Rang Bharti

Gomia Plant

Case Analysis by Group 2

INTRODUCTION
Rang Bharati was a leader in Decorative domestic paint
with 40 % of market share

Company produced around 5000 SKUs

Company set up Gomia plant in 1981 with capacity of

28000 MT which was upgraded to 40000 MT

Gomia plant was also producing Resins

Key ingredients of various paints

and Emulsions

CHALLENGE
Voice of Managing Director We will continuously upgrade our

manufacturing and R&D capabilities so that we can continue

to provide paint for every surface

Worry of Plant Manager Was Gomia plant competitive?? Manufacturing operation has become more complex due to

increase in product variety.

PRODUCT PROFILE
Distempe r Water Based Paint Solvent Based Paint

KSD

KAD

GSE

KPS

BulB ul

Primer

RP

REX

Super b

SD

NSA P

PROCESS FLOW : GOMIA PLANT

Resin House Resin Storage

Raw Material Warehouse Paint Block Finished Goods Warehouse

Solvent Storage

Packing Material Stores

RESIN HOUSE
Raw Materials Oil Penta & Other additives Total Grades 19 nos

4 grades Caters 90% of SB paints

15 grades Caters 10% of Production Plan SB paint 18400 KL per year Resin required - 12867 KL per year Monthly production plan 1073.3 KL

RESIN HOUSE
Nos 6 Capacity 60 MT Time 24-36 Hrs Nos 9 Capacity 269 KL Time 4 Hrs Nos 2 (23 plate) Nos 5 (11 Plate) Time 6 Hrs/ 8 Hrs Nos 31 Cap 5180 KL

RM

Reactor

Cooler

Blender

Filter

Storag e

Cycle time 24 - 36 hrs (considered 36 hrs for calculation) Throughput time 48 hrs Wt. average production rate of reactors 18.95 * 6 = 113.7 KL / batch Batches possible/ month 20 batch Asking rate of production/ month 9 batch

RESIN HOUSE
No constraints to meet target production Inventory of 300 KL costing Rs 90 Lacs can be reduced Variable reactor operation time can be reduced by training to operators

DISTEMPER LINE
Raw Materials Liquid Ingredients Water, Dispersing Agent, Surfactant, thickener etc Powder Ingredients Tinter or Coloring agent etc Total Grades 2 Production Plan Distemper paint 14000 KL per year Monthly Requirement 1167 KL

DISTEMPER LINE
Charging Time -0.5 Hr Liquid Ingredient Emulsion Inspection Time 1 Hr

Powder Ingredient Charging Time -0.5 Hr

PUG MILL

Storag e

Holding Tanks Nos - 12 Total Capacity 26 KL

Nos - 6 Total Capacity 13 MT Processing Time 2 Hr

Cycle time 4 hrs Throughput time 8 hrs

PACKING M/C

Nos - 7 Packing Time 4 Hrs

Production rate - 13 KL / batch

Batches possible/ month 119 batch Asking rate of production/ month 90 batch

DISTEMPER LINE
No constraints to meet target production Cycle time for 29 batch i.e. 116 Hrs/ month to be utilized for grade c/o including cleaning 29 changeover are possible, considering holding vessel cleaning is parallel to Pug mill cleaning / charging

WATER BASED PAINT LINE

Total Grades 5

Product Shade Batches - 60

Production Plan WB paint 5600 KL per year Monthly Requirement 466 KL

WATER BASED PAINT LINE

Raw Material TSD
Twin Shaft Dispenser

Approval Time - 8 Hrs

Storag e

Holding Tanks Nos - 12 Total Capacity 62 KL

3 No. for Bazaar Paints 2 No. for Premium Super Paint

Total Capacity 2 KL/ TSD

Processing Time 6 hrs

Cycle time 14 hrs Throughput time 22 hrs Production rate - 10 KL / batch Batches possible/ month 34 batch Asking rate of production/ month 47 batch
PACKING M/C

Packing Time 4 - 8 Hrs Nos - 5

WATER BASED PAINT LINE

Production with Current constraints of days of working is 73% of target, without any grade changeover Target can be met by working 357 day a year with 3 shifts with available grade changeover time of 60 hrs per month i.e. for 15 grade changeover. Time taken for approval of batch to be reduced Additional TSD to be added to avoid waiting time of 8 hrs

SOLVENT BASED PAINT PLANT

Total Grades 4

Color Stream - 5
Production Plan SB paint 18400 KL per year Monthly Requirement 1534 KL

SOLVENT BASED PAINT LINE

Raw Material

Nos - 44 Capacity 374KL Flow Rate 10 Lt/Min Processing Time 3.3 Hr

Total 5 independent sets for each color

Storage

TSD
Twin Shaft Dispenser

Sand Mill
Nos - 8 No. Each dedicated for color Stream

Final Mixer

Nos 5 Capacity 2 KL/ TSD

Nos 10 Capacity 20 KL

Processing Time 6 hrs

Flow Rate 3.5 Lt/Min

Processing time 9.5 Hrs

Approval Time - 8 Hrs Adjustment Time 8 Hrs

Cycle time 6 hrs Throughput time 96 hrs Production rate - 10 KL / batch Batches possible/ month 79 batch Asking rate of production/ month 153 batch
PACKING M/C
Nos 9 Time - 4 8 Hrs

SOLVENT BASED PAINT PLANT

Production with Current constraints of days of working is 52% of target, without any grade changeover 77 % of Target can be met by working 357 day a year with 3 shifts No of holding tank & Sand mill need to be increased to meet target Total throughput time need to be reduced by possible reduction in

approval time

Thank You