Award for Excellence in Consistent in TPM commitment
apcotex industries limited
Valia Plant, Gujarat, India

CORPORATE PROFILE

Works: Village: Dungri, Taluka: Valia, Ankleshwar,

CORPORATEPROFILE
Distt. : Bharuch – 393135 ,Gujarat,(INDIA).

Apcotex Industries Ltd. is one of the leading producers of Performance Emulsion Polymers inIndia and is engaged in manufacturing and supplying synthetic latex (XSB latex, XNB latex,
VP latex, styrene acrylics, and nitrile latex) and synthetic rubber (nitrile rubber, high styrenerubber, nitrile polyblends, and nitrile powder).Synthetic rubber finds application in Automotive
Components, Hoses, Gaskets, Rice roll industries, Printing and Industrial Rollers, Friction
Materials, Belting, and Footwear, while synthetic latex finds application in paper andpaperboard, textiles, carpet, construction, tire cord, Gloves surgical and industrial use, etc.
The company was first established as a division of Asian paints (India) Limited in 1980,
primarily, as an import substitution endeavor, for then fully imported producti.e., vinyl pyridine latex, key to tyre manufacturing. This was the first unit to manufacture thislatex in India.
Apcotex Industries Limited has two manufacturing facilities at Taloja in Maharashtra and Valiain Gujarat.
The Taloja manufacturing facility has a manufacturing capacity of 1,05,000 MTPA of synthetic
latex and 7,000 MTPA of high styrene rubber.
The Valia manufacturing facility has a manufacturing capacity of 25000 MTPA of nitrile
rubber and its allied products. Both the manufacturing facilities at Taloja & Valia are having
ISO 9001-2015, ISO 14001-2015, ISO 45001-2018 & Responsible Care (RC) certifications.
apcotex Industries Limited Valia has state-of-the-art manufacturing plants strategically locatedon the western coast of India. It has one of the broadest ranges of emulsion polymer products
i.e. Nitrile Butadiene Rubber & lattices (NBR), NBR powder, and NBR: PVC polyblends
manufactured at Apcotex Industries Ltd. Valia.
The main bulk raw materials used are Butadiene & Acrylonitrile. NBR is produced through theemulsion polymerization of Butadiene & Acrylonitrile. The technology was supplied by M/sGoodyear Tire & Rubber Co. USA.
The manufacturing facilities incorporate state-of-the-art emulsion polymerization technology
controlled by sophisticated DCS control systems to ensure fine control over operating
parameters.
A strong Research & Development base enables development, manufacture, and export ofproducts and compete effectively against global players. We also provide value-added services
to enable customers to constantly improve the quality of their final product. The Total Productive
Maintenance (TPM) awards recognize plants that full-fill the demanding requirements of the JIPM’scontinuous improvement program.

“We’re proud to receive this important recognition from the Japan Institute of Plant
Maintenance,” said Mr. Ravishankar Sharma, COO, Apcotex. “Total quality and continuous
improvement are the cornerstones of our commitment to customers every day.

 Milestones on the Journey of Manufacturing Excellence
Apcotex Industries Ltd. received ISO 9001 certification in the year 1999 by the General
Society of Surveillance (SGS), UK for Quality Management System. Again, received ISO
14001 certification on “Environment Management System” in the year 2012 and up-gradation

to ISO 45001 from OHSAS 18001 by the General Society of Surveillance (SGS), UK in theyear 2020 & Responsible care logo by Indian Chemical Council in the year 2019 and reresponsible care logo in the year 2022 for next 3 years (April 2022 to March 2025). Being a“Responsible Care company”,Apcotex Industries Ltd. is committed to the promotion and maintenance of the Highest degreeof the physical, Mental, and social well beings of its employees. By Implementing the Healthand Safety Program, Apcotex Industries Ltd. is ensuring the protection of the health and safetyof employees through the prevention of adverse effects caused by working conditions.
Regular training for all the employees with respect to Health and Safety is being conducted ata defined frequency.
Keeping in view, today’s competitive, cost-competitive, and quality-committed businessenvironment, Apcotex Industries Ltd. decided to embrace the TPM culture.

 The TPM Journey -Valia Plant
The TPM awareness training was started in February 2016. The Apcotex Valia Plant TPM
Journey is as below,
TPM Intent - April 2016



Selection of Model Plant - June 2016

Training of Executive - July 2016

Training of Non-Executive - August 2016

A.M. Launch - September 2016Complete Awareness Training - March 2017

TPM Kick-Off - April 2017

Health Check Up by CII - Jan.2020

1st Assessment by JIPM - June 2021

Final Assessment by JIPM – Dec. 2021



TPM Excellence Award Category “A” By JIPM – Year 2021



Excellence in Consistent TPM Commitment Kick–Off – June 2022

Application for Excellence in Consistent TPM Commitment Award – Dec. 2022



Excellence in Consistent TPM Commitment 1st Assessment by JIPM – July 2023



Excellence in Consistent TPM Commitment Final Assessment by JIPM – Dec. 2023

TPM Consistency drives very close together with our vision of becoming “A Globally AdmiredCompany”. I am certain that the apcotex Valia plant proves its mettle once again. As a resultof this TPM Level-2 Excellence in Consistent Final Assessment by JIPM – Dec. 2023.

 Benefits Achieved & Key of our Manufacturing ExcellenceWith the implementation of TPM at apcotex across the plant not only helped in improving
business results but also brought total change in the work culture and attitude of the employees
and drastic change in organization culture.
Below are a few tangible benefits on key business results in terms of PQCDSME.
UOMBenchmark(2015-16)

April
2023Sept.23

IMPROVEMENT, %OPE for NBR

%

62.00

97.20

35.20

Availability- NBR Line%

68.00

100.0032.00

FPP for NBR Line%

95.00

97.90

2.90

NBR Production

MT6843.00

7923

15.78

Number of breakdowns

No.

38.00

0100.00

External Customer
complaint

Nos/Yr.

260100

Steam consumption

kg/MT

1995.00

1575

21.50

NH3 Consumption

Kg/MT

1.66

0.65

60.84

Water Used

m3/MT

23.01

16.93

26.42

Power Consumption

kWH/MT

1003.00

549

45.26

On time Delivery

%

95.00

100.00

5.00

Major Accidents

Nos/Yr.

00100.00

Minor Accidents

Nos/Yr.

120100.00

M

KAIZEN / Suggestions

Cum
Nos/Yr.

82267

283 Times

EReduction of SOxemission in Ambient
Airµg/M380

12.14

84.83

SLPQ

CDS

KPI

2023 TPM Award -Achievement Sheet
Companyapcotex industries limited

Plant name

Valia Plant

TPM Slogan“ Bond’s Beyond Chemistry” proved true by adopting TPM in Apcotex.

Objectives

To make TPM a way of life in Apcotex from Top to Bottom in years to come.

Year when TPM activity
startedYear of benchmarkingCategoryApr-16
2015-16
Index(Calculation Formula)Unit

TPM Started
2015-26

Actual Status April-Sept.2023

Number of work-related
SCases/ year

0.00

0.00

accidents not requiring days off Cases/ year

10.00

0.00

Parts/Operator hours

1.47

1.98%

62.00

97.20

accidents requiring days offwork
Number of work-related

SworkPP

Productivity for main products
OEE(or Overall Plant Efficiency)

P

Availability

%

68.00

100.00P

Performance Rate%

97.00

99.60

P

Quality Products Rate%

95.00

97.90

P

Number of breakdowns

Breakdowns/ year

38.00

0.00P

MTBF

Hour

2600

31460

PMTTR

Hour

16.00

1.19

Q

Number of customer complaints Number/year

QQ

In-line defect rate, scrap
In-line defect rate, scrap andrework

26.00

0.00

%

0.00

0.00

%

0.00

0.00

C

Cost index

Cost/Kilogram

47.5

41

D

Production Lead time

Days

00

D

Delivery performance

%

95.00

100

0.00

0.00

82267

Accidents perS

Safety index

1,000,000 operator
hours

M

Number of Employee
Suggestions

Number/year