Field visit report MRF, PUDUCHERRY
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The field visit report summarizes a visit by interns to the Madras Rubber Factory in Nettapakam, Puducherry. The factory produces passenger car and truck tires. It has 3,200 employees across various departments. Key learnings included the factory's emphasis on transparency, bottom-up decision making, strong employee relations, and sustainable water and energy management. The factory achieves 95% water conservation and has stringent safety protocols to reduce accidents.
Field visit report MRF, PUDUCHERRY
- 1. VISITED ON 24.05.2019 YOUTH ENGAGEMENT PROGRAMME, RAJ NIVAS, PONDICHERRY FIELD VISIT REPORT MADRAS RUBBER FACTORY (MRF), NETTAPAKAM, PONDICHERRY
- 2. 1 FIELD VISIT REPORT MADRAS RUBBER FACTORY (MRF), NETTAPAKAM, PONDICHERRY Date of Visit: 24.05.2019 Intern team: Aditya V Gujjar, Anvita H, Karthik Kothari, Karthikeyan.K.H, Sabarinathan S, Saikiran Bogyam & Robert. Contact person at the plant: Mr. Bharathi, Chief Production Manager, Mr. Baskar HR Manager, Mr. Srinivasan, Safety Manager, Mr. Palaniappan, Mech. Dept, Mr. Hari ram, Knowledge centre. BRIEF / PURPOSE OF THE VISIT We the team of interns from Raj Nivas, Puducherry has been given an opportunity to visit MRF, Nettapakam as a part of goodwill through their CSR done for water rich Puducherry. The moto or objective of the visit is to know about the entire functioning of the plant and their key strategies on water conservation and other success mantras. BRIEF ABOUT THE FACTORY The MRF Plant at Nettapakam has been started in the year 1997 by the Founder K M Mammen Mapillai. The plant here produces only the Passenger car Radial (PCR) tyres & Truck Bus Radial (TBR). Recently they have manufactured the tyres for the Monorail Project too. The total area of the plant is about 3,11,814 Sq.m & Built up of 1,35,175 Sq.m. LAYOUT OF THE FACTORY Figure 1 Google Map of Nettapakam Plant.
- 3. 2 FACTORY TIMELINE MANPOWER AND PRODUCTION AT THE PLANT The plant has around 3200 employees of various category like Full time, Contract basis, Permit basis & Apprentices. The plant runs with 8 trade union with various identity or common factor among them. The plant produces the following category of tyres in the plant S.NO TYPE OF TYRE MANUFACTIRED 1 PCR/ SUV 2 SCV 3 TRUCK BUS RADIAL 4 MONORAIL Table 1Tyres Manufactured at the plant The plant has around 13 executives heading various department with the subordinates under them with the category of employees mentioned above. 1996 Ground Breaking and Bhoomi Pooja was done. 1997 Nettapakam Plant was Inaugarated 1999 First TBR Manufacturing started. 2000 First supply was done. 2003 Plant has got ISO Certification 2006 Q1 Supplying started 2010 Company has reached a milestone of 1000 CR. 2011 Landscaping was done 2012 Environmental sustainability was achieved 2014 Regoconised with many awards and the journey is still on Figure 2 Factory Timeline
- 4. 3 INDUSTRIAL RELATION The success mantra of the plant was very clearly seen that the transparency level was so high and involving the grass root employees for taking decisions at various levels. The company relay/ follow the following system for their success. The company make sure that even the families of their employees are happy and absolute care and responsibility is taken among them also. The company has family welfare association which works on the families good. They conduct various events and programmes to encourage more bonding among the employees and their family. Company even provides a medical insurance which covers an amount of 1.75 lakh per family. The company has various frame works as follows to maintain its standards. Industrial Relations Relation building TEE Training Conflict Resolution Improve Ordenity Figure 3 Industrial Relation Family CommunityEmployees Commitment & Competence 2C Pride, Performanc e & Productivit y 3P Role & Responsibil ity 2R Chart 1 Trimodal of the company Chart 2 Strategic plans of the company
- 5. 4 CONFLICT RESOLUTION The company follows the above-mentioned hierarchy / system to resolve their conflicts and find immediate solutions. Even the company organises various inter departmental events and programmes to create a healthy bonding among the employee which will in turn give backs more productivity and discipline in the system. Company even encourages the employee to participate in various events happening at state and national level to bring out their skills and talents. SAFETY SYSTEMS AT FACTORY The plant follows a very strict and systematic safety procedures to avoid the major accidents in the plant. the people under the safety committee make sure that anyone newly coming to the factory is oriented to the safety procedures and then only permitted to go inside the factory. The contract and permit workers are given orientation of safety instruction once in every 2 day. The committee traces the accidents and minor injuries happened on daily basis and take necessary action. The safety centre at the plant has a target of one accident per 10 million hours of work to maintain the safety of the employees. The following pyramid gives their target on the accident reduction Chart 3 Conflict Resolution
- 6. 5 Any employee faced with any kind of injury has to return to his job within 48 hours. If not, the accident is considered as Life hazard and necessary action will be taken immediately. INFRASTRUCTURE DEMAND AND SUPPLY AT THE FACTORY Water The factory used around 660 Kl per day for its various process in the manufacturing. The plant has 2 bore wells, 12 peculation pits, 140 direct recharges from rooftop & one hydrating pond. The factory recycles around 80% of water consumption through its STP which matches their daily water demand. The actual demand of the factory is 1220 Kl. The factory has a run of co- efficient of 0.8 which gives them 95% water conservation through the rainfall. These all initiatives make them to achieve the water neutrality. Electricity The plant has a sub station of capacity of 22Kv and the factory consumes around 12 to 15 Mw per day. The factory is also encouraging many solar initiatives to meet its demand at its offices and warehouses. Waste generation As the company is manufacturing tyres with synthetic fibres and natural fibres. So, it tries to recycle the waste generated and puts it in the tyre manufacturing again. The plant has a very great system of segregation of different types of waste at the source point itself. It helps them for better recycling. Chart 4 Accidents & Injury Pyramid
- 7. 6 LEARNINGS FROM THE VISIT As learning from the visit, we would like to tell that as their Success mantras. Few have been listed below Success Mantra 1: Transparency at all levels. Success Mantra 2: Bottom up process in the system. Success Mantra 3: Problem solving through good Industrial relation. Success Mantra 4: Tacking care of Employees family too. Success Mantra 5: Conflict resolution through a better planning. Success Mantra 6: Reducing the accidents through better safety management. Success Mantra 7: Managing the infrastructure in a very sustainable way. OBSERVATIONS Factory has a very good strategic plan to succeed in all its matters in various departments. They have a very good customer and employee relationship. The plant has a water efficiency of 95% through its various initiatives. The factory has a very good safety system. The success mantras of the company are well planned and implemented with timely update. ACKNOWLEDGEMENT We heartfully thank Dr. Kiran Bedi, HLG & Mrs. Asha Gupta, Comptroller of Raj Nivas for providing such a wonderful opportunity. We extend our sincere thanks to Mr. Bharathi, Chief Production Manager, Mr. Baskar HR Manager, Mr. Srinivasan, Safety Manager, Mr. Palaniappan, Mech. Dept, Mr. Hari ram, Knowledge centre for sharing their insights and knowledge. LIST OF FIGURES FIGURE 1 GOOGLE MAP OF NETTAPAKAM PLANT.......................................................................1 FIGURE 2 FACTORY TIMELINE.....................................................................................................2 FIGURE 3 INDUSTRIAL RELATION................................................................................................3 List of Tables TABLE 1TYRES MANUFACTURED AT THE PLANT.........................................................................2 List of Chart CHART 1 TRIMODAL OF THE COMPANY .......................................................................................3 CHART 2 STRATEGIC PLANS OF THE COMPANY............................................................................3 CHART 3 CONFLICT RESOLUTION ...............................................................................................3 CHART 4 ACCIDENTS & INJURY PYRAMID ..................................................................................3