fully automated, thus ensuring the perfect quality of the final
product.

12. 12
 It then goes under a laser welding process in a assembly, check point then to
the shower room where the car is given a bath 13 times at 360 degrees.
 After these initial treatments, further layers of paint are applied on the car
body, i.e. priming paint, interlayer paint, topcoat paint (base paint) and additional
layer of colorless paint which ensures the gloss and additional protection to the car
body.
 Then the car body is baked in such as a color is given amongst 10 of the
colors .Colors are exclusively bought from Asian paints. The car is washed in
Normal Water first followed by cold and hot water.
 The paint is sprayed by robots, while in places which are not easily
accessible the paint is applied manually by the workers. After painting, the car
body paint coating is subject to detailed quality control before the final acceptance.
 After final acceptance the car body is equipped with rubbing strips and make
emblems. Randomly selected car bodies are checked for the paint coating
thickness, its actual hue and structure in accordance with the concern's quality
requirements.
 The final stage of the painting process is preservation of internal surfaces,
during which pressurized liquid wax is sprayed through special nozzles so as to
protect the car against corrosion. At last, the painted, glossy and protected car body
is transported on the plant internal conveyor lines to the assembly hall

13. 13
Cockpit Assembly
High Line Area Assembly

14. 14
Low Line Assembly Area
In these sections, the internal equipment of the vehicle is installed, glazing is
Glued and additional equipment according to the customer order is installed.
When the car is further taken to the cockpit assembly line, the doors are removed
so as it becomes easier to install the cockpit
The cockpit is fitted through manipulator into the body which is again
controlled by a computer joystick so as the workers do not lift the heavy cockpit.
The doors are re-attached.
The floor is wooden as to avoid pressure of the body on the knees of the
employees. The car goes through another assembly line in which the glass is fitted
to the body.
Area of Assembly of the Transmission System (Wedding)
In this area, located out of the main assembly line, the "heart" of the vehicle,
i.e. Motor, transmission (gearbox) and other components re combined into the
transmission system, and then it is transported to one of the sections of the
assembly line where the so called "wedding" i.e. Connection of the transmission
system with the partially equipped car body takes place.

15. 15
Wheel Alignment

16. 16
Inspection
checking the car in a special cabin simulation of car ride on special rollers,
which enable checking functions of all car subassemblies and ride parameters, as
during the test drive
100% check for possible noises – the car is driven on a specially prepared sections
of road with different pavement, where the controller is able to trap any noises,
Check of tightness in a special sprinkling chamber – the car is checked for possible
leakages, e.g. Doors, glazing, etc.
The vehicle, prepared and checked as described, gets a permission to leave
the factory and may be transferred to external customer through a dealer network.

17. 17
Volkswagen India pvt. Ltd., in its commitment towards the economic development
of the state of Maharashtra, plans to hire 2500 skilled employees.
Sales
In the year 2010, VIPL recorded sales of 32,627 vehicles against 3,039
vehicles sold during the year 2009 and registered a sales growth of over 1,000%.
Today 1,35,000 Cars Roll out of the Chakan Plant if bifurcated 430 Cars a day
furthermore 31 cars an HOUR!
Volkswagen India Private Limited currently has more than 70 dealerships in
56 cities across 18 states and 2 union territories of India.
Currently in the Chakan Volkswagen Plant 2 Cars are Produced Mainly by
Volkswagen -
 Volkswagen Vento
 Volkswagen Polo.
The plant is also shared by Škoda Auto India Private Limited for assembling their
2 cars-
 Škoda Fabia
 Škoda Rapid.

18. 18
Product Line
The Polo The Vento
Skoda Rapid Skoda Fabia

19. 19
Research & Development
Volkswagen is the third largest automaker, yet it spent more than the two
companies ahead of it, Toyota and General Motors.
Volkswagen academy trains students in terms of mechanical electronics and it a
batch of 16 Students at the Chakan Plant and also offers internships to new
dynamic trainees.
Research and development activities in the Volkswagen Group in 2010
concentrated on two areas: expanding our product portfolio and improving the
functionality, quality, safety and environmental compatibility of Group products.
As we expand our model range, reducing the carbon emissions from our vehicles
becomes important.
The new Passat is taking innovations from the premium segment to the mid-
size range. These include safety features such as a fatigue detection system – a first
for a car in this class – that detects reduced driver concentration based on steering
behavior and warns the driver with an acoustic signal.
The new Sharan is family-friendly with sliding doors, integrated child seats
and the easyfold seating system, with which the seats in the second row can be
stowed quickly and easily in the vehicle floor, thus providing maximum flexibility.
With the Audi A8, the Audi A7 Sportback and the recently launched Audi A6, the
brand is once again demonstrating its expertise in aluminum lightweight
construction.
In 2010, Škoda presented the second generation of its environmentally
friendly greenline models featuring state-of-the-art engines, a cutting-edge start-
stop system and regenerative braking, as well as low-resistance tires. The greenline
range now includes models from all five of the brand‟s series.
CO2 Emission Least By Volkswagen

20. 20
Corporate Social Responsibility
At Volkswagen, corporate social responsibility (CSR) is seen as our
Company making a significant contribution towards sustainable development.
As a part of the company's Learning & Development initiative 5 cars were donated
to Industrial Training Institutes for the study purpose of the students to give them
latest technology in car making.
The organization which is very health conscious and want their employees
as well as the society to always be healthy. As an initiative they organize various
health awareness camps for SKODA employees and for common people in nearby
vicinity and the society at large.

21. 21
Free Health (Dental & pediatric) Check Up Camp: 09/02/11
Activities carried out:
Health check up camp at Shendra Z.P.School by SAIPL in coordination with
MGM Hospital.
Free Dental check up & oral hygiene guidelines to students by Dentist.
Free check up & Deworming by pediatrician.
Free Village Health Check Up Camp Date: 26.05.2011
Venue: Varjhadi Village (10 Km towards North from SAIPL)
Celebration of Republic Day in Shendra Z.P. School - 26.01.2011
Attended Flag Hosting Ceremony.
Distribution of Examination pad.
Distribution of pouch (containing- pen, Eraser, Sharpener, Scale & Pencil).
Distribution of Tiffin Box to Kindergarten students.

22. 22
Schreiber Dynamix
Dairy Industries
Limited, Baramati.

23. 23
Introduction
• Dynamix Dairy Industries Ltd. is a joint venture between Schreiber Foods
Inc., USA and the Goenka family with Schreiber as the majority shareholder
in the company
• 51 per cent controlling stake in DDIL.
• The association with the international fast food giant also provides suppliers
an access to overseas markets for the export of their products.
• Making Schreiber the largest shareholder in Dynamix Schreiber Foods
Dynamix dairy deal
• Rabo India Finance Pvt. Ltd.
• Replacement of around Rs 100 crore of high cost debt.
• Infusion of fresh equity worth Rs 35-40 crore
• Schreiber Foods is a $3+ billion global enterprise and the world‟s largest
customer-brand dairy company.
• The products to the biggest names in fast food chains.
• The world's largest supplier of private-label dairy products to grocery chains
and wholesalers.
• From manufacturing their own printed packaging to developing new
products.
Dynamix Group (Baramati)
• Promoted by two families, The Goenka Family and The Balwa Family
bonded together through a dynamic spirit.
• Therefore the association was known as the Dynamix group
• The Goenka Family & the Balwa Family have come together to form the
Dynamix Balwas Group
• Headed by young visionaries, the Group is dynamic in its approach.
• A proactive and strategic mind-set ensures that the Group surges forward,
always, with a dynamic spirit.
Dairy Sector in India
• India is the world's highest milk producer.
• Accounts for more than 14% of the world and 57% of Asia‟s Total
production.
• Largest dairy animals in the world 198 million cattle and 86 million Buffalo.

24. 24
All India Milk Production
0
20000
40000
60000
80000
100000
120000
ll India
0
50
100
150
200
250
300
Production (Million Tonnes)
Per Capita Availibilty (gms/day)

25. 25
Dynamix Dairy Industries Limited (DDIL)
• Headquartered at Mumbai, the Group companies are managed by well-
qualified and experienced professionals, known for their dynamism and
ability to achieve Corporate Goals.
• The slogan "Dynamism at work" says it all and it is the team's constant
endeavor to meet the high standards set by them.
• The Company is ISO 9002 certified with revenues in excess of INR 3 billion
in 2005-2006.
• State-of-the-art technology and back-up extension services.
• One of the front-runners and the most trusted names in milk processing in
India.
• Dynamix Dairy Industries Limited Deepak Jain, its managing director.
• The Milk shed of Dynamix covers seven districts in western Maharashtra.
Manufacturing Plant
• DDIL has a high-tech milk producing plant located at Baramati near
Mumbai.
• The Plant, designed by the renowned Valio of Finland, sprawls over an area
of more than 25 hectares.
• Processes more than one million liters of cow milk every day.

26. 26
• The plant is fully automated by Siemens India with inputs from Tachenhagen,
U.S.A. and Ireland.
• The plant strictly works on the guidelines laid down by the GMP and Hazard
Analysis Critical Control Point (HACCP) programs.
• Dynamix has made substantial investments in setting up bulk cooling facilities
- which protect the milk from contamination - at several collection centres
around its plant in Baramati.
Milk Procurement
• In Maharashtra, to procure milk has an agreement with the Baramati
cooperative; they have been able to establish a system that ensures the supply
of high-quality of milk.
• Payment is done according to the fat content. More often he gets a better price
than when he supplies directly to the cooperative.
• The dairy has the seven districts of Pune, Solapur, Ahmednagar, Beed, Satara,
Sangli and Kolhapur as its milk shed area.
• Satara, sangli and kolhapur are predominantly buffalo milk region which is
used to prepare cream cheese.
• Dynamix Dairy devised a quality program for milk procurement and invested
significantly in setting up bulk coolers at all milk collection centers Baramati
area.
• Bulk cooling centers were located at an accessible location so that the farmer
had to travel only a distance of 1-2 km from his farm to the collection centre.
• This ensures that the milk brought for processing if fresh enough and the
quality given to the customer is excellent.
• Dynamix dairy therefore believes in providing the best and safest milk to the
consumer.
Computerized Milk Collection
• As soon as a farmer arrives at the collection centre, a sample of the milk
poured into a tube.
• The sample's fat content instantly flashes up on a flickering computer screen.
This determines the price of the milk.
• The can is then weighed. A printed receipt for the farmer displays the milk's
fat content, weight and price and he collects his money.
• Every day of the 1.5 million liters of milk is been monitored thoroughly
through various stages.

27. 27
Global Technology
• The milk, before being sent for pre-processing, is checked for quality using a
series of stringent quality control measures.
• The best quality milk is then pre-processed by means of special equipment
imported from Germany, known as Bactofuges, to render it absolutely
bacteria-free.
Dynamix Dairy Products
• Cheese, Butter, Ghee, Dairy Whitener, Non-Dairy Creamer, Skimmed Milk
Powder, Yogurt, Lactose, Casein and Whey Protein Concentrate.
• The company is also into UHT flavored milk and fruit juices packed in tetra
packs, which do not require the cold chain.

28. 28
Dynamix’s Customers

29. 29
Funding
• Contract farming has commenced with financing of cows and bulk cooling
stations for collection of milk.
• Funding has come from State Bank of India‟s contract farming and value
chain financing, while Schreiber Dynamix Dairies Ltd has brought in the
processing power and this has touched a wide base of one lakh milk
producers in the milk shed area of seven districts of western Maharashtra
• The establishment of this 200 crore plant has proved as a boon for the
various villages connecting Baramati.
• The plant looks to increase its capacity even more by increasing its funds
generating capacity
• With FDI being allowed in Indian markets Schreiber would play a key role
in the expansion of the industry.
• DDIL's Rs 200-crore plant contract manufactures a range of products for
leading multinational brands in the country.
Corporate Social Responsibility
 Schreiber Dynamix has taken up the responsibility of the villages across
Baramati. They have installed street lights and other public utilities.
 They have built schools so that they provide better education
 They have built a demo dairy farm to educate the farmers about best
techniques to milk the animals
 Established water treatment plant for purifying the waste water emitted
out of the factory & to using it for plantation purpose
 They impart training on fertilizer usage fodder usage etc.
Health and Safety Environment
The safety of workers is not compromised in anyway proper health and
safety norms are followed. The safety of consumers is also not compromised
A third party contract is signed which states that any other person except the
employee of Schreiber dynamix is not allowed on the factory production facility.
Schreiber dynamix follows international standards and therefore imparts training to
its employees about safety norms and gives mock drills.

30. 30
SWOT ANALYSIS
 Technical manpower
 Demand
 Margins
 Problem in distribution
 Durability of Products
 Competition
 Flexibility in market
 Export Potential
 Milk vendors
 Competition

31. 31
Observations and Conclusions
 Dynamix dairies maintains a high level of safety measures in the factory
 Infrastructure provided by Siemens is world class and best in the industry
 The quality of the products made is the best & they maintain a high level of
customer satisfaction.
 Public relations were not well developed.
Suggestions and Recommendations
• Dynamix should develop a product line of its own.
• Public relations should be given importance.
• Brand building should take place.
• Marketing efforts need to be increased.
• Proper information about management functions must be imparted among
the employees.
• More impetus must be given on corporate social responsibility.
• Invent of FDI should be taken advantage of and the plant should be
developed on a huge scale.
• Crisis management should be well developed and able people need to be
hired for the same

32. 32
Piaggio Apé plant,
Baramati.

33. 33
Introduction
Piaggio vehicles private limited (PVPL), the pioneer of 3-wheeler goods
transportation in India, is today the no. 1 in its class. By setting global standards in
vehicle performance and customer service, it has revolutionized the 3 wheeler
cargo segment in India.
Today the company offers a range of passenger and cargo vehicles for many
customized applications.
It has achieved by operational excellence, customer focus, total quality, fast
response, high resources productivity, good maintenance and an empowered work
environment.
History

34. 34
PVPL (Piaggio Vehicle Pvt. Ltd.) is a 100% subsidiary of Piaggio &
C.S.P.A. of Italy, the inventor of 3-wheelers. PVPL commenced its Indian
operations in the year 1999 with the launch of the brand Apé which was an instant
success and has grown from strength to strength over the years.
Apé is firmly established in the hearts and minds of customers as a
dependable brand that helps them maximize their business earnings. Apé vehicles
are engineered for higher fuel efficiency, rugged performance and outstanding load
carrying capability. Living up to Piaggio‟s core philosophy, all PVPL vehicles
conform to the most stringent emission norms.
With a total market share of 41% in the 3 wheeler industry and 64% in the 3
wheeler cargo segment in 2010, PVPL has firmly established its position as an
undisputed leader in the 3w domestic market. This growth would not be possible
without PVPL‟s advanced R & D center, modern manufacturing unit and stellar
network.
In the past 10 years, over 1 million Indian transporters have trusted Apé for
total dependability, reliability and profitability. Today, over 300,000 tons of cargo
is transported daily across the country on the Apé.
Piaggio India has successfully introduced state-of-the-art products with world class
technology in India. Its reputation is built on its efficient network of over 804
touch points across India, providing world class customer care.
Vision
To be the no.1 and the most profitable global player with world class quality
and technology leadership in the light commercial vehicle category offering
transportation solutions for specific customer needs.
To be perceived as a unique, high-impact fast responsive, innovative and
growth oriented company which is known around the world for its unmatched level
of excellence.

35. 35
Mission
To become a market leader in the light transportation vehicle segment, and
achieve the status of a world class company which manufactures and markets a
wide range of high quality product to the total satisfaction of customer in the
domestic and overseas market by ensuring.
 Low cost of manufacture
 Highly profitable growth
 Sustainable domestic and global competition
 Maximized stake holders satisfaction and pride
 Business ethics
Through continuous improvement of process focused on:-
Total quality
Resource production
Technology
Cost effectiveness

36. 36
Milestones
1998: Piaggio, C.S.P.A. of Italy & greaves formed joint venture.
1999: PVPL rolls out 1st ape 501 at Baramati.
2000: Rolls out 10,000th
vehicle.
2001: PVPL becomes 100% subsidiary of Piaggio and C.S.P.A.
2002: Starts producing passenger vehicle under the name ape.
2003: New CED (cathode electro deposition) shop started, 100,000th rolls out.
2004: New chassis shop commissioned, with growth rate of 49%.
2005: Enhances its manufacturing capability with c the state of art CED paint shop.
2006: Piaggio sells highest ever 65000 cargo vehicles
2007: Launched India‟s first 4w in sub 1 ton category- ape truck
2008: Became leader in 3w with 42% market share
2009: Winner of “the commercial vehicle manufacturer of the year” by NDTV
2010: One millionth ape rolls out of Baramati plant.

37. 37
Plant details
A Piaggio vehicle limited is located in the heart of Baramati MIDC, a well
established and innovatively coordinated plant with high accessibility and
mobility.
Registered under the factory act, 1948. Occupier Mr. Ravi Chopra spread
over 106 acres of land. The 3 wheeler plant occupying a mammoth 96 acres while
the rest for the 2 wheeler i.e. vespa.
3200 laborers working dedicatedly in 3 shifts. Smaller parts taken from
small subsidiaries in the same vicinity.
Production Details as of 2013
750 units of 3 wheeler and 4 wheelers produced in 1 day. Different
platforms for different distribution channels are constructed. The plant has been
segregated in to export channel warehouse and domestic sale warehouse.
Exporting to countries like Sri Lanka and Cuba the Italian parent is also keen
to make its Indian subsidiary a worldwide manufacturing hub for three-wheeler
products. Piaggio vehicles had seeded the market in 18 countries and hoped to
Begin exports to these countries shortly. The markets include Africa, Latin
America, south East Asia and south Asia.

38. 38
Fabrication Shop
In the fabrication shop the chassis joints with other parts by resistance spot
welding. In the fabrication shop, resistance spot welding and mig co2 welding is
mostly used. Brazing joints the parts. The hydraulic pressing machine is used to
press the corners of door.
Following machines and tools are used in fabrication shop.
 Co2 welding machine.
 Resistance spot welding machine
 Brazing set.
 Chain hoisting tool.
 Fixtures
 Hydraulic press machine.

39. 39
Paint Shop
After the fabrication shop the vehicle Body or chassis come into paint shop
through conveyor system.
The paint Shop is divided in two processes.-
1. Pre Treatment Line
2. CDE (Cathode Electro Deposition)

40. 40
Pre Treatment Line
CED (Cathode Electro Deposition)
Hot Water Spray
Predegreasing Impurities And Oil Is Removed Here.
Degreasing Stage
Spray Water Rinse
Dip Water Rinse
Activation
Phosphating
Dip Water Rinse Phosphating Residual Removing
Passivation
Dip Water Rinse
Cathodic Electro Deposition
Rinse Spray
Rinse Dip
Rinse Spray
Water Spray

41. 41
Assembly Shop
1. Brake Fluid Filling Machine:
The machine provides a fast and precise method of filling oil in brake
System through the master cylinder Reservoir. The system is enhanced with a
vacuum trap, vacuum pump & Oil tank and pneumatic/ hydraulic Valves and
filling gun.
2. Dynamometer Testing
The chassis dynamometer is a comparator stand & is specifically designed to
provide a compact Arrangement, low maintenance requirements with high degree
of operational reliability Suitable for end of production line testing of 3 Wheelers
coming of the assembly line.
The design is suitable for pit installation. The Equipment layout is such that,
when the drive Axle (rear) of the vehicle is located centrally Onto the rear roller
module & front wheel on to The front roller module ensuring the wheelbase Is
selected correctly, the vehicles remains in Vertical position.

42. 42
Some of the tests, which can be carried out on this chassis
Dynamometer is:
Maximum speed
Acceleration (comparative measurement)
Power /torque (comparative measurement)
Brake performance (by distance measurement method)
Noise/leakage if any (observation or with specific instrumentation)
Drivability (gear shift ability)
Functioning of vehicle speed measuring system.
Functioning of vehicle accessories & indicating system.

43. 43
Product line
Ape xtra Ape xtra LD
Ape celession Ape mini
Ape truck plus Ape city

44. 44
Process success
 Ape auto rickshaw / delivery van / pick up van rolls out every two minutes.
 20 different manufacturing processes are used during production.
 250 work stages are manned with special tools and fixtures.
 1200 parts used every three 3 minutes to roll out the vehicle.
 40 workstations have daily run chart for process control.
 125 checks carried out during the manufacturer of every vehicle.
 35 trucks are dispatched with vehicles everyday to 200 dealers.
 12 export containers can be stuffed and dispatched every week.
 R & D block for innovative and superior efficiency
 Training centre

45. 45
Social responsibility
Being responsible. Being social.
In order to improve and facilitate public hygiene, PVPL has donated Apé 3-
wheeler special purpose vehicles for garbage collection & transportation. To
encourage greater participation from students as well as institutions, some of the
initiatives in this realm are:
 PVPL sponsored the national level science exhibition, organized by vidya
pratisthan, vidya nagari, MIDC, Baramati, attracted illustrious visitors such
as the then President of India, Mr. APJ Abdul Kalam.
 PVPL has sponsored the „interschool science quiz competition‟; an event
organized by vidya pratisthan‟s d. Ed College (English & Marathi medium),
MIDC, and Baramati.
 PVPL has donated personal computers to schools at Baramati.
Employee Welfare
In order to uplift the living standard, health and welfare of workers in
factory, we do a lot of social activities like:
 School uniform distribution to kids of workers.
 Book distribution to their children.
 Career counseling
 Blood donation camp
 Health check up camps

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Conclusion
 Piaggio vehicles ltd is steadily growing as a major light transport vehicle
manufacturer in the world, with a growth rate of 42% in 2005, which
surpasses the industrial growth rate of that time of 19%.
 The success of Piaggio lies in the fact it‟s forecasting and long sightedness
in terms of planning and management. With the advancement of new
enterprises and fuel hikes Piaggio stands out with cost effective and mileage
delivering mini commercial vehicles.
 With exports in the most of the pan Asia and east pacific Piaggio needs to
facilitate new projects overseas to cut shipping logistics and supply chain
costs. Countries like Sri Lanka are potential countries of plant set up due to
weaker foreign exchange than India.
 Implementing a different marketing mix for new launches such as Piaggio
ape city to compete existing monopolistic rival Bajaj in auto rickshaw
segment.
 Internships to students: Piaggio should give graduate student an opportunity
to work as interns and give them industrial exposure.
 Overall it was an excellent visit with my aspirations and good wishes to be
working in some company like this.

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Shri Chatrapati
Sakhar Karkhana,
Indapur.

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Introduction
The sugar industry processes sugar cane and sugar beet to manufacture
sugar. More than 60% of the world‟s sugar production is from sugar cane; the
balance is from sugar beet. Sugar manufacturing is a highly seasonal industry, with
season lengths of about 6 to 18 weeks for beets and 20 to 32 weeks for cane.
Sugar cane contains 70% water; 14% fiber; 13.03% sucrose (about 10 to
15% sucrose), and 2.7 % soluble impurities.
Juice is extracted from sugarcane. The juice is clarified to remove mud,
evaporated to prepare syrup, crystallized to separate out the liquor, and centrifuged
to separate molasses from the crystals.
Sugar crystals are then dried and may be further refined before banging for
shipment.
Sugar Manufacturing Process
Weighing and Sampling
Cleaning
Juice Extraction Process
Diffusion
Purification
Evaporation
Crystallization
Drying and Packing

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Weighing and Sampling
On arrival of Lorries in the factory ground, the Lorries drive over a
weighbridge where their gross weight is automatically measured. After that the
sugar cane is unloaded physically or mechanically by using cranes. And at same
time a sample of the particular load is taken to lab for checking the sugar
percentage and the amount of tare (impurities) in the overall load. Tare may consist
of clay, stones, beet tops, etc.
Sampling
Particulars High Quality Sugarcane Low Quality Sugarcane
Juice per quintal of cane 50 kg 40 kg
% of sugar in juice 22% 17%
Trolley in queue for Weighbridge

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Cleaning
In the cleaning stage of the process sugarcane is moved around in large
quantities of water, allowing the Sugar beet to pass through machinery which
'catches' stones but allows the beet to float over the top. Weeds and other trash are
also removed before the beet enters the factory, in this process the sugarcane are
cleaned or washed Excessive soil are removed.
Juice Extraction Process
Cane must be crushed within 24 hours because after 24 hour the sugar
begins to 'invert' into different sugars that will not form properly.
Every possible amount of juice needs to be squeezed from the cane and this
is done through big heavy roller. Heavy rollers break the cane & extract a large
part of juice. Revolving knifes cuts the stalk into chips are supplementary to the
crusher.
This process involves crushing the stalks between the heavy & grooved
metal rollers to separate the impurities. As the cane is crushed, hot water is sprayed
onto the crushed cane so that the impurities are removed.

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Use of waste material
The bagass remaining after squeezing the sugarcane in the extraction
process is dried & 30% of that husk is consumed as fuel for boilers for evaporation
and vacuum process in the same factory.
70% of the husk is sold in villages to the farmers as cattle feed. Here we can see
the optimum utilization of resources.
Purification
Before sugar can be produced in a white crystalline form, it is necessary to remove
as many of these non-sugars as possible. This part of the process is referred to as
juice purification. These substances are added to the juice causing non-sugars to be
precipitated out of the solution. (The carbon dioxide and the milk of lime (chuna)
re-combine produce calcium carbonate which takes out, most of the
Impurities from the juice. The colour of juice is pale yellow.
This important purification stage is called as carbonization.

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Evaporation
The purified juice is a sugar solution but it contains water. It is now
necessary to concentrate this solution. This is done by boiling off water from the
solution. The pale yellow juice which remains is called thin juice and which is in
pure form.
Particulars Sugar
Content
Non Sugar
Items
Water
Content
Before Evaporation 14% 1% 85%
After Evaporation 65% - 35%

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Vacuum
It is boiled again in a further set of vacuum pans to produce raw sugar.
This process is repeated once again to result in final product sugar and molasses.
Raw and semi sugars are re-dissolved into the thick juice. Content of the juice from
the previous 16 per cent in thin juice to 65 per cent in the thick juice. The
concentrated juice passes through filters, after which it is ready for the final stage
of the process; or it can be stored and brought back into the factory during the
summer to produce crystal sugar.

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Centrifugals
The next step in the operation is to separate the sugar from the syrup. This is
done in automatically controlled machines known as centrifugals. In them the
syrup is spun off (1100 rpm) and the sugar crystals remain. The wet sugar is then
dried, screened, cooled and sent to large bulk storage which can contain up to
50,000 tones.
The syrup from the centrifugals still contains a lot of dissolved sugar. This
syrup is put back through two more boiling stages in order to extract still more
sugar. And the final syrup from which it is no longer practical or economical to
extract more sugar its put aside as molasses.
The molasses is further used as raw material in liquor industry.

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Drying and Packaging
The dry sugar crystals are then sorted by size through vibrating screens (i.e.
they are separated by size) Sugar is then sent to be packed in the familiar
packaging. Sugar is packed in gunny bags with automated machine which was
having a rotating belt which took all the gunny bags out of the factory at a
specific place where the produced sugar is stored.
Quality Management
A laboratory is established in the factory campus in order to maintain the
quality of the sugar. Various chemical tests are conducted with the help of many
chemicals to check the properties of the sugar.

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Pollution Prevention and Control
A special pollution control plant is situated in the factory campus to purify
the polluted water emitted from the production process. Water is released in
external environment only after it is purified in the above plant.
Health and Safety Environment
The factory was spread over a huge area. The infrastructure was old.
Boilers up to 20 feet were used. The factory was divides into ground floor and few
stairs lead to first floor.

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Observations and Conclusions
 The type of Layout is Product Layout.
 Huge Capital investment. ISO 9001:2008 Company.
 No. of Employees total 900. Working in shifts
 They have their own transport facility and Distribution Channel.
 Bi-Products like bagasse, residue and molasses were also utilized.
 Chairman- Amarsinh Gholap
Suggestions and Recommendations
 The Health Safety and Environmental conditions need to be developed.
 There must be well ventilation in the factory.
 Lack of lighting facility was observed. Steps to provide sufficient light
should be taken.
 The factory management should try to minimize the noise in the production
process to
 Management should do regular repairing and maintenance of the machines
as they were too old.
 Management also needs to pay attestation to the hygiene and cleanliness in
the factory. As they are producing food product.

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Bibliography
 www.google.co.in
 www.wikipedia.org
 www.piaggio.co.in
 www.schreiberfoods.com
 www.volkswagen.co.in
 www.shrichhatrapatisugar.com
Disclaimer
In almost all the industries, we were not allowed to take photographs.
Hence we cannot put actual site photograph. For the photographs we refer
secondary sources. Hence few of the photos are just representing those
industries.
In few industries actual production process was not shown to us. And the
production process was not explained in detail because of their internal
reasons. So whatever information is collected for this report is sourced from
secondary external sources