1. Case Study
PROJECT OVERVIEW
n 250 acre campus housing 26 departments
n CCTV, Voice and Data on same fibre network.
n 85 kms of copper cables used for LAN.
n 18 kms of Molex SM & MM optic fibre used
n Achieved 100% network uptime.
Kemrock Industries and
Exports Limited-India
Overview
Established in 1981, Kemrock Industries and Exports Limited is a fully integrated
global leader in the manufacture of Fibre Reinforced Composite Materials. Kemrock
provides high quality, engineered solutions made possible by the exhaustive
resources and in-house capability of its Vadodara facility. Kemrock Industries &
Exports Ltd. manufactures and exports FRP/GRP (Composite) products for major
industrial sectors such as aerospace, defence, renewable energy, wind energy,
railways, chemical processing, oil and gas, water and waste water management,
infrastructure, construction, electrical and electronics, marine, telecommunications
and many more. A leader in the field of composites in India, the company
delivers standard as well as customized solutions that are ideal replacements for
conventional materials.
The Project
In this new site, the IT Dept. undertook to install and implement State-of-the
art technology to cater to Kemrock’s growth path in the coming years. The IT
Team worked on a migration plan to transition its legacy cabling network and
consequently charted out superior Network requirements to provide for reliable
and high speed network environment in the campus to connect and run the design
studio, manufacturing units, testing centres etc,. Kemrock has seven major
Business Units within the campus which are spread over a large area and were to
be networked on a high speed/bandwidth network layer for Data and Voice. The IT
Team at Kemrock decided that to design a network on this scale they had to meet
the following criteria
1. A Scalable and reliable network.
2. Optimized Bandwidth Connectivity for the smooth functioning of the ERP
System, several customized and complex computer applications, CCTV
Operations and Voice Communications.
3. Green Environment Sustainability and Energy savings
4. Lowest total cost of ownership
5. Automated processes for Administration and Security
In short a redundant, fail proof system had to be developed along with a scalable
cabling system along with provisions in place for future up gradations.
This seemed to be a challenge as the campus Infrastructure was already
established and functioning on its full strength. Full scale production was on and
many hurdles seemed imminent. It was very important that this task be carried in
a very short time frame without affecting the normal functioning of the production
processes.
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2. Case Study
PROJECT OVERVIEW
n 250 acre campus housing 26 departments
n CCTV, Voice and Data on same fibre network.
n 85 kms of copper cables used for LAN.
n 18 kms of Molex SM & MM optic fibre used
n Achieved 100% network uptime.
Kemrock Industries and
Exports Limited-India
Molex was chosen after careful assessment of its superior product portfolio. Molex
worked with Kemrock and the installation company to ensure a seamless execution
of the project. Through this they were able to achieve 100% network uptime. This
is a good example of the Consultative approach from Molex.
The campus spans over an area of 250 acres which houses the 7 major Business
units comprising of 26 departments and sections. The site essentially consists of a
ring topology Optic fibre network. There are 3 rings that cover the entire campus.
Two rings originate from the DataCentre ie the ITeS section and 1 ring originates
from the Wind Mill Blade Unit (WMB) section. The ITeS and WMB sections are in
turn connected to each other using 12 core Single Mode Optic fibre connectivity.
Ring 1 connects ITeS with the Technical Fabric Plant (Liba), Store, the Old
Administration building and the Accounts sections. Ring 2 links up the ITeS with
Export Oriented Units 1& 2 (EOU). Resin Plant (Epoxy Main), Occupational Health
Clinic (OHC), Warehouse and the WMB. Ring 3 connects the WMB Main with
the FRP/GRP Pipe Dept (1st floor), Railway (1st floor) and the Carbon Fibre (CF)
sections. ITes and WMB are already connected to each other. Please refer to the
schematic diagram alongside for a better understanding of the network layout.
Approximately 12 kms of Molex 12 core SM optic fibre cable and around 5.5 kms of
Molex 6 core MM optic fibre cable is used to connect all the 26 departments spread
across the vast campus. The CCTV, Telecommunications and Data lines are all
employed on the same fibre network.
65 kms of Category 6 copper cables & 15 kms of Category 5e copper cables were
used for the LAN cabling & Voice cabling within each complex. It was decided
that Category 6 will be installed on last mile connection for Data applications and
Category 5e on last mile connection for Voice applications.
There are 500+ nodes linked across the campus over an area of 100,000 sq.
Mtrs. This resilient cabling architecture resulted in increased manageability of the
campus and reduced the Total Cost in Ownership significantly.
Critical production was underway on the main shop floors and the networking
job had to be compromised to pave the way and facilitate urgent production
schedules. The IT team then had to quickly reassess the situation and make
amends. This time around they aligned the network implementation according to
the schedules of the various SBU’s within the campus. The installation company
supported Kemrock with the installation schedules which resulted in the successful
and timely completion of the project.
Also there were many shifts and realignment to the original network design plan
including the network points on the desk. These were addressed as and when
they encountered them one by one. Despite the apparent hurdles, processes were
online and network installation was conducted without any major disruption of the
functioning of the campus.
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3. Americas
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Tel: +1 630 969 4550
www.molexpn.com
EMEA
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England, PO6 3EN Tel: +44 2392 205800
www.molexpn.co.uk
APAC
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Tel: +61 3 9971 7111
www.molexpn.com.au
Case Study
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PROJECT OVERVIEW
n 250 acre campus housing 26 departments
n CCTV, Voice and Data on same fibre network.
n 85 kms of copper cables used for LAN.
n 18 kms of Molex SM & MM optic fibre used
n Achieved 100% network uptime.
Kemrock Industries and
Exports Limited-India
The deployment of Molex Structured Cabling products has benefitted the
operations in Kemrock immensely as more than 500+ computer users are all
efficiently networked within the campus. All users are mapped to the Active
Directory(AD) in the Data Centre thus preventing unauthorized access to the
network which in turn has also increased security in the premises. The new reliable
and faster network has negated any Downtime on the server while accessing Data,
programs and ERP thus making for seamless and fast connectivity. Data and Voice
communication has been implemented on this fibre optic network and thereby
eliminated the cost of laying extra telephone cabling.
In addition to tremendous cost savings on account of the superior solution
provided by Molex, Kemrock is confident that they will see maximum return on
their network Investment.
So far, since the installation in the year 2009, the network is functioning 24 X
7 – 365 days; without any stoppage whatsoever. There has been no single issue
related to the Copper and Fibre cables or the fibre modules or connectors and
patch cords that has caused any sort of downtime in the campus.
This is a great achievement for the Kemrock IT team who were tasked with the
network implementation on the campus. Furthermore, the Molex 25 Year System
Performance and Application Assurance Warranty helps to maintain a worry free
and fully efficient environment.
According to Mr. Naimish B Pathak, Manager-ITeS of Kemrock, “Molex has met
and exceeded our expectations by the very manner in which they approached
our project. They have provided for an excellent solution, exceptional service and
reliable products and contributed much to the implementation of the Network
infrastructure at Kemrock. We salute the Engineering and Quality teams of Molex
who have provided us with such an excellent product portfolio that we can safely
call 100% worry-free.”
Kemrock industries & Exports Ltd., is expanding their operations in India and
globally. Plans are underway for a new hi-tech Carbon Fibre Plant to produce
commercial grade Carbon Fibre in the next 6 to 8 months. Apart from this the
Wind Mill Blade, Pipe, Mass Transport etc. sections are all geared up for further
expansion in the campus.
Molex continues to be involved with Kemrock through consultation with the IT
team and is currently supporting them in the second phase of expansion of the
Network infrastructure implementation.
The ITeS Team voices that Molex is now benchmarked as their partner for the
passive requirements in coming years for all new projects within the campus as
well as in their new sites all over the globe.