“ INDUSTRIAL TRAINING REPORT ON PLASTIC MOULDING

INDUSTRY (ROOP POLYMER)”

A Summer Training Report

Submitted By

Surya pratap

19105080043

DEPARTMENT OF ELECTRICAL ENGINEERING

“ROOP POLYMERS, PANTNAGAR”

RUDRAPUR INSTITUTE OF TECNOLOGY BHAGWANPUR RUDRAPUR

(U.S. NAGAR) .
JULY 2021
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 ACKNOWLEDGEMENT

I express my gratitude to the management of “ROOP POLYMER

RUDRAPUR” for providing me with this opportunity to undergo
training in this industry.

I take the prerogative to express my gratitude to Mr., for his valuable

suggestions and guidance throughout my training period.

Last but not the least I express my gratitude to my H.O.D Mr. Rishav.
Verma ( RIT Group Of Institutions, Rudrapur).

I also like to thank the entire staff and respected HR sir of “ROOP
POLYMER” for making my brief stay in industry a memorable one.

Surya Pratap (19105080043).

RIT Groups of Institutions Rudrapur.

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 CONTENTS
Chapter 1
1.1 Introduction
1.2 Infrastructure
1.3 About Roop Group
1.4 Vision
1.5 Mission

Chapter 2
Products

2.1 Automotive

2.2 Non-Automotive

Manufacturing

2.3 Rubber Molding

2.4 Rubber Extrusion

2.5 Rubber Hoses

2.6 Plastic Molding

Chapter 3

3.1 Quality

3.2 R&D and Testing

3.3 Design and Tool Room

Chapter 4

4.1 clients

4.2 Safety department.

4.3 Paint shop Department.

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4.4 Kaizen Rules.

Chapter1
1.1 Introduction

Established in 1973 in the automotive industrial hub of Gurugram, Roop Polymers Ltd. (RPL)
is the flagship company of the Roop Group.

With over 45 years of rich experience in the automotive industry, RPL today is a world class
manufacturer of Moulded and Extruded Rubber & Plastic parts for Automotive OEM’s around
the globe. It operates through 7 state of the art manufacturing facilities which are strategically
located near the OEM’s customer base in Gurugram, Sohna & IMT Manesar in Haryana,
Pantnagar in Uttranchal, Chennai and Pune..

1.2 Infrastructure

1 Customer's satisfaction by delivering highly reliable products has been the forte of Roop
Group. The group, therefore, believes in manufacturing all critical and precision
components in-house and to this end, the production facilities of the group companies are
equipped with high precision machine tools and manned by a team of well qualified and
experienced engineers and technicians.
2 Various facilities include CNC turning centers, turn mill centers; horizontal & vertical
machining centers etc. To complement these machines, there are general-purpose machines
like lathes, milling machines, surface and cylindrical grinding machines etc. for
manufacture of tooling and fixtures and for pre and post CNC operations.

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3 The robust machine structures comprise of a large amount of heavy duty components. For
machining these heavy components, there are horizontal boring machines, Plano millers,
large capacity lathes and cylindrical grinding machines.
4 The company has CAD/CAM facilities.

1.3 About Roop Group

Established in 1973 in the automotive industrial hub of Gurgaon Roop polymers limited is the
flagship company of Roop Group.

To be an innovative, profitable and a preferred Automotive organization by creating the right

environment for our most valuable asset-the human capital while continuously striving to
reduce our carbon footprint and proactively engage our self in CSR activities.

1.4 Vision

 To be the partner of choice for our customers by providing technology based world class
products and performance enhancing services tailored to meet their requirements.
 To provide total customer satisfaction through quality products and services at
competitive costs.
 To attain the leadership in technology, quality, services and costs with integrity and
stability.

1.5 Mission

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  To follow the best practices as a responsible corporate and contribute in sustainable
development of the society including employees.
 To provide total customer satisfaction through quality products and services at
competitive costs.
 To make continuous up gradation in our products through innovation anticipating the
needs of our markets and customers.
 To maximize the exports of our all products by offering quality products and services at
competitive costs combining with our intellectual and trade resources.

Chapter 2

PRODUCTS

2.1 Automotive
Automotive product means any hardware product, software product, or combination of
hardware and software that provides Haptic Capability to the extent used in an automobile,
truck, bus, train, or other transportation vehicle.

Automotive product means any product for the integration or use in automobiles, trucks, buses,
motorbikes or stationary storage units.

Air filtration

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 Insulators

Hydraulic Brake Hoses

Air Filtration Duct.

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Non-Automotive

Non-Automative product means the product releted to hardware product but not used in
automobile.these products are used generally in generating sets parts ,electrical components you
frames, electrical plastic frames ,Etc.

Genset Components.

Electrical Plastic Parts

MANUFACTURING.

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2.3 Rubber molding .

1. Injection molding.

The group has deployed advanced Microprocessor controlled Desma Rubber Injection
Moulding machines of upto 400 Tonnes. Depending upon the nature of the product, machines
are run on fully automated processes right from compound feeding to product removal from the
mould.

2.Compression Molding.

Roop Polymers has installed various PLC controlled Vacuum Compression and Transfer
Moulding machines of different capacities for Rubber Compression Moulding. As a result of
Kaizens, many of these machines are run in sync with the low-cost automation for benefits like
cycle time reductions, compound savings, ergonomics etc.

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2.4 Rubber &Plastic Extrusion.

The in-house co-extrusion lines for extruding EPDM profiles are equipped with Glass beads
and microwave hot air curing system with or without metal inserts and flocking. The company
has recently introduced PVC Co-Extrusion line with facilities for Slicing, Cutting, Printing,
Taping, Notching, Punching, Drilling etc. It has achieved competence in the manufacturing of
single & twin layer fuel tubes with the capability to produce the most complicated shapes in all
sizes.

2.5 Rubber hoses.

Complete Automatic air brake hose line with highly process control accuracy. Spiral
Multilayered stream curing line with an annual capacity of 3 Million Meters. The Reinforced
Hose meets SAE J 1402-A Specification.

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2.6 Plastic Molding & Assembly.
RPL is equipped with latest Horizontal Plastic Injection Moulded machines ranging
from 90 T to 650 Tonnes. This is supported by various other Post Moulding operations
like Ultrasonic Plastic Welding Machines and ABS and Sheet Metal 3K system Paint
Shop etc. In a quest to further augment its product offering, RPL keeps upgrading itself
to the latest technologies.

Chapter 3
3.1 Quality

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Roop believes in ensuring quality at source and therefore for every set of product, the
QA team adopts specific validation processes, conducts performance checks along
with the standard guidelines as per IATF – 16949 and other applicable standards. All
the applicable industry standards are strictly adhered to ensure that we produce cost-
effective and right quality products.

3.2 R&D and Testing.

The constant endeavor of RPL is to be proactive in R&D and lead the latest technological
developments in the industry. In the quest to achieve this, RPL has developed a distinctive
capability to provide customer solutions through strong R&D. The in-house R&D facility is
equipped with the latest design and testing equipment manned by highly skilled professionals.

This team is given complete authority for conducting tests and experiments to ensure innovation
and improvise on the production parameters. “We understand the R&D leads to innovation
which is a backbone of an engineering enterprise like RPL”. The R&D cell is also well
supported by the in-house tool room and testing facilities to ensure well-coordinated product
development with minimum lead times.

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Apart from these equipments, the company also has other conventional testing machines.

3.3 Design and Tool Room.

Roop Polymers has centralised in house tool room for mould development, dedicated tool room in each plant
for mould maintenance, highly skilled and professional team for design and mould manufacturing.

The centre operates on latest equipment’s like: CNC Wire cut Machine, CNC Vertical Machining Centres, CNC
EDM Machines, CNC Turning Centres, Surface Grinders, Lathe Machines, Milling Machines, Drilling
Machines, Tool and Cutter Grinder Machines, and softwares like: CAD/CAM, CATIA, UG NX5 and IDEAS 9
for mold design, simulation, manufacturing and adherence to customer specifications.

The tool room employs a strategic mix of conventional and contemporary equipments like CNC machining and
turning centres, CNC wire cut, EDMs etc.

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Chapter 4
Client

1. International Clients.

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2. OEM.

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3.Tier 1’S

4.2 SAFETY DEPARTMENT

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The functions of safety department are as under:-

• Monitoring implementation of all directives issued by Rly Board & HQs in matters

pertaining to safety. Ensuring super checks of functioning of operational & maintenance
machinery on the division. ... Implementation of safety circular & safety drives on the division.

What is the importance of safety?

A safe and healthy workplace not only protects workers from injury and illness, it can
also lower injury/illness costs, reduce absenteeism and turnover, increase productivity and
quality, and raise employee morale. In other words, safety is good for business.

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4.3 PAINT SHOP DEPARTMENT
PaintShop Pro supports layers and lets you edit both raster and vector image formats—
something you'd need two of Adobe's Creative Cloud apps to do. You miss out on some of the
Adobe flagship photo editor's most advanced tools, however, including 3D modeling, detailed
typography, and face liquefy.

Acrylic Enamel. Acrylic enamel paint lasts a long time since it creates a strong, hard shell over

the whole of the car.

Acrylic Urethane. A great new option for paint is acrylic urethane.

Solid Paint. .

Pearlescent Paint.

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4.4 KAIZEN RULES.

Rule # 1: Discard conventional, fixed ideas.

Rule # 2: Think of how to do it, not why it cannot be done.

Rule # 3: Do not make excuses, start by questioning current practices.

Rule # 4: Do not seek perfection. Do it right away, even if only for 50% or target .

Rule # 5: Correct it right away, if you make a mistake.

Rule # 6: Do not spend money for KAIZEN, use your wisdom.

Rule # 7: Wisdom is brought out when faced with hardship.

Rule # 8: Ask WHY five times and seek out root causes.

Rule # 9: Seek the wisdom of ten people rather than the knowledge of one.

Rule # 10: KAIZEN™ ideas are infinite.

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 Conclusion

Hence ,In this training report we learn about various plastic products which is made in the

industries and supplied throughout the country.

We also learn about the rules and regulation of the industries which is most important part of

life as worker in the industry.

We have discussed about followings point listed below.

 Automotive

 Non-Automotive

 Rubber molding

 Rubber Extrusion

 Rubber Hoses

 Plastic molding

 Quality

 R&D and Testing

 Design and Tool Room

 Client

 Safety department

 Paint shop Department

 Kaizen rules

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 Thankyou

References

Websites:-
 https://searcherp.techtarget.com/definition/kaizen.
 https://rooppolymers.com/
 https://www.merriam-webster.com/dictionary/
nonautomotive#:~:text=Definition%20of%20nonautomotive.
 https://www.porscheengineering.com/peg/en/services/competence/
non-automotive/
 https://www.lawinsider.com/dictionary/automotive-
product#:~:text=Automotive%20product%20means%20any
%20hardware,train%2C%20or%20other%20transportation
%20vehicle.

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