420633887 Internship Report Master Tiles PDF

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MASTER GROUP OF TILES AND CERAMIC INDUSTRY

ALI RAZA

1.INTRODUCTION: Master group of Industries is the trendsetting leader in sanitary fittings, wall and floor tiles and bathroom accessories. The constant quest for perfection at Master spreads over more than three decades. These decades have witnessed unprecedented.Growth i f b r a n d e q u i t y , m a r k e t l e a d e r s h i p , p r o d u c t i n n o v a t i o n , h u m a n r e s o u r c e development, training and application of reliable management systems. The combination has really worked. Master today is not only the market leader in Pakistan but is also well positioned in the quality and service standards of the world leaders in its categories of business Master group of industries is in business from 1982, now with more than 8 different industrial units: • Master Tiles & ceramics • Master Granite • Master Sanitary • Master Poly Plastic • Master Baby(dipper) • Master Ballpoint • Master Poly Pack • Master PPRC pipes

Executive Summary: Master Tiles was formed in 1995 by Sheikh Mahmood Iqbal. Master Tiles is oneo f t h e b i g g e s t m a n u f a c t u r e r s i n P a k i s t an . M a s t e r T i l e s p r ov i d e s t h e o p p o r t u n i t y t o upgrade the life style by introducing granite Tiles for the first time in Pakistan with latest Italian technology. Master Tiles have a capacity to p roduce more than 3000 Sq/meter Tiles per day. In local market Master Tiles is a well-known Tiles manufacturing company. Mater Tiles ca p tures about 60% of local market share. It manufactures both wall and floor tiles. It manufactures good quality tiles at affordable prices. The marble and granite processing industry is closely related to the development the building materials and modernization which leads to progress of the tile industry. In the l ast two decades p eople ha ve been using chi ps and marble for floor finishing. As the time is changing the traditional construction styles and fini shing materials are also changing into modern construction which sales the time and cost factors gives people readymade finishing for a life time. The Tile industry in Pakistan has a huge potential in future. Availability of rawm a t e r i al a n d a l s o t h e i n c r e a s i n g d e m a n d m a k e s i t a g r o w in g i n d u s t r y . P e o p l e w a n t change. This trend shows increase in the demand of tiles. In future the local industry is trying to increase the Production capacity. The Company History: It is a tale of thirty years, more than 1/4th of a century. It’s a tale of a vision realized a g a i n s t a l l . I t ’ s a m a t t e r o f a c o m m i t m e n t w h i c h r e a l l y m at t e r . I t ’ s a n a c c o u n t o f a climbing task transformed into mere peanuts through a clear vision, narrow focal point, sheer devotion, meticulous hard work, dependable belief and stable quest for fineness.

MASTER GROUP OF TILES AND CERAMIC INDUSTRY

ALI RAZA

I t S t a r t e d i n 1982 a s a s m a l l s e t u p w i t h b i g t h o u g h t s , h i g h i d e a l s a n d h o n e s t commitment, Master today, stands as an unparalleled leader in world classwall,floor t i l e s , s a n i t a r y f i t t i n g s a n d p l a s t i c g a r n i s h e s a l o n g w i t h a h o s t o f o t h e r h i g h q u a l i t y products. In 1982: launched as com p any dev eloped and ad vertising high quality sanitary fittings, with clarity of concepts, the target at that time was to provide a well-coordinated complete bathroom to our clients. In 1987: Established as the p ioneer and market leader in world class sanitary fittings , Master introduced the conce pt of matching bathroom accessories in technical collaboration of England and Germany. In 1995: It a time when the market was busy with import wall tiles as the only quality op tion , as they called it, Master once again took the lead. Ba sed on the world’s top of the line Italian technology. Master launched its range of double fast fired wall tiles. F a r s u p e r i o r i n q u a l i t y a n d a r t i s t i c va l u e s t h a n i m p o r t e d o n e s , M a s t e r t i l e s t o o k t h e market by storm and immediately gained a ma4or share of the market. In 2000: Master tiles were such a tremendous hit in the market , to meet the growing demands, p roduction capacity had to be tri p led in the year 2000. Same year, Master added up world’s best plant and acquired best recipes for in house production of tiles raw materials including frits and colors. These advanced recipes in frits and colors r e s u l t ed i n g i v i n g a n e n t i r e new look to the product appearance, quality and finish. Adding endless possibilities to the imagination of our v alued cust o m e r s , M a s t e r introduced a range of decorative tiles including strips, trims, motives, panels and mosaics. To facilitate the customers in better a pplications an d maximizing their benefit , Master provided its own brand of quality grout and adhesives. In 2005 : Master Granite Tiles: bring a true revolution in the tile industry, this was the year when Master proudly introduced Granite tiles which were by their quality standards, second to none in the world. The years that followed witnessed an innovative a฀฀roach setting new benchmarks in p roduct quality, range st read , accessibility through a wider network and a bundle of v alue added serv ices like customer alert ness and direction cam p aign unmatched after sales service and complaint handling. In 2010: Customer Focus: After 10 years, C ustomer direction remains the key word in all our p lans and execution. Reaching at the doorstep of our clients, wherever they are, we are making sure are closer to their needs, aspiration, and affordability and after sales hope. Nature of Organization:

MASTER GROUP OF TILES AND CERAMIC INDUSTRY

ALI RAZA

Master industry is continuous to make innov ati ve and glorious p roducts forthe people over three and half decades. They are involved in technologically advanced produ cts with a view to provide an ease and betterment of the society. Their endeavors have resulted in bringing greater heights of luxury in every body’s range with affordable prices. According to a research launched by them in 2002, a large gap was in the demanded supply of quality flooring and facing materials in Pakistan. 8ith the increase inec nomic dev elo p ment in the country , the ga p was widening further day by day. They took it as a challenge and were all out to face it with commitment to make investments in terms of material and human resources and filled the gap with not only the quality but also with the affordability. Mission Statement : The ceramic tiles industry is a ma4or force for the improvement of quality of life across the world. Master aims to be the leading manufacturer of best quality ceramic tiles and pledges to provide its customers with latest designs varieties and innovative productsin line with the internationally changing trends. Through achivement of our aim we will enhance the wealth and well-being of our stakeholders, employees and communities, whom we serve and in which we operate. Vision Statement: Masters vision is to lead the market with innovations in product development to improve the quality of life and lifestyle of its customers. With timely adaptations to rapidly developing technologies and meaningful investment in human resource training. Master will strike to maintain the differentiation edge through provision of unmatched. Number of Employees: In Unit number three, there are overall approximately 725 employees including head of department, senior managers, managers, shift in charges, supervisors, technicians and workers. Products: There are following few products which are being manufactured by the Master Tiles. These products are available in different sites.         

Glazed wall tiles Glaze floor tiles Granite floor tiles Homogenized Porcelain tiles Other products Strips Trims Motives Mosaics

Product lines: The product line of master tiles is given as: 1. Raw Material 2. Body Preparation Department

MASTER GROUP OF TILES AND CERAMIC INDUSTRY

ALI RAZA

3. Spray Dryers and Silos 4. Presses 5. Horizontal Dryers 6. Glaze Line Department 7. Kilns 8. Polish Line Department 9. Sorting and Squaring line department 10. Qualitron (Quality and Inspection Department) 11. Palatizing

Processes: The brief detail of the process from raw material to the export of tile is given below 1. Raw Material: The raw materials used in the production are easily available in Pakistan. The raw materials are being purchased from the areas of Kohat, Mianwalli and other northern areas of Pakistan. These raw materials are mined from the northern areas and are easily available.

2. Body Preparation Department: The raw material is the being is drawn in the hopers as shown in figure. There are nine different hopers in which different raw material is drawn with the help of tractors. From hopers the material comes on the conveyor belts which leads to the crusher, where raw material is being crushed.

MASTER GROUP OF TILES AND CERAMIC INDUSTRY

ALI RAZA

From crushers the raw material enters in the ball mills where water is added and a liquid mixtue is mixed and crushed. There are two ball mills one is continuous and the other is refinery. In refinery ball mill further is mixed and after the refinery ball mill the liquid past is call “Slips” is stored in the underground storage tanks.

3. Spray dryers and Silos Department: The slips the enters in the small storage tank from where it is pushed in the Spray dryers. There are nozzles in the spray dryers, from nozzles slips is launch up and hot gasses are coming from the top of the spray dryer, the liquid slips fall down in the powdered form which contain five percent moisture in it. Which I then stored in the silos.

MASTER GROUP OF TILES AND CERAMIC INDUSTRY

ALI RAZA

The slips that don’t fall down enters in the cyclones after recycle in is added with the five percent powder and the waste is stored in the scrubbers. Presses: The stored silos is then enters in the press department where tile is formed. Tiles of various sizes are formed ranges from small twelve inches to one meter. In unit number three only large tiles are formed.

MASTER GROUP OF TILES AND CERAMIC INDUSTRY

ALI RAZA

Horizontal Dryers: After presses the tile enters in the horizontal dryers where five percent moisture is removed.

Glaze Line Department: In the glaze line department the edges of the tiles are sharped and glaze is drawn on it, and the required design is obtained. The designing department at Master Tiles is responsible for the designing of the tiles. The new designing have to be introduced to the market so that the customer should be attacked towards the new product. The designing department checks the design of the tiles which are being manufactured; they monitor the computerized s ystem through which the designing of the tiles is being controlled. Kilns: The tile is then enters in the furnace, at start the temperature of the kiln is 240 degree Celsius, in the middle temperature is 1140 degree celcius and at the end its temperature is 240 degree celcius.

MASTER GROUP OF TILES AND CERAMIC INDUSTRY

ALI RAZA

There are special air columns attached from which cold air is entered in the furnace and tiled is to be cold. When tiles leaves the furnace its temperature is about 90-100 degree celcius. Polish Line Department: From kilns the tiles are carried in the polish line department with the help of Techno Ferrari Guide Vehicles (TGV) as shown in figure.

In polish line department the tiles enters in the calibration and are polished with the help of abrasives. Abrasives are manually changed after every hour since it is consumed to shine the tile.

Sorting line: In sorting line quality of the tile is checked and is the categorized as scrub, commercial tile etc.

Departments: In the following departments I served as an intern  Maintenance department

MASTER GROUP OF TILES AND CERAMIC INDUSTRY

ALI RAZA

In maintains there were total of 20 employees, at a time there was one shift in charge and other were technicians. In maintenance department we learned the different faults occurred in the machinery, we worked their and saw how it was repaired.  Body Preparation department In the body preparation department, there were total of 25 employees, and we learned how he body is prepared for the tile. From crushers the raw material enters in the ball mills where water is added and a liquid mixture is mixed and crushed. There are two ball mills one is continuous and the other is refinery. In refinery ball mill further is mixed and after the refinery ball mill the liquid past is call “Slips” is stored in the underground storage tanks.  Polish line department In the polish line department there were total of 35 employees. Here we studied how the tile of different material is polished and which type of abrasives are used. For example for the granite tile the abrasive used was made of steel martial.  Sorting line In sorting line there were total of 40 employees working in which there were workers, and managers. In sorting line the operations like squaring, palatizing, packing etc. was being carried out. And we studied I in detail that how tile is being categorizes and what are the issues that occure in the tile. Also we studied from where the issue was occurred either from spray dryer, glaze line or polish line etcetera.

Short-falls:  The production capacity of unit 3 is about 25000 square meter but it is producing 1500016000 square meter  Maximum loss occurs in the kilns due to irregular temperature and unskilled labor for the kilns. Since the temperature of the kilns is high so there must be high protection for labor.  Delay in the cleaning of machinery, machines remain close for many hours for their cleaning.  Inexperienced technicians took ages to repair the machine, which results in the shortage of the net production.

Duties and Responsibilities: As a student intern my duties and responsibilities are as follows:  Review engineering schedules, engineering specifications, process flow, and other information to understand methods and activities in manufacturing and services.  Figure out how to maintain parts or products, or delivery services, with maximum efficiency  Develop management control systems to make financial planning and cost analysis more efficient  Enact quality control procedures to resolve production problems or minimize costs

MASTER GROUP OF TILES AND CERAMIC INDUSTRY

ALI RAZA

 Design control systems to coordinate activities and production planning to ensure that products meet quality standards  Confer with clients about product specifications, vendors about purchases, management personnel about manufacturing capabilities, and staff about the status of projects

Knowledge Gained: From my one-month internship in Master tiles and ceramic industry I gained different kind of knowledge including technical, non-technical, professional, managemanterial etc. I learned about new tools and techniques used to encounter the problems. For examples I learned and understand the mechanism of ball bearings, conveyors, belts, pullies, pump, motors, roller, shaft, wheel, hub, sleeve, load, rings, flange, spherical rollers and grease etc. And professionally I learned how to receive different people of different posts and how to deal with them etc. I also learned how to control and manage such mega industrial plants and what parameters should I come keep in my mind if I works as a project manager. Conclusions:  Group of Industries is a big group of Pakistan, they are in business since 1982.They are in different businesses, they have diversified products and their products are of high quality due to which they are enoying their brand loyalty. They came up with the latest technology in Pakistan and they have biggest market share in Tiles and Sanitary fittings market.  As an internee in Master Tiles I hav e learned a lot about the d ay to day business. It was a great e xperience working with Master Tiles, I came to know about the daily operations of the firm, how the product is being produced, how it is being marketed and sold to the end consumers. The most imp ortant I came to know was how they were financing such a big industry. They were financing through different banks.Their HR department is the most important department as it controls all the recruiting of the productive employees and they were also monitoring the whole administration of the company.  Master Tiles is the biggest manufacturer in the tile industry of Pakistan,. They are reducing the wide range of tiles through which the customer is being attracted; they do not comp romise on the quality. The quality of their product is far better than their competitors and the foreign players in this industry. They are having more than 60% market share in the

MASTER GROUP OF TILES AND CERAMIC INDUSTRY

tiles industry of Pakistan. They are p lanning their production and come up with new designs and colour.

ALI RAZA

to

increase

Recommendations: As I have been employed as internee at Master Tiles so according to my observations there are some recommendation by which they can increase their productivity.Few recommendations are as follows: • T h e mai n p r o b l e m t h e i n d u s t r y i s f a c i n g i s o f e n e r g y c r i s i s , t o o v e r c o m e t h i s problem they should set up their own plant for generating electricity. • They should use solar energy system, it would decrease the cost of energy and there will be continuous production. • They should also setup a LPG plant so that they could not face any problem in their production. • T h e y s h o u l d m i n i mi z e t h e i r c o s t o f p r o d u c t i o n t o c o m p e t e wi t h t h e f o r e i g n players of this industry. • They should increase their production due to increase in the demand of tiles, as tile industry in Pakistan has a great potential. • They should come up with the low price tiles as the customer are more attracted towards low price items, the local manufacturers are producing low quality good sat low price. • They should make their distribution network stronger; they should also focus the northern areas of Pakistan. • The pr ices of Master Tile s are bit higher than their comp etito rs so they should adjust their prices according to their competitors prices. • The structure of the organization should be changed to decentralized structure so that the managers have the authority of making decisions. • Training should be given to the employees to increase their productivity. • They should increase the marketing of the product; they are only using the old strategies of marketing. They should come up with new marketing stra tegies to increase their sales....