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To know about the facilitylayout and the process of the Rahimafrooz Batteries Ltd
To suggest the ways and means for improvement in policy and techniques.
1.3 Methodology
In this study, exploratory research was undertaken to gain insights and understanding of
their operation management system and for preparing the assignment. There are found
both qualitative and quantitative data. To prepare this term paper, we have collected
information from different sources: from personal interviewand secondary source like
internet. Hence a more comprehensive conclusive research was prepared to fulfill the main
purpose of the study.
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Lucas and Spark are the leading names in the local automotive battery market while Volta,
Optus and Delta are gaining equity as international brands.
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assembly manufacturing (i.e. repetitive process). Another drawback in using other processes
is the sensitive nature of the chemicals used; only repetitive process allows for the batteries
to be immediately sealed during assembling.
II)
III)
Calcium Blocks
IV)
Lead caps
V)
Plastic caps
VI)
3.2 Battery Lines There are two main brands of battery that RBL manufactures. They are
Lucas and Volta. Its main product range includes:
i) Automotive battery
ii) Motorcycle battery
iii) Appliance battery
iv) Deep cycle Flat plate battery
v) Industrial tubular battery
vi) VRLA battery
vii) UPS
viii) Solar system
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Here we have focused on automotive batteries only. A brief description of each of the two
kinds of batteries that we have chosen is given below:
(i) Lucas: Lucas Battery basically is a LEAD ACID BATTERY, which requires maintenance after
being purchased. It is provided with a warranty. Regular checkup is required after 6
months. Maintenance cost is free as Rahimafrooz has got outlets in every corner of the
Country.
(ii) Volta: The most modern and the new technology introduced to the market, especially
for Vehicles like (Cars and Commercial Vehicles). This technology has created vast the
market in countries like Europe because this battery placed the marketing strategy
which says CONNECT IT - FORGET IT . The battery chemicals are used are calcium
based compounds.
3.3 Capacity Availability
Rahimafrooz has state of the art manufacturing plant. It is equipped with all latest
technologies with complete air treatment and lead-recycling management. RBL produces
different types of batteries to meet the local and international market.
Its capacity in Automotive Battery is 660,000 (N50) units per annum and 15 million AH of
Industrial Battery per annum. All the products are manufactured under strict quality control
and ensured by international certifications.
The initial plant capacity for our chosen battery specifications (i.e. LRT13S, LX17L and L180)
was 30,000 batteries per annum based on the demand on 2000 with provision for
expansion. Later it experienced further successive expansion as the demand increased and
is currently at ceiling of 120,000 per annum. Currently RBL is planning to shift to a new plant
to cater new demand.
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2) Plate Processing:
a. Grid Pasting: During the pasting process, lead oxidepaste is applied to the grid panels
in a pasting machine to fill the spaces of the grid.
b. Enveloping and Wrapping: Enveloping involvesplacing a plate (usually positive),
either automatically or manually, within porous membranes.
c. Handling and Transport: Handling and transportingof materials is an essential part of
the battery manufacturing process. Materials are primarily transported through the
use of mobile equipment (forklifts).
Demand
50
40
30
LRT13S
20
LX17L
10
L180
1st 2nd 3rd 4th
Qtr
Qtr
Qtr
Raw
Materials
Qtr
Oxide
Processing
Grid
Processing
Oxide
Storage
Grid
Storage
Plate
Processing
Plate
Storage
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5. Labelling and Packaging: The formed batteries are than send to the labelling and
packaging department where they are transformed into finished goods ready for sale.
Grid
Storage
Lucas
Volta
Stacking
Stacking
Group Burning
Group Burning
Inter-cell Welding
and Post Burning
Inter-cell Welding
and Post Burning
Formation
Formation
Labeling and
Packaging
Labeling and
Packaging
Raw
Materials
Raw
Materials
Oxide
Storage
Finished Goods
Warehouse
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4.3
Forecast Market
Demand
Production Plan
Capacity
Availability
No
Problems?
Start Production
Quality Control
Yes
Lost Revenue
No
Defects?
Replacement
Sales
Yes
Yes
Under
Warranty?
No
Defects?
No
Yes
End
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The above flow diagram is the process of how RBL conducts its operations from the very
start till the customer service. Initially when they start their operation the first thing they
consider vital is the assessment of the demand for different types of batteries. After
forecasting demand they move on to the planning phase. In this phase they try to form a
production plan base on their assessed market demand. After doing so they move on to see
whether their current capacity allows them to execute their production plan. If it is feasible
than they move into production. In case of capacity problems they have to re-plan their
production so as to meet the capacity requirements.
In the production phase quality control is maintained throughout the entire process
to minimize scraps and other avoidable wastages. If during the quality control process any
defective items are found than that item is scrambled and any recoverable portion of that
battery is put back into production. In any case there is a cost added to this and which is
considered as loss of sales.
After the quality control phase the finished goods are sold, there maybe further
defective items. If so than RBL has replace or repair the goods if they fall under warranty
claims. This also results in loss of sales and most importantly as RBL states Loss of
goodwill. However, if there are no defects and the batteries fail only after their warranty
period than RBL has successfully made sales and therefore profit. The whole process restarts
with the assessment of next possible demand scenario.
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5. Recommendations
After the analysis we suggest that Rahimafrooz Batteries Limited (RBL) to take the followings
into consideration to improve their existing process:
The workstations in the assembly line are linearly arranged. To reduce production of
defective items RBL may consider implementing U-shaped assembly setting to
ensure quality in production.
RBL could increase their plant capacity more frequently as not doing so maybe
causing potential loss in sales.
RBL may want to consider further processing of the by-products that are generated
from the manufacturing process to increase their revenue instead of bearing the cost
of discharging them.
6.0 Conclusion
RBL is currently doing extremely well in their market segment and they are also the largest
lead acid battery manufacturer in Bangladesh which is their competitive advantage over all
other competitors. Moreover, RBL is not sitting around being the largest manufacturer;
instead it is expanding by attracting customers at a global perspective. In addition, RBL is
constantly generating new innovative ideas through their Research and Development (R&D)
department which has strongly ensured their future position as the dominant battery leader
in Bangladesh market. Along with a few improvements in their manufacturing process and
given the current trend of their growth it will not be long before they actually achieve their
vision of being among the top two battery suppliers within the SAARC countries.
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Bibliography
1. Lead-acid battery. (2007, August 3). In Wikipedia, The Free Encyclopedia. Retrieved
11:56 am, november30, 2012, from http://en.wikipedia.org/w/index.php?title=Leadacid_battery&oldid=149029222
2. Rahimafrooz Batteries Limited. (2005, June 5). Rahimafrooz Website. Retrieved 12:13
pm,
november
30,
2012,
from
http://www.rahimafrooz.com/rahimafrooz_battery_products/world_wide_best_batt
ery_products.asp
3. Chase R. B., Aquilano N. J., & Jacobs F. R. (2000) Production and Operations
Management. 8th Edition\
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