INDUSTRY PROFILE

RUBBER WOOD INDUSTRY

RUBBER PLANTATION SECTOR IN INDIA

The rubber industry is one of the key sectors of the Indian economy. Commercial
cultivation of rubber in India started in 1902.India is one of the largest rubber
producers in the world and occupies the 4th position in the production of natural
rubber. Thailand, Indonesia and Malaysia occupy the 1st, 2nd and 3rd positions
respectively, accounting for more than 9% of the global output. India ranks 5th in
terms of acreage, 4th in terms of production and 1st I terms of productivity. The rubber
plantation sector in our country is dominated by small holdings(less than 0.5 hectares)
almost 10 lakh in number, covering 88%of the total area; and about 71 lakh of people
derive their employment from rubber plantation sector either directly or indirectly.

Rubber cultivation in India has been traditionally confined to hinder lands of south
west coast; mainly the state of Kerala and Kanyakumari district of Tamilnadu. The
non-traditional regions cultivating rubber include coastal Karnataka, Goa, Konkan
region of Maharashtra, coastal Andhra Pradesh, Orissa, Tripura, Assam, Meghalaya,
Mizoram, Manipur and Andaman Nicobar islands. Kerala contributes 90% of India’s
total production of natural rubber; Also Kerala and Tamil Nadu together occupy 86%
of the growing area of natural rubber.

IMPORTANT CHARACTERISTICS OF THE INDIAN RUBBER

INDUSTRY
The following are the special characteristics of the rubber industry in the country,
which make India a little different from many of the other natural rubber producing
countries;

• India is a major producer and consumer of natural rubber

• The rubber products manufacturing industry in India had been mostly inward
oriented, catering to the domestic market

• In recent year India has entered the global market exporting both raw natural
rubber as well as rubber products

• With its large population base India is emerging as a large market for rubber
products and with the opening up of the economy, import of rubber products
has also been increasing in recent years

• The rubber product mix in India is based mostly on the dry forms of rubber
dictated by the requirement of the domestic market
ROLE OF INDUSTRY IN THE ECONOMY
Due to various factors like extensive plantations good availability of raw materials
availability of economical and technically skilled man power and a vast domestic
market, India is all set to make a mark in the global rubber industry. India is ideally
poised to supplement and compliment overseas manufacturers through joint
collaborations and technical exchange to contribute substantially to the world rubber
trade.

The main purpose of rubber plantations is the production of latex, which is major raw
material for all the rubber products manufacturing industries. In India, 72.2% of the
production is processed as ribbed smoked sheets (RSS).block rubber, concentrated
latex, crepe rubber and others constitute 9.8%, 10.5%and 7.77% respectively. a rubber
tree with a useful economic life span of 23 to 30 years will yield high amount of
latex . Also being a tree crop it has tremendous potentials for eco restoration. Rubber
plantation also provides a variety of auxiliary products like honey seed oil rubber
wood and scope for rearing honey bees

Established in 1921, the Indian rubber goods manufactured industry has grown to the
4th largest producers and consumers of natural rubber. It is also the 4 th largest
consumer of natural rubber and synthetic rubber. Put together, India has about 5000
rubber goods manufacturing units including large and small scale unit’s .the range of
rubber wood product manufactured in India caters to all most every sectors including
the common people. it also helps a social cause through condoms. In tandem with the
manufacturing sectors growth, the industry is posing to deliver high growth rates in
the domestic and export sectors. Development of rubber wood industry in our base
particularly in the automobile industry and the availability of competitive labor the
country offers great opportunities for rubber products manufactures with country will
help to generate employment strengthen national economy make rubber cultivation
sustainable and preserve the environment. considering the large population and the
large manufacturing further investments in r&d and infrastructure ,the country is
poised to become a leader in rubber product manufacture in the years a head
COMPANY PROFILE
 RUBCO HUAT WOODS PVT LTD

RUBCO HUAT WOODS PVT LTD, registered under the company act 1956 is the
rubber wood processing and furniture manufacturing factory of RUBCO set up with
financial and technical collaboration with M/S long Huat group Berhard Malaysia a
well known name in the field of rubber wood industry for the last 30 years .it was set
up in the year 2000 with plant capacity of 40 000 metric tones per year and started
commercial production only on January 2001. RUBCO HUAT WOODS PVT LTD is
an ultra modern rubber processing plant situated in KINFRA small industries park in
tellichery kannur district, with state of the art machines imported from various parts of
the world

RUBCO HUAT WOODS PVT LTD is a world leader in rubber wood furniture
industry .the factory is the largest rubber wood processing unit in the country and the
plant employees around 8000 employees. This division manufactures a range of
elegant furniture and quality edge glued panel using the eco friendly rubber wood.

Rubber wood furniture range comprises of dining table and chairs designer’s
wardrobe futon kitchen cabinets computer and office furniture and is available in a
choice of design and finish. The EGP manufactured by the finger joining technology
is easy to saw drill and bore and have an excellent nail holding capacity.

Rubber wood properly treated and processed is emerging as the ideal substitute to rain
forest wood, as it offers the same strength durability and finish as the latter and helps
preserve the environment. The RUBWOOD furniture combines excellent aesthetics
with long term durability, and comes in a variety of shades and designs, adding
elegance to the interior of homes and workplace .the product are being exported to
UK, USA, Japan and many other countries across the globe.

The company also has technological collaboration with the Long Huat Berhard of
Malaysia, through which the company received its finger joining technology. Along
side the employees of rubco got the training from the representatives of M/S Long
Huat Berhard of Malaysia during the initial stages of the production.
OBJECTIVES OF RUBCO HUAT WOODS PVT LTD
 Maximum utilization of production capacity

 Minimum number of rejections

 Low break down of machineries

 Low rate of complaints from the customers

 Maximum customer satisfaction

PLANT LOCATION
Plant location means the place where the plant is located for achieving maximum
operating economy and effectiveness. An ideal location may not by itself guarantee
success, but it certainly contributes to the smooth and efficient working of the
organization.

RUBCO HUAT PVT LTD is situated at KINFRA small industries park chonadam
near thalassery, Kannur district of Kerala .The plant is located about 4 km from
thalaserry town, spread over 18 acres of land and is also on the path of further
expansion

The main reason for the selection of location was the fact that it had favorable
infrastructural facilities like power water and transport .The location is also beneficial
in getting adequate supply of raw materials. There are two kinds of raw materials that
are required for the production process they are direct and indirect materials. The
direct material of rubber wood furniture production is the log rubber woods .These are
mainly purchased from Kerala and Karnataka .The direct and indirect raw materials
are easily available fro the near market.

Continuous supply of power is another important reason for the plant location. The
power is provided at cheaper rate compared to other areas because of the special
subsidy package by Kerala KINFRA Structural Development Cooperation to the
industries located in the special areas.

Adequate supply of local labors is another advantage of the location of the plant and
wages are given as per the Minimum Wage Act.

The region is well connected with rail and transport system. Road transport system is
mainly used for carrying the raw materials to the yard and the finished products to the
markets .it also make use of rail and shipping transport; postal and tele-
communication are also utilized

The plant is 100% eco friendly and causes no pollution

INFRASTRUCURE

The company is located in 18 acre of land. It has sophisticated machines imported

from Germany, Italy, Malaysia Japan UK, Taiwan and Netherlands. It has a combined
layout capable for producing standard furniture continuously well as customized
production on the request of consumers .The upgraded production capacity of the
plant is 40 000 cubic metric tons/year

The operation of machines is pollution free and the plant was accredited with
pollution free award. The company has an electrical substation of 1250kv and has a
stand by generator capable of producing 750kv electrical power to serve during power
failure.

The 220000 sq feet factory building is a single storied building with natural
ventilation, natural lighting and enough working space for workers. The single storied
buildings help the easy movement of materials with in the factory. The tool room and
storage are located in the centers of the factory so that easy access from different
production sections is possible.

New multistoried office building will be completed in a short span of time. The
company uses computerized punching system for keeping attendance. It has good
canteen for the employees. Company provides drinking water in the factory at the
easiest access to the workers
 ORGANISATION CHART

OF

THE RUBCO HUAT WOODS PVT LTD

Chairman

Managing Director

General Manager

Chief Purchas Account Admin Sales & Marketin

Productio cum g
e s Shippin
n personnel Manager
Manager
Manage Officer Officer
g
r Manage

Producti Store Junior Time Sales Asst

on Keeper Clerk Officer Executi Marketin
Manager ve g
Manager

Shift Clerical Computer Head Clerical Junior

Enginee Staff Programm Guard Staff sales
r er officer

Quality Section Maintenan

Sales
Supervis Supervis ce
Executiv
or or Engineers
e

Skilled/unskilled workers
PRODUCT PROFILE
 PRODUCT PROFILE
Rubber wood, properly treated and processed, is an ideal substitute to rain forest
wood, as it offers the same strength durability and finish as the later. The technical
properties of rubber wood which makes it ideal for making furniture are

colour Cream to pale stream colour

Structure Uniform wood structure

Figure Cross section shows vague concentric markings, which resemble

growth rings. the markings combined with large vessels give the
timber an attractive appearance

Weight Density comparable to oak and teak

Strength Good binding strength

Shrinkage Low shrinkage compared to teak

Chemical Similar to that of hardwood

composition

The RUBWOOD furniture introduced by RUBCO HUAT WOODS PVT LTD,

comprises of elegantly design modern furniture fashioned out of eco friendly rubber
wood. Manufacturing in technical collaboration with M/S Long Huat Berhad
Malaysia, it is the country’s largest rubber wood processing plant situated at
thalaserry in kerala.The RUBWOOD range confirms to international standards in
finish and durability .the RUBWOOD furniture is crafted from specially treated
rubber wood for extra durability and finish.

Following are the various ranges of products offered by rubco Huat Woods’s pvt ltd.

RUBCO TIMBER PANNEL

Rubco rubber wood pre-finished panels open unlimited possibilities in design and
processing on pair with the highest standards unequal elegances .RUBCO timber
panels are produced by the sophisticated process of finger joining and edge gluing
,using the resigns of polymers which are either white or translucent; and excellent
finish or durability, is guaranteed .They also confirm to international quality
standard. The solid Lumber panels of RUBCO are easy to saw, machine, drill, bore or
strain. Sanded to 240 grit they offers smooth finish and excellent nail holding
capacity, making it the ideal usual-friendly choice of furniture manufactures and
carpenters .This proven concept which is popular among builders and architects in
western countries, offer the perfect solution the problems routinely encountered in
handling various cross sections of timber scantlings. The panel boards are made to the
standard of British Wood Preserving Assocaition.RUBCO timber panels are eco
friendly; they ensure lower wastage of materials and cut down of labor, time and
overall cost

The panel board specifications made by Rubco Huat woods pvt ltd are:

Data Thickness(mm) Length(mm) Width(mm)

Minimum 12 305 150

Maximum 50 5200 1300

RUBCO’S timber panel come in varied size from 12mm thickness onwards with a
maximum cross section size of 5200mm x 1300mm.RUBCO timber panel can be
applied for the following uses:

Door and window frames

Office furniture and partitions

Modular tables and peripherals for computers

Designer wardrobes

Kitchen cabinets

Dining tables and chairs etc.

RUBCO HUAT FURNITURE

The colonial furniture collection from RUBCO is the ideal way to add splendor and
comforts to the home.RUBCO’S range of the finished furniture range comes in varied
shades coated with several layers of lacquers

The furniture ranges offered by RUBCO HUAT are:

Dinning table with chairs

Computer tables

TV stand

Sofa sets

Rocker chairs

Cot

Tables

Designer’s wardrobe

Futons

Kitchens cabinets

Teapoy

Kids table

Display rack
DEPARTMENTAL STUDY
 FINANCE DEPARMENT
Finance consists of rising, providing and managing of money, capital or funds of any
kind to be use in connection with the business. The finance department is an
organization which is responsible for managing financial activities off the firm. The
finance department deals with a wide range of activities like planning rising
controlling and administrating the funds of the business.

In Rubco Huat Woods pvt ltd, the accounts officer is the head of the finance
department and takes all the financial decessions.He is assisted by the clerical staff

ORGANIZATION STRUCTURE OF FINANCE

DEPARTMENT

Managing director

General Manager

Accounts officer

Junior Clerk

Responsibility of accounts officer

• Maintenance of accounts

• Auditing company accounts

• Preparing of financial statement

• Preparing reconciliation statement

• Issue of TA bills, purchase bills and other miscellaneous bills

 CAPITAL STRUCTURE OF RUBCO

The authorized share capital of RUBCO as per the byelaws is 300 crore made up of

25000 ‘A’ class shares of Rs 10000 each - 25 crore

5600 ‘B’ class shares of Rs 25000 each - 14 crore

26000 ‘C’ class shares of Rs 100000 each - 260 crore

1000000 ‘D’ class shares of Rs 10 each - 1 crore

‘A’ class shares are open to primary agricultural cooperative credit societies or banks,
primary cooperative rural banks and rubber marketing societies functioning in the
area of operation of RUBCO.

‘B’ class shares are open to Kerala State Cooperative bank, other state level
cooperative federation or institution, district cooperative banks etc.

‘C’ class shares are open only to the Central and State govt and rubber board.

‘D’ class share are open to individuals, who are within the area of operations and
having business association with RUBCO, either by keeping deposits or by supplying
materials either for processing or for sale.

CAPITAL STRUCTURE OF RUBCO HUAT WOODS PVT LTD

The Rubco Huat Woods pvt ltd is 100% owned by Kerala State Rubber Cooperation.
The annual turn over of the company is nearly 30 crores
ADMINISTRATION AND PERSONNEL DEPARTMENT
Human resource refers to the boy of persons employed in an organization. Human
resource management is the art of processing employing and maintain competent
workforce to achieve organization goals effectively.HRM is management functions
that helps managers to recruit select train develop motivate and maintain members in
an organization if focus on people is an organization.

In Rubco Huat Woods Pvt ltd, the Administrative cum personnel officer (APO) is in
the charge of this department, who is assisted by Time Officer

ORGANIZATION STRUCTURE OF
ADMINISTRATION AND PERSONNEL DEPARTMENT

Managing director

General Manager

Administrative cum personnel

officer

Time Officer

Head Guard Computer Receptionist Junior clerk

Programmer

Security Clerical Staff

Guard
Manpower deployment at Rubco Huat Woods pvt ltd
The company has a total workforce of 775, of which 120 are female, employed in
different sections of work. The man power deployment is as follows:

Specialist / highly skilled workers – 35

Skilled workers – 146

Unskilled workers – 347

Semi skilled workers – 31

Learners – 54

Casuals – 73

Saw workers – 35

Staff (including managerial staff) – 54

Specialist or highly skilled workers – they are mainly carpenters ,who

concentrate on work like final sanding assembling of finished parts etc.They have
more than 5 years experience in the concerned field. They receive a remuneration
of 300/- + VDA per day (Variable daily allowance, VDA is Rs 4 / day)

Skilled workers – they are specialized in doing a particular job or operating a

specialized machine .They are basically ITI / ITC diploma holders with 4-5 years
experience in the concern field .They receive remuneration of Rs 250 + VDA/day.

Semi skilled workers – they also do specialized task but of lesser complication or
less risk, mainly female workers involved in specialized job under this category
they receive a remuneration of Rs 220 + VDA / day.

Unskilled workers – they are workers who have undergone initial 6 months
training in the company they receive a remuneration of Rs 111 + VDA / day.

Learners – they are newly selected workers who undergo training for the first 6
months and then are promoted to unskilled category, based on their performance
they have a remuneration of Rs 90 + VDA / day

Casual workers – they work only in the saw mill section. Casuals are entrusted
with job of sorting of rubber wood, stacking , pallet clearing etc
 PURCHASE DEPARTMENT
The purchase department plays an important role in the organization, since
purchasing has its effect on every vital factor concerning the manufacture, quality
cost efficiency and prompt delivery of finished goods to the customers.
Purchasing is the act of buying an item at a price. The main objective of
purchasing is buying raw materials of the right quality, in the right quantities, at
the right time, at the right price, and from the right source. Purchasing is a vital
function of materials management as the moment an order is placed for the
purchase of materials a substantial part of the companies finance is committed,
which affects the cash flow position of the company

Rubco Huat Woods Pvt Ltd has an efficient purchase department which is
entrusted with the purchasing of quality raw materials in the required quanity, at
the right time for the entire departments functioning in the organization. The head
of the purchase department is the purchase manager

ORGANIZATION STRUCTURE OF

PURCHASE DEPARTMENT

Managing director

General Manager

Purchase Manager

Asst Purchase Manager Store keeper

Store assistant Unskilled workers

FUNCTIONS OF PURCHASE DEPARTMENT
The company mainly requires two types of materials – direct and indirect materials.
The direct material is the round log rubber wood and indirect materials include
hardware items used for production. The amount of materials purchased by Rubco
Huat Woods Pvt ltd is around Rs 30 lakh per month, which comprises of items like;

• Round log rubber wood

• Hardware items like screws, nuts, bolts, nails, lock and keyset

• Chemicals like boric acid and borax

• Finger joining glue

• Finishing items like lacquer, thinner, Steiner, sanding paper etc.

The company makes use of VED analysis (Vital Essential and Desirable) for grouping
the materials based on their criticality for the purpose of purchasing

The company purchases rubber wood from eight suppliers, mainly located at
Perumbavur, Taliparamba, Kasargod, Iritty and Peravoor in Kerala. The company also
owns a rubber estate in Sullya, Karnataka. Purchase committee checks the quality of
the raw materials Purchase comprises of purchase manager, accounts officer, saw mill
supervisor and Quality supervisor. As a substantial portion of companies finance is
used for the purchase of rubber wood the purchase department should keep in mind
the following specifications at the time of purchasing rubber wood

• The logs of rubber wood must have a minimum 24 inches diameter

• It must have minimum 4-8 feet length

• There must be nor or very less tapping marks bending nails etc

• The logs having excess fiber should be rejected

The items which are frequently purchased include glue, chemicals sanding paper and
packaging items. Most of the items are purchased from local markets with in India.
The finger joining glue is made by a German company based in Mumbai. Lacquer is
imported from Korea and Saudi Arabia whereas thinner is from Dubai.
 STORES DIVISION
A store is an important part of an organization which has an active production
department.’ stores’ is defined as supplies of goods. ‘Store’ is the function of
receiving storing and issuing of Materials. The stores is a place were all critical and
consumable goods are stored Critical items are those which are essential for the
production with out which the production cannot be carried out; whereas consumable
items are those which are used o support production process .Stores ensure ready
accessibility of major materials there by providing efficient service to users.
Minimization of store cost and continuous supply o materials are the prime functions
o the stores.

At Rubco Huat Woods Pvt Ltd, the stores section is headed by the store keeper, who
comes under the direct purview of the Purchase Manager.

ORGANIZATION STRUCTURE OF
STORES DIVISION

Managing director

General Manager

Purchase Manager

Store keeper

Store assistant

Unskilled workers
The company has four major sections for stores for storing raw materials and finished
goods .They are :

Stores for rubber wood

Stores for saw mill and impregnation

Stores for glue, paints, packing items and tools

Stores for finished goods Panel boards and furniture

The major items stored in the store for saw mill and impregnation are

Hardware items for sawmill

Chemicals – Boric acids and Borax

The major items stored in the store for EGP, finishing and packing are:

Hardware items like screw, bolts, nuts, locks, bearing.

Finger joining glue

Finishing items like lacquer, thinner, Steiner, sanding paper etc

Spares and tools

Stores are maintained under First In First out (FIFO) method. The sores section
maintains a reorder level and reorder Quantity. When the items reaches the reorder
level the stores section issue purchase requisition
 PRODUCTION DEPARTMENT
Production is the process of conversion of raw materials and other inputs into finished
products, using men machine and tools. Production consists of sequence of operations
that transform materials from a given form to a desired form. The highest efficiency
in production is obtained by manufacturing the required quantity of products, of the
required quality, at the required time, by the cheapest method.

At Rubco Huat Woods Pvt Ltd, the chief production manager is the head of the
production department, who controls the overall production activities with the help of
assistant production manager and shift engineer.

ORGANIZATION STRUCTURE OF
PRODUCTION DEPARTMENT

Managing director

General Manager

Chief Production Manager

Production manager

Shift engineer

Quality supervisor Section Maintenance

supervisor engineers

Skilled / unskilled workers

The plant operations are divided into six sections, each section executing different
operations of production .Each sections is monitored and controlled by section
supervisor, who records the day to day operations of the concerned sections in a
register .Section supervisors compare the day’s labor and productivity; and report to
the chief production manager. The worker report directly to the concern supervisors

The workers in the production department can be classified as;

Specialist / highly skilled workers

Skilled workers

Unskilled workers

Semi skilled workers

Learners

The worker in the production department works in two shift’s in a day 8.30am-
5.00pm and 5.00pm-1.00am.But the boiler and seasoning chamber work 24hrs a day
and so maintenance department works 24hrs taking three shifts .So a part of the
production department – ie Maintenance department –works 24 hrs ; even on holidays
and harthals.
 WORK FLOW MODEL (END TO END)
The overall production process at Rubco Huat Woods Pvt Ltd can be dividing into six
important sections where each sections carries out an individual process of the overall
production, the six important sections of production are:

• Saw mill and boiler section

• S4S section

• EGP section

• Furniture section

• Finishing section

• Assembling , Packing & Dispatching section

Saw mill & boiler section

The production process begins from the log yard. The rubber wood supplied by the
suppliers are unload at the factory log yard in the presence of the security guard, who
maintains a register to the detail like the name ,weight of the load, and date of receipt.
The quality department checks the log for any visible defects

The main operations at the saw mill & boiler sections can be divided into three stages

• Sawing

• Chemical treatment / impregnation

• Kiln drying

Sawing

The rubber wood from the yard is directly sent to the saw mill. The saw mill
operations are controlled by the saw mill supervisor. At the saw mill the rubber wood
log are first weighed by the means of Weigh Bridge. Then the wood under go the
process of sawing, whereby the rubber wood logs are cut into required length and
width. It is estimated that only 48% of a rubber wood log can be used for the
production and the rest 52% of the wood is unfit/wastage due to tapping marks, curb,
nails etc.So when logs are taken the quality checkers inspect the quality of rubber
wood and grade them
Three types of saws are mainly used for sawing.

1. Band saw – it helps to cut thick and huge rubber wood logs into smaller ones.
There is one band saw for this purpose.

2. Re-saw – the logs that are cut by the band saw are taken here. The logs are cut
in to the required width and size according to the instruction given by the
supervisors. There are 10 number of re-saw in the factory

3. Jump saw- the logs cut from the re-saw are taken to jump saw, where the logs
are length wise cross cut and made into smaller ones according to the
specifications given by the supervisors. There are 12 umber of jump saw in the
saw mill section.

After the sawing process the chopped pieces of rubber wood are brought to conveyer
belt and the pieces are sorted according to the width length and thickness. The sorted
wood pieces are stacked over a trolley by using aluminum rods and they are tied well.

Chemical treatment / impregnation

The stacked wood pieces are taken in a trolley to the impregnation chamber. Natural
rubber wood is a soft wood in which the glucose content is higher than the cellulose
so a rubber wood is easily attacked by the fungus, bacteria and other insects. The
impregnation process is done to provide rubber wood the resistance from the attack of
insects and fungus; it increases the durability of rubber wood.

The chemicals used in impregnation process are Borax and Boric acid in the ratio 3:2
72kg of borax and 48 kg of boric acid are mixed with 4000 liters of water in the
mixing tank of the impregnation chamber. The stacked rubber wood pieces are then
fed into the impregnation chamber and dipped into the chemical mixture. About 15
bars pressure is applied in every 15 min for about 2.5hrs. At this high pressure the
chemical penetrate into the inner most layer of the wood and its sap is removed. It
gives the rubber wood hardness and also resistance from the attack of the fungus and
other insects.

Kiln drying / Seasoning

The stacked wood pieces, after the impregnation process are taken to the kiln drying
section. Kiln drying is a quick method of seasoning the timber so that the moisture
content of the logs is reduced to 8-10% and the wood pieces become light weighted.
Stacked wood pieces are placed in the drying chamber and arranged in rows and
coloums.There are 10 drying chambers of 72 cubic meter capacity and almost 70
stacks of one cubic meter each can be feeded in one chamber. The wood stacks are
dried with he help of hot air that is passed to the drying section from boiler, through
pipelines. The temperature of the kiln drying chamber is maintained at 65 degree
Celsius throughout the day continuously till the moisture content of the wood reaches
the required level Moisture content is measured with the help of computerized
equipment. It takes approximately 10-21 days in the seasoning chamber for the wood
pieces to reduce the moisture content to 8-10%. Hence the boiler section and the
seasoning chamber function continuously for 24 hrs , till the moisture content reduces
to the specified level. After the kiln drying process the semi finished product known
as RSKD (Rough Sawed kiln Dried) is stored in the store, till it is taken for further
processing.

S4S section
After the kiln drying process the dried wooden pieces are then transferred to S4S
section. The machine in the S4S section and their functions are:

• Two side plainer – this machine is used to rip the top and bottom sides of the
wooden pieces and smooth the surface.

• Multiple ripsaws- this machine rips the remaining two sides of the wooden
piece, thus smoothing the sides and reducing the width to the desired
specification. After the operation of both two sides plainer and multiple rip
saw the wood pieces will have smooth surface on all four sides. (S4S – means
smooth 4 sides)

• Jump saw – the wood pieces which have smooth surface on all four sides are
further cut into desired length with the help of jump saw.

Sorting process

The rubber wood pieces are sorted and classified into groups based on its quality,
color and damage. It is done manually .The timber is classified into following
categories.

• A grade - if two sides of the timber are clear.

• B grade - if only one surface of the timber is clear.

• C grade - if both the surfaces are not clear.

 • X grade – if all sides are clear. Clear wood is the first quality

EGP section
For the manufacture of furniture and panel boards the wood piece should have certain
length and width. So the wood pieces should join properly. It is done by the process
called ‘finger joining’ which is based on the Malaysian technology. The various
machines used in the section are

1) Finger joining machine

In finger joining process the finger joining machine is used to make long timber
pieces. The timber after sorting process from the S4S section is sent to the finger
joining machine.10-12 pieces of rubber wood having the same width but may vary in
length are horizontally arranged and fed to the finger joining machine. At first these
woods are cut in its edge 90 degree with the cutter machine. Then these pieces
automatically pass through a finger utter machine which rotates at high speed. The
finger cutter machine gives a teeth shape to the each sides of the timber and the timer
moves automatically to the other side if the machine which is glue spreader. The glue
spreader sprays the glue PVA (Poly Vinyl Acetate) to one side of the timber. The side
of the timber to which the glue is spread is known as the female part and the other
side is known as the male part of the timber. Each timber is then fed one by one to the
feeding machine where the male side of the timber is joined to the female side of the
timber. In the feeding machine there is a sensor which helps to measure the length of
the rubber wood pieces and the jump saw cuts the rubber piece in to the required the
length. A hydraulic pressure pump presses the two sides of the long timber and it
helps the tight joining of the rubber pieces. After this an iron beam automatically falls
on the surface of the timber to increase the hardness. There are 3 finger joining
machines in the EGP section. After making the long timber it is kept aside for a day
for the drying and setting of PVA. These long timbers are then sent o t the moulding
machine to mould the four sides of the timber.

2) Radial arm saw

If any defect occurs in the finger joining process the timber is sent to the radial arm
saw. The machine consists of a high speed rotating saw which cuts the default area.
After the default area is removed then the timber is once again sent to the finger
joining machine.

3) Moulding machine

This machine is used to mould the four sides of the rubber pieces that are joined by
finger joining machine. The moulding width is adjusted according to the requirement.
After moulding these rubber pieces they are sent to the hydraulic rotary composer
machine for composing. These machines are imported from Malaysia.

4) Hydraulic rotary composer

There are three hydraulic composer machines in the EGP section to do the composing.
A conveyer and a glue spreader are attached to each hydraulic rotary composer which
is used for making panel boards of different sizes. The timber pieces of equal
thickness from the moulding machine are used for making boards. As the rubber
pieces pass through the conveyer the glue spreader spreads glue on either side of the
timber pieces. Hardener is also used to make the board hard. It is used at the ratio of
1:10 that is 150g of hardener is mixed with 1kg of the composing glue. Hydraulic
pressure is applied whereby the long wooden pieces are pressed to form panel boards.
It varies with the thickness of the wooden pieces. For making panel boards pressure is
applied for minimum half an hour whereas wooden beams requires at least 40 min of
pressure.

5) Panel saw machine

The panel saw machine equipped with a scoring saw gives a smooth cut the sides of
the panel board to give the correct shape. It is also used to cut the panel board to the
required size.

6) Sanding machine

Wide belt sander is used for sanding the panel board to give it a fine and smooth
finish. Two numbers of three head wide belt sanders give a superior finish to the panel
boards and table tops.

Finishing for panel boards

Finally at EGP section the panel boards are tested for its quality. Skilled workers
check the panel boards to identify any minor defect occurred in the process. The holes
in the boards are corrected by the wood putty (wood powder mixed with glue) and
finished by sand paper. After quality checking the finished panel boards known as
EGP boards (Edge glued panel board) are sent to dispatch where as furniture parts are
sent to the furniture section.

Furniture section
The overall operations of the furniture section are controlled by the section
supervisor. This section produces different types of furniture using a variety of
machines of which many are imported and costly machines. Rubco provides a variety
of house hold furniture like sofa set cots dining table with chair TV stand wardrobe
etc

Finishing section
The furniture items from the furniture section are sent to the finishing section. Here
the activities are controlled by the concerned section supervisor. The finishing section
has two main units

a) Sanding unit

b) Spray painting section

Sanding unit

The furniture items come first to the sanding unit of the finishing section. A material
mix called sand putty is used to fill the finger joints, holes and scratches on the
furniture parts. After filling sanding is done. 180 grit sand papers are used for
sanding. After sanding the furniture items are sent to pallet conveyor and hanging
conveyer in the spray booth section depending on the size of the furniture parts.

Spray painting section

Here there are two types of conveyors - pallet conveyors and hanging conveyors both
having spray booths attached to it.

• Pallet conveyor – spray painting of large sized furniture items are done with
the help of pallet conveyor. There are about 70 pallets in the conveyor, which
is used to hold the furniture

• Hanging conveyor – spray painting of small sized furniture parts is done with
the help of hanging conveyor. There are 525 hangers in the conveyor where
various parts of 150 chairs can be hanged at a time.

Spray booth

This is used to spray Steiner, sealer and lacquer. There are two spray booths in the
hanging conveyor and four spray booths in the pallet conveyor. In every spray booth
there is water flowing through huge pipes from top to bottom over a metallic
background. At the time of spraying Steiner or sealer the excess chemical sprayed is
washed away by the water. The various coats of spray applied in the painting section
are:

Steiner

The type of Steiner depends on the type of colour that is required. Different colours
are given to the furniture based on the requirement. The general using colours are:
 • Honey

• Northern rose wood etc

First sealer

After spraying the Steiner the conveyor is stopped for drying the Steiner and after
drying the furniture items moves through the conveyor and reaches the second spray
booth where a sealer is sprayed over the side of the furniture, then it is sanded.

Second sealer

The concentration of Steiner and sealer depends on the colour specification. After
spraying the second sealer the conveyor is stopped till it dries and then it is sanded.

Lacquer

It is the final stage of spray painting. It gives a shining appearance to the furniture.
Then the furniture is dried in room temperature. After drying it is send to the
assembling and packing section

Assembling, packing & dispatching section

From the finishing section the furniture is sent to the assembling section where the
activities are controlled by section supervisor. At Rubco only chairs are assembled
after finishing while the rest of the parts of sofa, cots, table etc are only finished and
then send to domestic dealers and other agencies. After assembling, the quality of the
products are checked and damaged and defective parts are sent for repair. After
quality checking by the quality department the products are sent for packing. The
finished panel boards come directly to the packing area of the EGP section. The
finished goods are over with p-form and bubble sheet and placed in cardboard so as to
protect it from mishandling during transit.
 QUALITY CONTROL DEPARTMENT
Quality of a product is a customer’s perception of the degree to which the product
meets his / her expectations. It is the sum total of features of a product which
influence its ability to satisfy a demand.

At Rubco the entire activities of the quality control department are controlled by
quality supervisor. The department is responsible for maintaining and improving the
quality of products. About 25 people are working in this department.

ORGANIZATION STRUCTURE OF
QUALITY CONTROL DEPARTMENT

Managing Director

General Manager

Chief Production Manager

Production Manager

Shift Engineer

Quality Supervisor

Quality Assistant

Skilled/unskilled workers
Rubco’s quality objectives
• High yield from input materials

• Low levels of rejection

• High level of profitability

• Low level of machine break down

• Less customer complaints

• Maximum utilization of plant capacity

• Enhance competence of employees

Quality control tests

The quality control department at rubco conducts following tests at various stages of
production, to verify whether the chemical physical and functional specifications are
met. Some of the tests conducted by the department are:

• Dry salt retention test - after the impregnation process

• Reagent test or penetration tests - after the impregnation process

• Moisture content tests –after seasoning of the wood

• Boiling water soak delamination test – done on EGP

• Cold water soak delamination test – done on EGP

 MAINTENANCE DEPARTMENT
Maintenance refers to upkeep and protection of plant, building, machinery and other
fixed assets of the firm, which are subject to deterioration due to their use and
exposure to environmental conditions over a period of time.

At Rubco there is a well equipped maintenance department to look after the proper
functioning of the plant and machinery. The maintenance department of the company
has three chief engineers, each responsible for the maintenance activities of electrical,
mechanical and civil areas. The maintenance department undertakes all functions
related to maintenance and report its activities to the chief production manager.

ORGANIZATION STRUCTURE OF

MAINTENANCE DEPARTMENT

Managing Director

General Manager

Chief Production Manager

Asst Production Manager

Shift Engineer

Electrical Mechanical Civil

maintenance maintenance maintenance
engineer engineer engineer

Skilled / unskilled workers

Sections of maintenance department
Mechanical section

Mechanical section undertakes weekly inspection and lubrication of machine tools

and other equipments. The room is functioning under the mechanical engineer. The
welding function is also performed in the tool room

Electrical section

Electrical section ensures uninterrupted power supply to the production unit. In case
of power failure the company uses generators. The electrical consumption of the
company depends on the production capacity. Electricity charges of the company
come around Rs 10-12 lakh per month.

Civil section

The civil section is concerned with maintaining service facilities such as water gas
steam compressed air heating and ventilation plumbing and carpentry work
maintaining drainage and fire fighting equipments.

MARKETING DEPARTMENT
Marketing is meeting needs profitably. It is a human activity directed at satisfying the
needs and wants through an exchange process. In Rubco the entire range of products
is marketed by RUBCO Sales International Ltd (RSIL). They formulate marketing
strategy for both domestic and international market. The marketing department is
headed by marketing manager. He is assisted by junior sales officer in Kerala and by
sales manager outside Kerala.

ORGANIZATION STRUCTURE OF
MARKETING DEPARTMENT

Managing Director

General Manager

Marketing Manager

Asst Marketing Manager

Inside Kerala Out side Kerala

Junior Sales officer Area sales manager

Sales executive Sales executive

Promotional tools
Promotion involves a variety of techniques, including advertising sales promotion;
public relation and personal selling that are used to communicate with the potential
customers. The customers of Rubco are informed in the following ways:

Advertisement in print and electronic media.

Conducting dealers meet once in a year.

Discounts on bulk purchase of products.

Gifts pack during festival season

Advertisement and publicity

Advertisement helps the organization to create awareness to their products and about
the organization itself, among the target audience. Advertisement also helps in
building a strong image of the product or brand apart from increasing its sales. The
advertisement methods followed by RUBCO are:

Ads through press media

Ads in visual and electronics media

Sales promotion schemes

Hoardings

Exhibitions

Branding of the product

The products produced by the company are sold under the brand name RUBWOOD
furniture

Pricing policy

Rubco follows cost based pricing policy. The price of the product is compute by
adding a certain percentage of profit to the cost of the product per unit.

Discount

The company provides 2% trade discount on furniture’s and boards. If the per
purchase value exceeds Rs 8 lakh then 10% discount is given.

SALES AND SHIPPING DIVISION

Rubco Sales International Ltd (RSIL) is the sales and marketing outfit of entire
RUBCO group of companies. The company has already well established dealer /
distributor network and it is expanding its horizon through out the world.

RUBCO has a sales and shipping officer, who controls the sales activities of the
company on behalf of RSIL.

Shipping is the activity taken by the central excise and they check all the products in
the company itself to avoid damages incurring in loading. It is done at Cochin
shipyard.

ORGANIZATION STRUCTURE OF
SALES AND SHIPPING DIVISION

Managing Director

General Manager

Sales and shipping

manager

Sales executive

Clerical staff
SWOT ANALYSIS

Swot analysis
SWOT is acronym for Strength Weakness Opportunity and threat. SWOT analysis is
a technique for analyzing a firm’s competitiveness by assessing organizations internal
strength and weakness and impact of environmental opportunities and threats. An
organization should evaluate its internal characteristics to determine its strength and
weakness, and the relevant external environmental factors to determine the
opportunities and threats.

The SWOT analysis of RUBCO Huat Woods Pvt Ltd is:

Strengths of the organizations

• Honored with ISO 9001-2001 certificate

• Strong brand name and reputation of the company in the market

• Wide range of quality of products

• Technological collaboration with M/S Long Huat Company in Malaysia

• Preferred by customers for its quality products

• Good financial management system of the organization.

• Trust worthy suppliers who supply quality raw materials

• Company owns a rubber estate in Karnataka

• Highly competitive skilled and experienced workforce

• Effective material management system

• High utilization of machines for production

• Good relation with trade unions

• Wide market acceptance in short period

Weakness of the organization

 • Under utilized plant capacity

• In capacity to meet market demand

• Improper utilization of work force

• Low productivity

• Lack of proper training to the employees to meet the changing work

• High price compared to the competitors

• Very low promotional activities

• Not attracting new customers as rapidly as competitors

• Low retail outlets

Opportunities for the organization

• Since company has not utilized 100% plant capacity, they can undertake new
projects

• Company is trying to find new markets in European countries

• Rubco is starting a new venture, shoe factory in Tellicherry.

• High market demand for quality and branded furniture items

• Cheap labor easily available in the neighboring states

Threats for the organization

• Increasing price if rubber in domestic market

• Scarcity of domestic supply of rubber wood

• Imported furniture from china available in market at cheaper prices

• Recent inflation in the global economy

• Competition from domestic companies as they started using the technology of

finger joining

• Changes in the countries export policies

• Availability of furniture in market in variety of designs and colours

 7’s MICKENSY MODEL

BACK GROUND OF THE MODEL

The 7’s model is better known as Mc Kensy’s 7s. This is because the two
persons who developed this model. It is developed by tom peters and Robert
waterman. They published their 7’s model in their article “structure is not
organization “(1980) and in their books “the art of Japanese management”
(1981) and in search of excellence (1982).

Struct
ure

Syst
Strat
em
egy

Shar
ed

Valu
es

Skill Style

Staff

Mickensy’s 7’s model

The 7’s model is a tool for managerial analysis and action that provides a structure
with which to consider a company as whole. So that the organizations problems may
be diagnosed and a strategy may be developed and implemented.

The 7s of Mckensy’s model are:

• Strategy

• Structure

• System

• Style

• Staff

• Skill

• Shared values

These are the 7 s elements are distinguished in so called hard S’s and soft S’s. The
hard elements are feasible and easy to identify. They can be found in strategy
statements corporate plans organizational charts and other documentations.

The four soft S’s however, are hardly feasible. They are difficult to describe since
capabilities values and elements of corporate culture are continuously developing and
changing. They are highly determined by the people at work in the organizations.
Although the soft factors are below the surface, they can have a great impact of the
hard structure , strategies and system of the organization.
Practical relevance of hard S
Here strategy, structure and system can consider as “Hardware” of success of an
organization.

Strategy

Actions a company plans in response to or anticipation of changes in the

external environment.

HRM strategy of Rubco Huat Woods Pvt Ltd

• To provide social welfare measures to work force

• To make the best and efficient

• To recruit and select right person for the right job at the right time in the right
place.

Production strategy of Rubco Huat Woods Pvt Ltd

• Producing high quality of goods

• Quick production of products or goods

• Efficient use of raw materials

• Minimize the waste in the production process

Financial strategy of Rubco Huat Woods Pvt Ltd

• Maintaining the perfect accounting and auditing system

• Reducing the block of capital

• Maintaining the cash receivables

Marketing strategy of Rubco Huat Woods Pvt Ltd

• To create new customers

• To motivate the sales team

• Making profit through customer satisfaction

• Develop a pricing strategy

Structure
Organizational hierarchy - RUBCO rubber wood division.

Chairman

Managing Director

General Manager

Chief Purchas Account Admin Sales & Marketin

Productio cum g
e s Shippin
n personnel Manager
Manager
Manage Officer Officer
g
r Manage

Producti Store Junior Time Sales Asst

on Keeper Clerk Officer Executi Marketin
Manager ve g
Manager

Shift Clerical Computer Head Clerical Junior

Enginee Staff programm Guard Staff sales
r er officer

Quality Section Maintenan

Sales
Supervis Supervis ce
Executiv
or or Engineers
e

Skilled/unskilled workers

Organizational hierarchy – RUBCO

System
The formal and informal procedure that support the strategy and structure.

System of HR in Rubco Huat Woods Pvt. Ltd

The system oh HR undertaken by Rubco is enough competent for leading their

employees towards the ultimate objectives. Below given the diagram briefly explain
the system of HR in Rubco.

Resource Resource HR
Requirement Planning budgeting

Resource Selection Responsibili Performanc

allocation process ty allocation e
verification

Appraisal Training Posting for

employees on job new area

Performanc Designing Implementat

e evaluation of system in ion of HR
in the new new area system in
area new area

Study the Check the Allocation of

conformanc effectivenes duties,
e in the new s of each responsibilities
area employee and authority of
each personnel

HR system in Rubco
Practical relevance of soft ‘S’
Skill, style, staff and shared values can be seen as the “software” of success of an
organization

Skill
The Rubco’s recruitment is mainly through advertisement in leading newspaper based
on the recruitment of the organization. The MD consulting with administrative
personnel officer to decide the number and type of people needed for the organization.

Qualification required for the personnel

Technical staff : ITI/Diploma and 1or 2 years experience

Office staff : Degree, sufficient computer knowledge,

Fluency in English and minimum 2 years

Work experience.

Managerial personnel : Minimum 5 years of work experience,

Qualified from reputed institution and

have a relevant knowledge in the latest

Computer terminologies and MBA

Style
It says about how the decisions are made and the flow of authority in the organization.
The Rubco was using the participative leadership style order to take the decision is
taken by the management by discussing with concerned supervisors or workers. The
organization is taking the day to day decision such as the quality of output usage of
materials, purchasing etc are determined by the production manager to concerned
supervisors or workers. So the decision making is decentralized.
Staff
The term staff refers to the way organization introduce young recruits into the main
stream of their activities. Around 775 workers are working in the company. They are

Specialist / highly skilled workers – 35

Skilled workers – 146

Unskilled workers – 347

Semi skilled workers – 31

Learners – 54

Casuals – 73

Saw workers – 35

Staff (including managerial staff) – 54

Shared values
These are the guiding principles, fundamental ideas around which a
company is built. It must be simple usually stated at the abstract level, have great
measuring inside the organization even through outside may not understand them.
These are the main values on which the company is built. These values are shared by
the members in the organization.

It remains customer focused by providing the quality cost and through

manufacturing excellence, adopts a continuous of all organization activity to meet
dynamic requirement of customers. It empowers all employees across the
organization to achieve total quality. The company aims at customer delight by
exceeding expectation blend of quality-cost-delivery of the company’s products and
services that company provides.
 FINANCIAL SUMMARY OF RUBCO HUAT WOODS PVT LTD
Profit and loss account for the year ended 31-03-2010

Particulars 1-04-09 to Particulars 1-04-09 to

31-03-10 31-03-10

Opening stock Sales accounts

Finished goods 34,52,383.96 Sales Non taxable 1,62,24,538.84

Raw materials 77,97,861.26 Sales Taxable 87,32,575.70

1,12,84,226.0 2,49,57,114.54
8

Purchase accounts Direct incomes

Furniture handicraft Nt 3,09,419.33 Goods transferred to 8,31,050.00

exhibition

Mattresses – Nt 58,59,363.05 Stock transfer to branch 8,36,331.54

Mattress-taxable-Nt 8,61,038.79 Closing stock -

Purchase-non taxable 1,24,481.25 Finished goods 34,85,406.93

Purchase-others Nt 3,85,343.56 Raw materials 79,96,440.27

Plastic and steel 1,35,554.00 Work in progress 1,02,415.94

furniture Nt

Raw materials form 18 7,22,597.76 1,15,84,263.14

Raw materials Nt 59,82,837.63

Purchase-taxable 76,500.15

Purchase-timber-25A 8,06,273.95

Purchase timber-5A 310,000.00

Purchase timber-against 2,17,738.00

C form

Purchase timber form 18 3,49,296.00

1,61,17,583.5
3

Direct expenses 21,48,452.29

Stock transfer from 30,46,404.55
branch

Gross profit c/o 56,12,092.77

3,82,08,795.2 3,82,08,795.22
2

Indirect expenses 1,46,715.00 Gross profit b/f 56,12,092.77

EPF paid 19,13,311.00 Indirect income

Auditors fee 7,500.00 Accounting charges 25,000.00

Auditors fee for tax 8,265.00 CST-12.5% collected 1,17,065.18

audit

Ban charges 35,424.87 Discount received 24,445.00

Bank interest 6,19,515.89 Sales tax collected 2.3% 54,797.67

Bank interest on term -1,27,486.78 Sales tax collected 9.2% 5,08,686.43

loan

Bonus 89,979.00 Sales tax collected 1500.75

KGST-13.8%

Cellular phone charges 1,59,085.00 Vehicle collection 4,45,040.00

Cst paid 1,18,172.50 11,74,535.03

Depreciation 12,90,427.62

Electricity charges 3,53,036.62

Finance charges 92,571.28

Insurance premium 62,752.70

Loss on sales of vehicle 29,197.20

Office expenses 11,108.00

Postage and telegram 4,131.50

Preliminary expenses 2,170.00

written off

Printing & stationary 30,884.00

Purchase tax paid 37,200.00

Rates & taxes 37,302.00

Rent 70,800.00

Repairs & maintenance 1,02,061.00

Sales tax paid 6,09,230.50

St paid-03-04 29,498.93

St registration charges 1,650.00

TDS paid 5,997.00

Telephone charges 20,555.00

Vehicle Exp Batta 89,008.00

Vehicle Exp fuel 1,55,826.86

Vehicle insurance 63,999.00

Vehicle maintenance 30,472.26

Vehicle tax paid 7,960.00

3,82,08,759.2
2

Net profit 5,884,307.47

Total 67,86,627.80 Total 67,86,627.80

Balance sheet as on 1-04-09 to 31-03-10

Liabilities As at 31-03-10 Assets As at 31-03-10

Capital accounts Fixed assets

Share application 26,000.00 Building 63,86,821.30

Share capital 1,47,32,000.00 computer & software 56,940.00

1,47,64,000.00 Office furniture & 2,82,230.11

equipments

Loans (liability) Plant and machinery 40,317.00

Bank OD a/c 54,35,665.35 Power and electricity 10,88,632.23

Unsecured loans 14,55,906.81 Tools and equipment 5003.73

68,91,572.18 Vehicles 18,97,948.73

Current liabilities 99,14,303.32

Deferred tax liability 10,64,012.00 Current assets

Sundry creditors 3,65,790.00 Closing stock 1,15,84,263.14

Employees 77,40,595.30 Loans & advance 2,89,523.68

contribution to pf

12,539.00 Sundry debtors 5,49,155.39

91,82,935.30 Cash in hand 19,66,003.19

Bank accounts 9,694.43

Chappanagadi branch 18,17,987.27

1,62,16,627.10

Miscellaneous expenses
( assets)
 Deferred revenue 2,13,141.50
expenditure

Profit & loss Account

Opening balance 50,78,743.01

Current period -5,84,307.47

Total 3,08,38,507.46 Total 3,08,38,507.46

Ratio analysis for the year 2010

Sl no Ratios 2010
1 Current ratio 0.9:1 times

2 Liquidity ratio 0.56:1

3 Absolute ratio 0.1:1

4 Debt equity ratio 6.5

5 Proprietary ratio 0.06

6 Fixed assets to net worth 10.16

7 Debtors turn over ratio 6.4

8 Gross profit ratio 24.76

9 Net profit ratio 2.9%

10 Selling admin expenses 29.35

11 Working capital turnover 9.286

12 Funded debt to total capital ratio 76.88%

13 Solvency ratio 15.57%

14 Debt service ratio 1.87 times