Sheela Foam Pvt. Ltd.

Induction Report
By - Raj Ratnam

Management Trainee [Operations]

2010
 Sheela Foam Pvt. Ltd.
Induction Report

INDUCTION REPORT

2
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

CONTENTS
1.0 COMPANY................................................ page 5
1.1 ABOUT COMPANY............................................ page 5
1.2 INTERNATIONAL JOINT VENTURES.................... page 6
1.3 MILESTONE ACHIEVED BY GROUP..................... page 6
1.4 PRODUCTS....................................................... page 6

2.0 B.R.M.P.................................................... page 7

2.1 ABOUT B.R.M.P................................................ page 7
2.2 EXPORTS.......................................................... page 8

3.0 TECHNICAL FOAM.................................... page 9

3.1 ABOUT TECHNICAL FOAM................................ page 9
3.2 TYPES.............................................................. page 9

4.0 EXPORTS.................................................. page 12

4.1 ABOUT EXPORTS.............................................. page 12
4.2 EXPORTS TARGET............................................. page 12

5.0 ACCOUNTS............................................... page 13

5.1 ABOUT ACCOUNTS............................................ page 13

6.0 LEGAL....................................................... page 14

6.1 ABOUT LEGAL................................................... page 14

7.0 FINANCE................................................... page 15

7.1 ABOUT FINANCE................................................ page 15
7.2 BANK COLLABRATIONS...................................... page 15
7.3 INSURANCE AND FIRE POLICY............................ page 15
3
Page

7.4 FUNCTION OF STAFF......................................... page 16

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

8.0 SLEEPWELL DIVISION................................ page 17

8.1 ABOUT SLEEPWELL............................................ page 17
8.2 MATTRESSES..................................................... page 17
8.3 COMFORT ACCESSORIES................................... page 18

9.0 PURCHASE............................................... page 20

9.1 ABOUT PURCHASE........................................... page 20
9.2 FUNCTION....................................................... page 20
9.3 ROLE OF E.R.P.................................................. page 20

10.0 OPERATIONS........................................... page 21

10.1 ABOUT OPERATIONS....................................... page 21
10.2 FOAMING....................................................... page 22
10.3 PROCESS......................................................... page 22
10.4 PEELING.......................................................... page 23
10.5 MAINTAINANCE.............................................. page 23
10.6 FIRE AND SAFETY............................................ page 23
10.7 RESEARCH AND DEVELOPMENT...................... page 23

REFERENCE.............................................. page 24

4
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

1.0 COMPANY
1.1 ABOUT COMPANY

Sheela Foam Pvt. Ltd. Company established in the year 1971. Its production
started in the year 1972. Presently it has 70 distributers all over the India. And
about 3500 distributors located in whole country.

As per company concern, the main customer of this company is distributor.

The product manufactured in factory first goes to distributors, then
distributors
ibutors supply it to dealers, and then it reaches to the customers.

PRODUCT
FROM DISTRIBUTOR DEALER CUSTOMER
FACTORY

FIG 1.1 Flow dig. Showing flow of product.

Company has presentlytly 10 manufacturing facilities available all over India.

And total employee strength of group is about 1500.
5
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

1.2 INTERNATIONAL JOINT VENTURES

As far as international joint venture concern, Sheela foam has 35% share of
Joyce foam of Australia. The group also have joint venture with Woodbridge
of Canada in the field of automobile seats.

The company also have joint venture with A.H. Beard Company. Their plant is
located in Silvasa (Dadar & Nagar Haveli) known as S.B. Bedings Int. Pvt. Ltd.

1.3 SOME MILESTONES ACHIEVED BY THE GROUP

YEAR ACHIEVEMENT

1994- Sleepwell started.

1996- 97- Silvasa & Hyderabad plant open.

2001- Noida plant setup.

2002- Rajpura plant setup.

2003- Sikkim plant setup.

2005- Joyce foam acquired.

2006- Joint venture with Woodbridge.

2008- Joint venture with A.H.Beard.

2010- Talwara plant setup.

1.4 PRODUCTS

As far as products concern, company presently producing 150 + types of foam.

Few of their names are Feather Foam, Flex Puff, Champion, Restwell,
Rainbow, Indigo, Classic, Magic, and Lami Flex.
6
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

2.0 B.R.M.P.

2.1 ABOUT B. R. M. P. (BULK RAW MATERIAL PURCHASE)

This department of the company is concern with purchase of raw material

which is utilised by the company in bulk. This department is headed by Mr.
Arvind Kumar who is V.P. of this department.

In this department, total staff strength is of 15 peoples.

As per import concern, there are basically two types of imports in this
department.

They are -

RAW MATERIAL
PURCHASE
IMPORT
SPARE ITEMS
AND
MAINTAINANCE

All the purchase is done on the basis of demand forecasting. This is

developed with the help of Enterprise Resource Planning. ERP have all the
data related to the use and consumption of material in the company. This
data is developed due to input of all the activity into the system. So due to
this, it is easy to forecast the demand and to maintain an inventory level.
7
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

2.2 EXPORTS

Presently company is exporting their products in many countries like U.A.E.

Qatar, Sri Lanka, Germany, Argentina, United States Of America etc.

The company gives their product advertisement on the internet. So with the
help of their advertisement on internet, company get export order to the
different countries.

8
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

3.0 TECHNICAL FOAM

3.1 ABOUT TECHNICAL FOAM

This section of the company is headed by Mr. K. K. Bhandari. He is AGM of this

department. There are three major categories of foam produced in the
company. They are,

Foam

Sleepwell Industrial Technical

Matresses Foam Foam

3.2 TYPES

The major technical and industrial foam produced by the company are

1. Flame Retardant Foam

2. U.V. Stable Foam
3. Reticulated Foam
4. Anti Static Foam
5. Polyester Foam
9
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

Details of different kind of foam are as follows-

1. Flame Retardant foam-

This type of foam is special kind of foam which does not catch fire
easily. Such type of foam has wide application in different kinds of field.
This type of foam is used in automobile industry and genset industry. In
genset industry, flame retardant foam is used in covering inner surface
of box carrying genset. The inner temperature of sound proofing box is
more as the normal foam catches fire. So this kind of foam is used in
covering inner surface of sound proofing box.

2. U.V. Stable foam-

This type of foam has special quality that it does not turns yellow due to
exposure to sun. These types of foam have no effect of ultra violet rays
produced by the sun. So its colour last longs more as compare to any
other kind of foam. This type of foam is used in lingerie industry and
also has much other application.

3. Reticulated foam-

This type of foam has PPI less as compare to other foam. They are used
in filtration. They are used in oil filters, air filters and water filters. This
foam is made from polyester. They are also used in spare industry.

4. Anti Static foam-

This type of foam has special quality that they do not develop static
charge when it comes in direct contact with body. So this foam is used
in packaging industry to pack electronic items which damages if static
charge developed in the foam. So they pack the electronic items and do
10

not develop charge.

Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

5. Polyester foam.

This type of foam has more strength as compare to polyether foam. So

this foam is widely used in automobile industry. It is used in insulation,
as a headliners, seats etc.

TPV film coating is special type of coating which prevent oil, water, and
any other material to stick on the surface of the foam.

Foam is also used in medical field, offices and buildings etc.

11
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

4.0 EXPORTS
4.1 ABOUT EXPORTS

In the year 2005, export unit of the company has established. This
department is headed by Mr. Rajeev Nayyer. There is a team of six
peoples who are working in this section. This team look after all the
export of this company.
The company start the export by exporting P.U. Foam. Now they are
looking forward for exporting U.V. Foam, T.F. Foam, Hard foam etc.
Presently company is exporting their products in many countries like
U.A.E. Qatar, Sri Lanka, Germany, Argentina, United States Of America
etc.
The company gives their product advertisement on the internet. So
with the help of their advertisement on internet, company get export
order to the different countries.

4.2 EXPORT TARGET

The target of the company to export up to end of this year (2010) is 20

crore.

12
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

5.0 ACCOUNTS

5.1 ABOUT ACCOUNTS

This department of the company is looking after by Mr. Ravinder Singh.

This department of the company has centralised function. Apart from

accounting, this department also look after the taxation. In taxation, it
includes taxes like sales tax, company tax etc. The account function of this
company is aided by Enterprise Resource Planning.

Management Information System is also used by this department. This is

used in doing audits.

Apart from accounting and taxation, this department of the company has
third function. The third function of this department is to handle company
law.

So the account department of the company handles all three functions, i.e.
accounts, taxation, and company law.

13
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

6.0 LEGAL
6.1 ABOUT LEGAL

This department of the company is looking after by Mr. Alok Sharma

who is advocate. He joined the company in year 1997.

All the legal matters of the company are looking after by this
department. This department handles all the matters like excise,
custom, service tax, Value added tax etc.

This department not only look after in legal issues, but also trouble
shoots on various issues.

14
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

7.0 FINANCE

7.1 ABOUT FINANCE

This department of the company is headed by Mr. T. A. Sundar Raman.

He is G.M. of this department.
This department look after all the profits, funds, and capital
expenditure of whole organisation.

7.2 BANK COLLABRATIONS

The company is collaborated with two banks. The two banks are-
1. Central Bank of India
2. Yes Bank

All routine payments of company are done by the Central Bank of India.
The company limit in this bank is about 45 crore.

The company receives account statement every month which consist all
the details of transaction.

7.3 INSURANCE AND FIRE POLICY

This department also look after the insurance and fire policy. It consists
terms and conditions of credits, time of renew of the policies.
15
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

7.4 FUNCTIONS OF STAFF

In this department, function of Staff members is as follows-

1. Payment – Mr. Ashok Aggarwal.

2. Payment (B.R.M.P.) – Mr. Hari Prasad.
3. Draftsman / Bank Man – Mr. Bachhi Lal.
4. Cash collector from parties – Mr. Jhabbi Lal.
5. Finance Management Trainee – Miss Divya Tyagi.
6. Record Keeping – Mr. Hari Mohan.

16
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

8.0 SLEEPWELL DIVISION

8.1 ABOUT SLEEPWELL

This division of the company is started in 1994. And now it is a well known and
leading brand in India and also leading brand in the world. Under this brand
name, the company produces variety of mattresses with very wide and luxury
range.

Under this brand the company is also focussing more on premium and luxury
mattress due to receiving good response from world market in mattress
section.

8.2 MATRESSES

There is variety of mattresses produced by the company. They are-

1. Spring fresh mattress.

2. Flexi puff mattress.
3. Flexi coir mattress.
4. Regular sheet for mattresses.

Under these major types, there are various subtypes of the products. They
are-
1. Spring fresh mattress.
a. Bliss
b. Harmony royale
c. Tranquil royale
d. Serenity
e. Harmony
f. Tranquil
g. D’light
17
Page

2. Flexi puff mattress

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

a. Impression
b. Latex plus
c. Latex luxury
d. Duet
e. Resitec air
f. Dura firm
g. Covered quilted
h. Covered mattress

3. Flexi coir mattress

a. Galaxy
b. Zenith
c. Dura firm
d. Sigma
e. Alpha dlx
f. Omega
g. Vega

4. Foam sheets
a. 50
b. 40
c. 32
d. 28
e. 23

8.3 COMFORT ACCESSORIES

Apart from mattresses, company have also a wide range pillows and
comfort accessories. They are-

1. Pillows
a. Fibre pillows
b. Flexi puff pillows
18

c. Specialised pillows
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

2. Back cushions
3. Blosters
4. Twin touch cushions
5. Sofa ‘n’ Bed
6. Regular sheet for furniture’s

These are the product range of the company under Sleepwell brand.

19
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

9.0 PURCHASE

9.1 ABOUT PURCHASE

This department of the company is looking after by Mr. Sunil Tyagi. This
department consisting with the team of four people.

This department work for GNA and SJP, both units combinely.

9.2 FUNCTION

This department is responsible for all kind of purchase including raw

material purchase, packaging material purchase, and all inventory item
purchase.
Uneven items like parts of machine, and other factory and office items
are also purchased by this department.
All regular items like raw material are supplied directly by the vendor to
the company. But for all irregular items, one person from the
department goes to the market once in a week and buys all the items.

9.3 ROLE OF E.R.P.

E.R.P. plays a very important role in this department. All the purchase
order, regarding any item, is given to the purchase department through
E.R.P. Indent is created regarding the item by the user department and
then forward to the purchase department.
E.R.P. also helps the purchase department to be centralised and be in
communication with other departments and units of the company. The
user department can also check the status of the purchase order on
E.R.P.
20
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

10.0 OPERATIONS
10.1 ABOUT OPERATIONS

This is the biggest division in the whole organisation which produce final
product from raw material. This division of organisation is headed by
different head of departments and combinely they work as operations.

The flow chart of different departments in operations is given below,

which shows flow of material from one department to another in flow
form raw material to finished product.

PROCESS

RAW
FOAMING CURING STORAGE DISPATCH
MATERIAL

PEELING

Fig. Showing flow in operations.

21
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

The major department which plays important role in operations are –

1. Foaming department
2. Process department
3. Peeling department

10.2 FOAMING

This section of operations is responsible for the production of foam from

raw material. This department is headed by Mr. Jitendra Thakre who is
H.O.D. of this department.

The production of foam is scheduled by P.P.C. (Production planning and

control). This schedule depends upon the order status received by the
P.P.C. from the customers. According to the requirement, P.P.C. schedule
the order in E.R.P. and foaming is done as per requirement.

The foam blocks produced in foaming are of length about 56 mts. And 28
mts. They are then sent to curing shed where they are stored for few hours
(as per requirement). Then they are transferred to long block storage. From
long block storage, foam blocks as per requirement are cutted and send to
process and peeling.

10.3 PROCESS

This section of operations is responsible for the production of sheets and

blocks used in different products of company as per requirement. In this
section, foam block is cutted in small required shapes. This is done by
different types of cutting machines available in process shed. After cutting,
foam sheets and blocks are packed as per requirement and send to the
finished product storage.
22
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

10.4 PEELING

In this section, foam blocks are peeled layer by layer. This is done with the
help of machine called LOOPER. In this machine, foam block of 56 mts. And
28 mts. are loaded and then peeled and rolled. These rolls are then packed
and send to storage section. This peeled foam is used in different industries.

SOME OTHER DEPARTMENTS WHO ARE PART OF OPERATIONS

10.5 MAINTAINANCE

This department of operations look after all technical works. This

department is lead by Mr. I.P. Singh who is H.O.D. of this department. This
department is responsible for the maintenance of all machines and plant.
This department also look after all physical work (apart from production) of
the company, whether it is installation of machine, or renovation of any
part of company.

10.6 RESEARCH AND DEVELOPMENT

This department of the company is responsible for the R&D in foam section.
This department is headed by Dr. D. K. Chattopadhyay who is AGM of this
department. All the research in foam is done by this department in order to
develop more new kind and advance type of foam.

10.7 FIRE AND SAFETY

This department of the company is responsible for the safety of the

company from fire and other accidents. This department is headed by Mr. I.
P. Singh who is H. O. D. of this department.
23
Page

By- Raj Ratnam

 Sheela Foam Pvt. Ltd.
Induction Report

References
i. Fire and safety manual. (Sheela Foam Pvt. Ltd.)
ii. Sleepwell product catalogue (w.e.f. 2009)
iii. Fire and safety presentation (by Mr. I.P. Singh, HOD –Fire and safety.)
iv. Company history and achievement presentation (by Col. S. C. Uprethi, G.M. – H.R.)
v. Research and development presentation (by Dr. D. K. Chattopadhyay, A.G.M. – R & D.)
vi. Maintenance presentation (by Mr. I. P. Singh, H.O.D. - Maintenance)
vii. B.R.M.P. Presentation (by Mr. Ashok Kumar, V. P. – B.R.M.P. & Exports)
viii. Exports Presentation (by Mr. Rajeev Nayyer, Exports)
ix. Standard operating procedure (store).
x. Standard operating procedure (process and peeling).
xi. Standard operating procedure (maintenance)
xii. Working instruction manual (process machineries)

WEBSITES
http://www.sheelafoam.com
http://www.sleepwellproducts.com
http://www.wikipedia.org
http://www.scribd.com
http://www.google.co.in

24
Page

By- Raj Ratnam