Production methods, work flow and layout
Production methods are very minutely planned keeping in mind the best output of quality product. The station based production system is applied as main production method. This system is made up of work stations which have a material (raw and semi raw) flow through themselves. The system is based on the double check system between the integrated stations and a client / supplier chain has been accomplished. The afore mentioned stations and their descriptions are as follows ;

Production stations:
1) Storage area; Storage of different Grades of Rubber , Chemicals, Process Oils, Carbons etc
2) Raw Materials; Highest Grades and Quality available in the market are used.
3) Mixing & Compounding; Mixing and Rubber Compounding with a formula to fabricate the desired product or article. (by extrusion or moulding methods)
4) Manufacturing; Production of different Rubber Articles.
5) Vulcanising; By using Steam, and Electricity.
6) Finishing; Cutting and finishing / Trimming of the product.
7) Testing; The Chemical and Physical properties in, In-House Laboratory.
8) Inspection; Inspection and quality control department certifies the product.
9) Packing; Packing and necessary labelling for desired destinations.
10) Shipping; Dispatch; via best shipping companies, also on door delivery basis.

Design
Although principally there is no basic design work in Lion Factory, all know how driven from the operation expertise of the company is reflected to the basic and detailed designs of the end products. In this respect it is important to note that LION RUBBER has a great know how experience. The factory has well qualified design team that produce virtual model of each product before production.

Planning
The planning is held up to the level of activities through projects and sub projects. The activities are principally accomplished as block, system or location based. One of the main important steps of the planning is checking the inputs and making sure they are fit for purpose before the manufacturing commences. The material and men power supply and infrastructure can be observed by means of these activities.

Material Control & Production control
Material control is done completely under ISO 9001-2008 regulations. Basically materials are divided into two types which are standard planned materials and specific project materials. Standard material catalogue has been created which our design department uses to make the choices. MRP (Material Requirement Planning) is used for the standard planned materials in order to make the comparison of the supply / demand data, in case of a demand of any material, the purchasing department is informed. The materials, which are associated with the project, by the planning department, can be seen in the purchasing departments screen according to the dates planned within the project. On time procurement of all these materials is very important therefore follow up process is done with special reports.

In production process work is carried out by work packages called work assignments. Work assignment dates and the responsible personnel are clearly described in ISO System. The assigned production responsible can start the process of work assignments by making material demands from the warehouse. The duty of the assigned production responsible is to ensure the timing of work assignments and work finishing. Some data has been dedicated for his service to make this system work properly. These are both inputs for work assignments and variables for man/hour work budgets. The organization in production is also station based and different departments are able to follow up each other enabling client / supplier chain relations.

Quality
The determined target in Lion Rubber Factory is not only maintaining the quality control but at the same time maintaining a continuously improving quality system which assures the production system quality. ISO 9001:2008 certificate covering the manufacturing process, which is under process and is likely to be completed shortly, by the Company.

All checks and tests for ensuring the quality of the product through on-going production are clearly planned and documented. In each production station, records of all planned controls and tests such as non-destructive tests (tensile, elongation, deflection,) dimensional accuracy controls by modern equipment and system tests; are all held according to documented procedures.

All raw materials such as Carbon Black, Oils, Rubber Chemicals, etc. are checked in the company laboratory, by a team of chemist and lab experts for ensuring the quality of incoming materials. All other incoming materials are certified ones as they come from Branded Companies like United Carbons / Cabot India / Philips Carbon, HP Oils / IPOL, Nocil Chemicals.

Our production and quality control processes and their results are constantly monitored and approved from design to delivery by Inspection Authorities such as Indian Register of Shipping, TATA Consulting Services, Bureau Veritas, Germanischer Lloyds, etc.

Lion Fenders can be manufactured and supplied in accordance with IS-13848, PIANC, ASTM, BS & JIS standards, which are accepted globally.

Lion Seals are in accordance with IS-11855, IS-4622, ASTM, BS & JIS standards.

Health, Safety, Environment
Lion Rubber is utmost sensitive for HSE regulations. All personnel are trained for HSE requirements before being employed. An independent HSE department is established and given full authorization. Lion Rubber obeys not only local legal obligations but does its best to be in accordance with all legislations in target markets.