Customer in Focus

Plastic Injection Molding Components & Assembly

About Vignesh Polymers Vignesh Polymers is one of the fast growing

Moulding company in South India, catering tothe White Goods and Automobile Sectorssince 2005.

The Company has two State of ArtManufacturing Facilities in Chennai (CertifiedISO 9001:2015 & 1ATF 16949:2016) andGoa.

48 Injection Moulding Machines ranging from160T to 2000T including Vertical InjectionMoulding

Over 312 Components Ranging from1.5 grams to 7.0 Kg

Specialized post moulding activities likeAssembly, Printing, Welding & Painting

Driven by over 255 qualified professionals.

Business Services

Sales Value in (MINR)

Sales in Qty (Million)Head count

Injection Molding

74%

Sub Assembly14%

Painting5%

Printing5%

Welding2%

2013 2014 2015 2016 2017 2018 2019

31.2 31.8

2013 2014 2015 2016 2017 2018 2019 2020Target

246 258

2013 2014 2015 2016 2017 2018 2019 2020Target

2150 3000

30.2 M$

42.1 M$

FOUNDER / CEO: R.B.SIVAKUMAR

The Company has been promoted by RB.Sivakumar a first Generation Entrepreneur, a Post GraduateDiploma Holder in Plastics Mould Making technology from CIPET – Ahmedabad-Gujarat

Experience of over 20 years in various capacities in Plastic Industry ,worked in Companies likeNational Plastics Ltd, Pentadaewha Auto Parts, Supreme Industries and GM Pens

Undergone training in Korea and Taiwan for understanding the best practices in manufacturing ofplastic components which requires high precision and quality

His tireless efforts has helped to become a Global Supplier/Bench Mark Vendor to Major OEM’s

CEO Profile

Vignesh Polymers

Started at

Pondicherry

Vignesh Polymers

Shifted to

Padappai

Got SQ Mark

Certificate

Business Started

with Samsung India

Electronics-Chennai

Enhanced the Machine

Capacity with 13

Molding Machines

ISO/TS-16949

Completed

Mile Stones

New Plant

Started In

Vallam

Entire Plant

Automated with

Robot System

Business Started with IFB

with New Plant-Goa with 12

Machines

Warehouse-Chennai &

Paint Shop-Goa Started

Vallam plant with

capacity of 28 Molding

Machines

Special type Packing

Materials & Food and

Beverages Business

Started

Manufacturing Unit

Ware-Housing & Assembly

Paint Shop

Chennai Plant-

2015

Ware-House

2018

CERTIFICATIONS

ISO 9001:2015

IATF

16949:2016

Goa Plant-

2017

Paint Shop-

Goa 2018

Manufacturing Plant -LocationsInjection Molding

Sub Assembly

Painting

Printing

Welding

We Used Special type Raw Materials PA6, PA66 GF 30% & 35% PBT-PET PP & PE (filled/unfilled/glass filled) GPPS ABS-FR PC ABS ABS-Sparkling Materials ABS

We are running Multiple Colors in White Goods

White Silver Blue Red Violet Black Grey

Our Esteemed Customers

Organization Structure R.B.Sivakumar

Managing Director

S.BaburajanGeneral ManagerGoa Operations

VikramkumarFinance

ThangarajHR & Admin

DilipProduction

M.SelvakumarQuality

PrabakaranMaintenance/Paintshop

SasikanthMould Maintenance

ThangarajHR & Admin/ Finance

Venkat RamanaStores

SridharIT

JeganathanSafety

J.RaviPlant Head/

New Projects

U P SelvakumarNPD

Jose P JosephPurchase

SaravananStores

JohnsonWare-House

G.SivaprakashAGM-Operations

Jithendar/Tamilselvam

Production

Senthil MuruganMachine Maintenance

ShanmugamMould Maintenance

Nandakumar/Suresh

Quality

BalasubramaniPPC

Injection Moulding Machines

TonnageVallam-Chennai Verna-Goa

TotalMilacron Toshiba LS Woojin TKC Milacron

160 - - - - 2 - 2

180 - 1 - - - - 1

250 2 1 - - - 1 4

350 2 - - - - 2 4

450 2 2 - - - - 4

500 7 1 - - - 3 11

650 3 2 - - - - 5

660 - - - - - 1 1

750 - 1 - 1 - - 2

775 1 - - - - 1 2

850 1 - - - - 1 2

950 - 1 - - - - 1

1100 2 - - - - 1 3

1300 3 - - - - 1 4

1500 - - 1 - - - 1

2000 - - 1 - - - 1

Total 23 9 2 1 2 11 48

Year 2005 2007 2008 2009 2010 2012 2013 2016 2017 2018 2019No of Machines

1 1 3 5 7 9 13 16 36 40 48

Injection Moulding Machines - Vallam ChennaiMACHINE TON MAKER DIE BAR DISTANCE QUANTITY

2000 LS 1800 X 1600 1

1500 LS 1500 X 1400 1

1300 MILACRON 1550 X 1200 2

1300 MILACRON 1530 X 1120 1

1100 MILACRON 1390 X 1070 2

950 TOSHIBA 1120 X 1000 1

850 MILACRON 1080 X 1080 1

775 MILACRON 950 X 950 1

750 WOOJIN 1010 X 1010 1

750 TOSHIBA 1000 X 900 1

650 MILACRON 1000 X 900 3

650 TOSHIBA 870 X 870 2

500 MILACRON 830 X 830 7

500 TOSHIBA 810 X 810 1

450 TOSHIBA 730 X 730 1

450 TOSHIBA 720 X 720 1

450 MILACRON 710 X 710 2

350 MILACRON 700 X 650 2

250 MILACRON 620 X 620 2

250 TOSHIBA 580 X 580 1

180 TOSHIBA 510 X 510 1

Auxiliary EquipmentSpecification Make Vallam-Chennai Verna-Goa

Shop floor 50K sq.ft 35K sq.ft

Ware-house/Paint shop 60K sq,ft 25K sq.ft

Robots Wittmann 22 9

EOT Cranes K2 Cranes 10,15 & 20 tons 15 ton

Real Time Monitor Digiwave/Crunch 27 11

Electricity Capacity 1290 KVA 950 KVA

Diesel Generator Kirloskar 750,500,380KVA 750KVA, 160KVA

Conveyors Wittmann Final & Assembly Final & Assembly

Centeralized Feeding SystemWittmann/ Prasad

1 1

Volumetric Feeders ConAir 13 -

Air Compressors Kaeser 3 3

Mould Temperature ControllerWittmann/Toshiba

19 6

Chiller Prasad/ConAir 11 7

Dehumidifier Prasad/ConAir 9 4

Hopper Dryer Toshiba 12 7

Hot Runner Controller Yudo/Elmac 42 15

Quality Lab Equipment

Instruments Type RangeVallam-Chennai

Verna-Goa

Digital Vernier Caliper Mitutoyo 0-150mm to 0-1000mm 9 5

Digital Weighing Scale essae 0-650 gms to 0-150 kg 11 6

Digital Height Guage Mitutoyo 0-1000mm 2 1

Pin Guage Progressive 0-7.0mm 2 1

Slip Guage Mitutoyo 0.05 to 100mm 0 1

Moisture Analyzer Presto 0-200deg 1 1

Melt flow Indexer Presto 0-400deg 1 1

Muffle Furnace Deeps Engg 0-1200deg 1 1

Dial Guage Mitutoyo 0-13mm 2 1

Torque Wrench Mitutoyo - 0 1

Surface Table Alpha 1000*1000mm 3 1

Color Cabinet - 2 1

Color Meter Deeps Engg - 1 1

Gloss meter Deeps Engg - 1 1

Cross Cut Teaster - 1 1

Push Pull Guage Mitutoyo - 1 0

Digital Lux meter Lutron 0-2000lux 2 0

Manufacturing Setup

Manufacturing Units – Vallam Chennai

Ware House – Mambakkam Chennai 60000 sq. ft Assembly / Ware house for Stocking FG/SFG

New Plant Setup for IFB – 2017

Manufacturing Unit – Verna Goa

Paint Shop & Assembly Unit–Verna Goa New Plant Setup for IFB – 2018

Injection Moulding Components we

Manufacture

Industry Segments Served

Automotive

Engine Components

Automotive Lightings

Automotive Bumpers

White Goods

Home Appliances – Refrigerator

Tray chilled Room

1- Door Refrigerator-Samsung

Guard fre up small

Guard Variety

Guard Jumbo Fresh MaxCase Vegetable

Guide

Tray ice

Guard Jumbo

Cover Veg

Cover Hinge up

Home Appliances – Refrigerator2- Door Refrigerator-Samsung

Guard Variety

Case Veg low

Rail Shelf

Tray Chilled Room

Tray ice cube

Case tray ice

Guard fre up

Guard Egg

Cap Door Ref up

Cap Door fre Low

Foot Front

Cover Hinge up

Cover Deodorizer

Home Appliances – Air Conditioners

Panel FrontBack Body

Air Conditioner-Samsung

Home Appliances – Air Conditioners

Deco Panel

Support Evap Cover Evap Holder Evap Cover Terminal

Cover Bearing

Case Control inn

Support Up

Home appliance – Washing Machines

Semi Outer Tub

Door lid Washing

Assembly Door lid TC

Assembly Semi Cover Top

Assembly Cover TC

Assembly Cover Panel

Fully Automatic Washing Machine-Samsung

Home appliance – Washing Machines Door lid Spinning

Window lid Spinning

Door lid IS

Basket Spin

Plate Top

Cover Tub

Base

Twin Tub

Semi Auto Washing Machine- Samsung

Home Appliances - Washing Machine

Door Assembly

Front Panel

Back Panel

Panel Housing

Pulsator

Back Panel

Tub Lower

Top Loader-IFB

Drum

Balancer

Home Appliances - Washing Machine

Door Assembly

Base Plate

Top Lid

Tub Rear

Tub Front

Front Loader-IFB

Fitting water outlet-AH2

Duct lower BA

Throttle Shell - BA

Diffuser - IB

Cylinder head cover

Duct lower

Air filter PA

Body air cleaner HCI K1.4 & G1.6

Cover air cleaner 1.4

Mid shell

Automotive – Engine ComponentsIB Project - Elite i20-HMI

Cylinder head cover

Automotive – Engine Components

Water Temperature Controller System

AH2 Project – New Santro-HMI

Diffuser

Air Cleaner Cover

Air Cleaner Body

Automotive – Engine/Exterior Components

Shield Air intake

Resonator Upper

Duct Adaptor

Stanchion Roof

Cover Roof Rack

QXI Project – Venue-HMI

Automotive – Bumpers

Skid Plate FR Bumper

Skid Plate RR Bumper STD

Skid Plate RR Lower

GS-PE Project – Creta-HMI

Automotive – Exteriors & Interiors

Garnish A Pillar

Garnish FR DR UPR Garnish RR DR UPR

SP2I- Project – Seltos-KIA

G02A

650 LED Body

660 LED Body

Extension C

Extension A

660A RCL Body

Bull Body

Automotive – Lighting Components660A Project – Innova -Toyota

650A Project – Fortuner -Toyota

Best Practices & Initiatives

Best Practices @ Vignesh Polymers

Centralized Material Feeding Systems

POKA-YOKE Monitoring System

Robot Installation & Conveyor System

Real Time Visual Display Monitoring System

Industry 4.0(Internet of Things –IOT)

Centralized Material Feeding System

Centralized Material conveying system capable of managing up to six material receivers, with a smart suction unit and centralized high efficiency filter.

Integrated with volumetric dosing units, Hopper Dryers Reduced Man effort , Avoids Mix up of materials and saving in loading Time.

Material Bin/ Dehumidifier Entire Material Conveying Arrangement

POKA-YOKE Monitoring System POKA-YOKE is a mechanism in any process that helps an equipment operator avoid

(yoke) mistakes (poka). Its purpose is to eliminate product defects by preventing, correcting, or drawing

attention to human errors as they occur. Robots has interfaced with Weighing Machine For Part weight POKA-YOKE System.

If part weight out of

Spec Robot Move the

part Rejection bin

If part weight Within

the Spec Robot Move

the part to Conveyor

POKA-YOKE

Robots & Conveyor System Eliminate Machine and Operator idle time

during molding process. Increase output with consistent Cycle time. All Robots having EOAT Application

Eliminate Man power Movement & Reducing Manpower

Assembly issues avoided Avoid Handling issue (Damage &

Scratch)Robot System Conveyor System

Real Time Visual Display Monitoring System

Every Molding Operator Table installed with a 24’’ Visual Monitor Based on Mold change Visual Displays shall be updated Machine Operating Work Instruction displayed visually to avoid manual error Visual Inspection Displayed for how to Inspect/Pack the material Customer Matrix/Defect Matrix displayed to know about Product Knowledge To know Recent Internal & External Quality issues

Real Time Dash Board Monitoring of all Machineswith OEE detailsCan monitor remote locations machinesAvailable as a mobile app

IOT@ Vignesh Polymers

Real time Overall Plant Performance Analysis

IOT@ Vignesh Polymers Real Time Alarm Monitoring of all Machines

Shop floor wise OEE Comparison Analysis Real Time Operational Parameters Analytics

Automated Scheduled Reports by Mail end of each shift and consolidated for the Day

IOT@ Vignesh Polymers

Tablet Interface for Rejection/Downtime Reason entry Tablet Interface for Operations Team to View

Historical Data while on the Move in Shop floor

Accreditations & Awards

Accreditations IATF 16949:2016

ISO 9001:2015 SQ MARK

Accreditations

BEST VENDOR 2015

OUTSTANDING AWARD 2017

PRO 3-M AWARD -2016

PRO-3M AWARD 2016OUTSTANDING AWARD 2016

Best Vendor Awards From Customers MACHINE & UTILITY IMPROVEMENT AWARS 2018Best Supplier Award Quality -2019

Global Recognition – By Samsung

Industry Players Visit for Best Practices

Employee Recognition – 10th Anniversary 2016

Employee Recognition – 13th Anniversary 2019

Vignesh Polymers

A Trusted Product Manufacturing

Partner