24-10-2016, 03:20 PM
1460876768-finalprojctreportdraftak.docx (Size: 807.99 KB / Downloads: 7)
I. ABSTRACT
HLL Lifecare Limited (HLL) is India’s leading provider of a wide range of contraceptive products. HLL has an exhaustive assortment of products including condoms. The manufacturing of condoms includes processes such as compounding, moulding, vulcanizing, inspection and packing. After inspection the final product quality control section checks the accepted products. Here the condom samples are again tested. The lots that pass the tests are sent for packing. In the packing section, depending on the customer requirement, the condoms are lubricated and packed in foils, called primary packaging. They are then further packed in wallets, dispenser cartons and master cartons as per the customer requirements before dispatch. The condoms were packed in cartons manually. HLL procured a cartoning machine which can pack at a speed of 120cartons/min however the pouches and the paper pamphlet has to be fed manually. The PAM-PAC machine has a carton opening mechanism incorporated into the machine, but the cartons are not opening properly. The PAM-PAC machine operates satisfactorily only with high quality cartons, the cartons normally used by HLL do not open properly with the mechanism provided in the machine. HLL is using the lower quality cartons because of some economic reasons. The project shall attempt to design and fabricate a system that shall assist the machine to operate satisfactorily even with low quality wallets. Several mechanisms can be employed to avoid this problem. These include use of Air Knife, Air Nozzle, Suction Cup, and Mechanical Linkage. Air knife is a tool which can blow a stream of laminar air which can be used for opening the cartons. Air nozzle does the same process but the main advantage is that Air nozzles are more economical than Air knife. Suction cups which is also known as a sucker, is an object that uses the negative fluid pressure of air or water to adhere to nonporous surfaces, creating a partial vacuum. This vacuum is enough to open the cartons. Mechanical linkages can also be used for this purpose. All the above methods shall be studied for both technical and economic viability and a most optimum method adopted.
INTRODUCTION
HLL LIFECARE LIMITED PROFILE
HLL Life care limited’s journey started with its incorporation as a cooperate entity under the ministry of health and family of government of India on March 1, 1966. HLL was setup in the natural rubber in the rich state of Kerala, for the production male contraceptive condoms for national family planning program. The company commenced commercial operation on April 5, 1969.
Among the 7 manufacturing units of HLL life care limited, the Peroorkada unit is the single largest unit in the world producing male contraceptive condoms with total capacity of more than one billion condoms per annum.
HLL continues to make its mark by setting new goals and taking on challenges others often view as impossible. HLL, from being condom manufactures diversify into contraceptive manufactures and later into hospital manufacturing including surgical sutures, surgical gloves, hydrocephalus shunts, tissue expander and blood banks as a commitment to social cause. HLL has setup non-profit organization whose current activities include implementing sexual and reproductive health projects, HIV/AIDS target interventions, and IEC projects funded by national/ international development agencies.
Production facilities:
• Peroorkada Factory, Trivandrum ( PFT )
• Akkulam Factory, Trivandrum ( AFT)
• Kanagala Factory, Belgaum( KFB )
• Kakkanad Factory, Cochin( KFC )
• Manesar Factory, Gurgaon( MFG )
• Pharma Factory, Indore (PFI)
• Irapuram Factory, Cochin (IFC)
SECTION 1: PRIMARY PRODUCTION
The primary production division consists of four units; plant A, B, C, D which are completely mechanized, consisting of Japanese OKAMOTO Technology machines and German RITCHER Technology machines. The first plant, plant A was installed on April 5 1969 under technical collaboration of M/s Okamoto Riken Gomo co Ltd. Altogether there are 13 moulding machines -5 NT machines and 8 Okamoto machines.
SECTION 4: PACKING
It can be divided into two:-
1) Primary Packing or Strip Packing
2) Secondary Packing
Naked condoms from quality assurance are received batch wise and differed batch coding will be generated in the packaging stage according to quality assurance. Silicone oils, foils, pouches, wallets, cartons, boxes etc. after passing the incoming inspection made at Material Testing department are received from the stores department. Naked condoms are issued to packing machines for strip packing in foils as per the packing scheme. Required quantity of silicone oil is dosed in the strips as a part of the machine operation. Quantity of silicone oils dosed as per the customer requirement; for example PEG+Benzocaine gel, having higher viscosity than silicone oil is used for extra time condoms. After completion of packaging of a batch (about 5 lakh pieces), it is informed to QA department for inspection.
SECTION 5: COMMERCIAL
This section comprises of three sections namely:
1. Purchase department
2. Sales department
3. Stores department
SECTION 6: ENGINEERING
Engineering department is functionally further divided into the following sections with separate section heads:-
1. Mechanical section
2. Utility section
3. Electrical section
4. Instrumentation section
1. Mechanical section
Mechanical section plays a key role as a service section to keep the plant and machineries in satisfactory condition according to the standards set by the management,
The primary functions of a Mechanical section include:
1. Maintenance of plant and machinery.
2.Inspection of all incoming mechanical materials spares, intended byMechanical section.
3. Modification, new installation, technology up graduation and continual improvement of equipment or machinery.
2. Utility section
As the name implies, all the Utilities except electricity, for the factory are provided from this engineering section, such as:
• Steam
• Water
• Chilled water
• Compressed air
3. Electrical section
Un-interrupted power supply to the factory is the main duty of the section. Forthis, the factory has a substation ,which two feeders, four step-down transformers and two D/G sets to provide alternate source of power supply; distribution panels to distribute the power to various points in the factory and winding and over-hauling section to carry out maintenance works.
4. Instrumentation section
This section incorporates various electronic instruments used in various sections of factory, mainly; primary production, ETD, quality assurance and packing sections.PLCs (programmable logic controllers)are installed at various stages of production which carries out control functions of many types and levels of complexity.