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MACHINE TOOLS Ltd, Kalamassery.

introduction

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MACHINE TOOLS Ltd, Kalamassery.

INTRODUCTION
HMT Machine Tools Ltd., Kalamassery is among the five machine tool manufacturing units of the subsidiary company HMT Machine Tools Ltd. The holding company is HMT Ltd. Machine Tools production started in India in 19 ! "ith the commissioning of the first factory of HMT at #angalore in collaboration "ith $%&L%K$' ("it)erland to cataly)e industrial gro"th. (ubse*uently, the machine tools mar+et gre" by leaps and bound and HMT stood and remained a leading Machine Tools company till ,!!-. $ne of the most challenging tas+s of a business may be organi)ing the people "ho perform its "or+. . business may begin "ith one person doing all the necessary tas+s. .s the business becomes successful and gro"s, ho"ever, there is generally more "or+, and more people are needed to perform various tas+s. Through this division of "or+, individuals can become specialists at a specific /ob. #ecause there are several people often in different locations "or+ing to"ard a common ob/ective, 0there must be a plan sho"ing ho" the "or+ "ill be organi)ed. The plan for the systematic arrangement of "or+ is the organization structure. $rgani)ation structure is comprised of functions, relationships, responsibilities, authorities, and communications of individuals "ithin each department. The typical depiction of structure is the organi)ational chart. The organi)ational chart has been described as loo+ing li+e a tree, "ith the roots representing the president and the board of directors, "hile the branches symboli)e the various departments and the leaves depict the staff "or+ers. $rgani)ational study helps a researcher to understand the "or+ing and policy ma+ing activities of the company as a "hole. It provides a researcher the practical +no"ledge about the functioning and co1ordination of the activities of the various departments.

OBJECTIVES OF THE STUDY


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i. ii. iii. iv. v. vi. vii.

To familiari)e "ith overall performance of HMT M.2HI'% T$$L( LIMIT%3 Kalamassery To study different departments in the organi)ation and their functioning. To enable and understand ho" the +ey business process are carried out in organi)ations. 4nderstanding the $rgani)ational 5or+ culture. 4nderstand ho" information is used in organi)ation for decision ma+ing at various levels. 6inding the problems and limitations of the organi)ation, if any and giving appropriate suggestions to overcome the difficulties. To identify opportunities, threats, strengths, and "ea+ness of the departments.

METHODOLOGY OF THE STUDY


I have conducted a descriptive type study by personally visiting the firm. The main sources of information "ere primary data and secondary data.

Primary data7 it "as collected by personally intervie"ing and interacting "ith the managers, officers, staff and "or+ers of various departments of the company.

Seco dary data7 it "as collected from various records li+e the annual reports of the company, company brochure, company documents, company /ournal and the "ebsite of the company.

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SCOPE OF THE STUDY


$rgani)ation study provides an opportunity to the management trainees to have practical +no"ledge about the organi)ational activities in a company by conducting a study there. He gets "ide range of +no"ledge about the organi)ational structure, functions of various department and officials. It enables him to do the (5$T analysis of the company. 6inally he can put for"ard suggestions for the improvement of the company.

LIMIT!TIONS OF THE STUDY


The study has limited scope, as it aims an overall organi)ational study and not an in1depth. Information obtained is incomplete and inaccurate since the financial and some other confidential information "ere not provided by the company. The data collected from different personnel in the company contain biased statements. It "as difficult for me to grasp the technical operations of the company The study "as only for limited days 89! days:.

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INDUSTRY PROFILE

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M!CHINE TOOL INDUSTRY


#eing an integral sector, gro"th of the machine tool industry has an immense bearing on the entire economy especially India;s manufacturing industry. It is even more crucial for the development of countries strategic segments such as defense, rail"ays, space and atomic energy. Machine tools production started in india in 19 ! "ith the commissioning of the first factory of HMT at #angalore in collaboration "ith $erle+on s"it)erland to catalyse industrial gro"th. (ubse*uently, the machine tools mar+et gre" by leaps and bound and HMT stood and remained a leading Machine tools company till ,!!-. %fforts "ithin the industry are no" on to the better the features of the 2'2 machine and provide the further value additions and lo"er and lo"er costs, to meet the specific re*uirements and uses. #ased on the perceptions of the current trend and emerging demands 2'2 segment could be the drive of gro"th for the machine tool industry in India. ,!!< "as the second successive year of e=alting performance in the Indian economy and its industry especially in manufacturing sector. It "as clearly a year "hich
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"itnesses a high of <.9> ?3@ gro"th ma+ing India one of the most progressive countries in this part of the "orld. . remar+able 9.!> gro"th in Indian manufacturing industry "as lead because of an ecstatic performance by several +ey sectors, in particular the automotive, the auto ancillary and customer durables. The three industry sectors sho"ed their true global process in ,!!< "ith a great sho"ing on the e=port front. The machine tool industry had therefore, reasons enough to celebrate. 3emand for metal "or+ing machine tools scaled to ne" heights for Indian manufactures in the last calendar year. Metal "or+ing machine tools output of the Indian industry "orth &s 1!111 million, registered a phenomenal gro"th of 9 .!> in Aanuary13ecember ,!!<, over the previous year. Much of the increase happened in the "a+e of the spurt in demand in for metal "or+ing machine tools from the automotive sector the auto ancillary industries, defense, rail"ays, /ob shops and small scale industry units. In short a surge in order boo+ings "as from all across the Indian manufacturing sector. 5ith gro"th and business optimism on a further s"ell in the Indian economy and the industry, the year ,!!B is e=pected to result in a ne" pea+ for the Indian machine tool industry both in the home and overseas. The Indian machine tool industry averaged more than 9 per cent gro"th in ,!!-1! . Imports e=ceeded production in the year ,!!- "ith 4(C 9 < million "orth machine tools being imported "hile the production "as only 4(C ,, million. Machine Tools form 1 per cent of IndiaDs engineering industry and contribute !.9 per cent of total machinery e=ports. The Indian machine tool industry currently consists of about - ! manufacturing units of "hich appro=imately 99 per cent 81 ! units: fall under the organi)ed category. 6urther, ten ma/or Indian companies constitute almost B! per cent of the total production. .ppro=imately B per cent of the Indian machine tool producers have received the coveted I($ certification. 5hile the large organi)ed players cater to IndiaDs heavy and medium industries, the small scale sector meets the demand of ancillary and other units. #angalore is considered as the hub for the Indian Machine Tools industry. The city, for instance houses HMT Machine Tools Ltd and .2% ?roup, t"o Machine Tools giants that manufacture nearly -!> of the total industry;s output.

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.ll the machine tools item attract a total import duty of !.E> this include a basic duty of , >, additional duty of 1<> and special additional duty of ->. Top ten destination of India;s e=port for machine tools are 4(., ?ermany 4.%, Femen .rab republic, #elgium, Lu=embourg, Indonesia, china, Italy 4K and (ingapore. The early E!s "as a period of technological revolution "ith drastic changes in the use of heavy machine tools. The integrated chip "as invented in 4(, "hich helped in the computeri)ed manufacturing of heavy machines tools and e*uipment "ith high accuracy and precision. The performance of seven of the top ten machine tool manufacturing countries of the "orld sluggish during ,!!,, and the "orld output declined by 1-> during this year. The total production of ,E machine tool manufacturing countries during the year ,!!,, valued at 91 billion 4( 3ollars "as the lo"est of the last five years. ?ermany and Aapan "ere ran+ed first and second in machine tool production. Aapan;s production fell by about one1third, mainly due to its mar+et corrosion I 'orth .merica. @roduction in the 4(. slipped by 99> Ho" ever, 2hinese machine tool industry;s production indicated a gro"th of 1 > during ,!!,, and "as ran+ed -th above the 4(., in overall out put. ?ermany "as the leading e=porter of machine tools, during the year, follo"ed by Aapan. Through both these countries e=ported about !> of their production most of the ma/or producers, including thee t"o, faced severe decline in e=ports. Marginal gro"th in e=port "as achieved by Tai"an, (pain and 2hina. Most of the ma/or machine tool consumers indicated severe decline in consumption, 4(. registering 9<> decline follo"ed by 1< other indicating double digit percentage decline. Ho"ever, china, the largest consumer of machine tools during the year ,!!,. &egistered ,!> gro"th over the previous year in consumption.

I dia "ce ario


Machine tools production in India during ,!!! G !1 "as estimated at &s7 E-B Million. This "as reduced to &s7 1 B million in ,!!1 G !, 8111>: and to &s7 -Emillion 81<>: in ,!!, G !9 consumption "as of &s7 E9 ! million ,!!! G !1, &s7 BBEB million in ,!!1 G !, 8119>: and &s7 9!,9 million 8H1 >: in ,!!, G !9 about -9> of
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consumption in the last financial years "as met by imports valued at &s7 - !E million "hich has gro"n by about - > over the previous year.

COMPANY PROFILE
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MACHINE TOOLS Ltd, Kalamassery.

VISION
To be an %ngineering 2ompany of International &epute, @roviding #est of @roducts I (ervices "ith 2ontemporary Technologies to suit 2ustomer 'eeds.

MISSION
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MACHINE TOOLS Ltd, Kalamassery.

To establish ourselves as one of the "orld;s premier companies in the engineering field having strong international competitiveness. To achieve mar+et leadership in India through ensuring customer satisfaction by supplying internationally competitive products and services. To achieve sustained gro"th in the earnings of the group on behalf of shareholders.

HMT M!CHINE TOOLS LIMITED


#y the end of the (econd 5orld 5ar, the ?overnment of India "as confronted by a big problem of disposing the colossal "ar "aste. 4ltimately a committee "as constituted
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MACHINE TOOLS Ltd, Kalamassery.

to in*uire into the possibilities. The committee report of 19-E proposed the establishment of a ?overnment o"ned machine tool industry. This "as e=pected to fulfill t"o aspects. The first "as being utili)ation of the &s -!!! Million "orth of metallic "aste. The second "as the incorporation of state o"ned infrastructure manufacturing facility. The result "as the birth of the JHI'34(T.' M.2HI'% T$$L( LIMIT%3 #.'?.L$&%;, "hich diversified in due course of time to the present stature of the multi core, multi location, multi unit, multi product, industrial giant HMT Ltd.8. ?ovt of India 4nderta+ing 2ompany: The HMT Ltd "as started as a single factory to produce Tool room Lathes at #angalore in collaboration "ith MKs $erli+on of ("it)erland in 19 9, "ith a capacity to manufacture around -!! machines per year. (ince then different 2ollaborations, continued in house & I 3 and tremendous mar+eting efforts brought HMT, to present in status. The gro"th of HMT "as characteri)ed by bac+"ard and for"ard integration of technology and product diversification. Thus, the company that started "ith manufacturing and selling lathes e=panded its machine tools product range to evolve as the ultimate solution in metal cutting. The product diversification efforts too+ the company to the business of "atches in 19<,, Tractors in 19B1,3ie1casting on plastic machinery in 19B1,@rinting machinery in 19B,, @resses in 19B,, Lamps and Lamp ma+ing machinery in19B<, 6ood processing machinery in 19E!, 2'2 system in 19E<, #all scre" in 19E< and &econditioning in 199!. The multi product activities made HMT Ltd changes its identity as Hindustan machine tools Ltd. Today, HMT Ltd. has 1< manufacturing units "ith ,, product divisions, spread through the length and breadth of India. . subsidiary namely HMT 8International: Ltd, ta+es care of the e=ports of the company products. They also e=port several items for other Indian companies. HMT Ltd "as restructured in 199, to facilitate better administration of the multi product business activities. .ccordingly, the follo"ing business groups "ere established.

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Machine Tools #usiness ?roup, to concentrate on metal cutting machines.

Industrial machinery #usiness ?roup, to deal "ith @rinting Machines, 3ie casting and @lastic in/ection moulding machines, 6ood processing Machines and metal forming machines.

.gricultural #usiness ?roup to concentrate on Tractors. %ngineering components #usiness ?roup, to deal "ith 2asting and #all (cre"s.

2ustomer product #usiness ?roup, to deal "ith "atches and Lamps.

In addition to these #usiness ?roup, the company o"ns three subsidiaries as follo"s. HMT 8International: Ltd ."hich underta+es the overseas pro/ects and e=ports.

@&.?. tools Ltd. "hich manufactures machine tools. HMT #earing Ltd. "hich manufactures precision #earing in collaboration "ith mKs Koyo Aapan.

.s per the revival of this public sector Industry a turnaround plan has introduced in the early days of this millennium and reorgani)ed as HMT Ltd Gholding company including Tractors division and presently comprises of the follo"ing subsidiaries. 1. ,. 9. -. HMT M.2HI'% T$$L( LIMIT%3. HMT 5.T2H%( LIMIT%3. HMT 2HI'.& 5.T2H%( LIMIT%3. HMT #%.&I'?( LIMIT%3.

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MACHINE TOOLS Ltd, Kalamassery.

. <.

HMT I'T%&'.TI$'.L LIMIT%3. @&.?. T$$L( LIMIT%3.

#$ HMT M!CHINE TOOLS LIMITED.


The HMT Machine tools limited is engaged in the manufacture and mar+eting of ?eneral @urpose Machine tools, (pecial purpose Machine Tools, 2omputer 'umerically 2ontrolled Machine Tools, @recision machinery systems, printing machines, Metal forming presses, 3ie casting and @lastic In/ection molding machines, 6errous and non ferrous casting.

THE PRODUCT R!NGE OF HMT M!CHINE TOOLS UNITS B!NG!LORE


Heavy 3uty Lathe. (ingle and Multi (pindle .utomobile. &adial 3rilling Machines. Multi (pindle 3rills. 2ylindrical and (urface ?rinders. ?ear 2utting Machines. Laser 2utting Hobbers. 2'2 Turn Mill 2enters. 2'2 5ire cut %3M. 6ine #oring MachinesK(@Ms.

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PINJORE
6M( and 6M2. Hori)ontal Machinery 2enters. Lertical Machinery 2enters. Milling Machines. #roaching Machines.

%!L!M!SSERY

2'2 Turning centre. Turn Mill 2entre. 6le=ible Turning 2ell. 2opying Lathes. 2entre Lathes. $ffset @rinting @resses. @aper 2utting Machines.

HYDER!B!D

(pecial @urpose Machines.

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Hori)ontal Machinery 2entre. 6M(. 2'2 Hori)ontal #oring 2entre. #ed Type and 6loor #oring Machines.

!JMER

?rinding Machines. (@M ?rinders. 2'2 grinders.

M!JOR M!CHINES !ND INSPECTION F!CILITY !V!IL!BLE IN DIFFERENT M!CHINE TOOLS UNITS
1. ,. 9. -. . <. 2'2 &am Type @lano Millers. Hori)ontal Machining 2enters. Lertical Machining 2enters. Hori)ontal Aig #oring Machines. Lertical Aig #oring Machines 2'2 Turning 2enters.

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MACHINE TOOLS Ltd, Kalamassery.

B. E. 9. 1!. 11. 1,. 19. 1-. 1 .

Turn Mill 2enters. (lide 5ay ?rinders. 2ylindrical ?rinders. Internal ?rinders. @recision ?ear (hapers. @recision ?ear Hobbers. ?ear ?rinders. Induction Hardening Machines. 93 2o1ordinate Measuring Machines

. &$ HMT '!TCHES LIMITED7


HMT 5atches Ltd manufactures and mar+ets "atches including Hand 5oundK .utomatic and Muarts.

($ HMT CHIN!R '!TCHES7


HMT 2HI'.& 5.T2H%( LT3 is also one of the subsidiaries engaged in the manufacture of 2hinar model "atches located in (rinagar, Kashmir (tate.

)$ HMT BE!RING LTD*


HMT #earing Ltd is one of the subsidiaries engaged in the manufacture of different types of industrial bearing, situated in Hyderabad.

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+$ HMT INTERN!TION!L LTD*


HMT International is engaged in the e=port of HMT;s range of product 5orld"ide. HMT8I: also mar+eted other Indian %ngineering @roducts in the 5orld Mar+et and bac+ed up by a good sales and service net"or+. It also underta+es Turn+ey @ro/ects and technical services for developing countries.

,$ PR!G! TOOLS LTD*


@raga tool limited is also a subsidiary of HMT Ltd engaged in the manufacturing of Machine Tools located in Hyderabad.

THE %!L!M!SSERY COMPLE- OF HMT. %!L!M!SSERY


The Kalamassery 4nit, the 6ourth Machine Tools unit "as established in 19<9 and started production in 19<-. The 4nit originally manufactured only t"o types of 2entre Lathes namely, HIL#, but later added special purpose Lathes li+e 2opying and Turret Lathes. Model LT1,! "as the first product to be indigenously developed by the unit 819<E: and the development of this product "as a landmar+ in the history of the unit. The production of this machine "as later licensed to MKs M%T2$( Kerala, M.T$$L(, @hilippines, 2eylon steel corporation, (rilan+a. The original 2entre Lathes H I Lb "ere then replaced by a ne" family of unified series of lathes "hich "as designed and developed by the unit, incorporating the concept of computer optimi)ed design, typification, standardi)ation and unification.

DIVERSIFIC!TION OF %!L!M!SSERY UNIT !ND BIRTH OF PRINTING M!CHINE DIVISION


3uring the period of 19B,1B9, Kalamassery unit diversified its product range to include @rinting Machines. Thus "as born the Machinery division 8@MK:. The commercial entry of @MK "as "ith the t"o types of letter presses namely. &T% and &T.% under collaboration "ith MKs 'eibiolo of Italy. .uto platen an indigenous development came up subse*uently. 3uring the ensuring years @rinting Machinery 3ivision came upto "ith offset presses namely $MT& in collaboration "ith mKs 'ebiolo.
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Later indigenous offset presses namely .($M 19< "as introduced in the mar+et. The first t"o color machine from HMT "as K@$ in collaboration "ith MKs Koenig and #auer of ?ermany. The latest development of @MK is paper cutting ?uillotine @? 9, 39 in collaboration "ith MKs @ivano #inders of Italy

THE CURRENT PRODUCT R!NGE


@&$342T $66(%T @&I'TI'? M.2HI'%( M$3%L ($M -9< ($M -, ($M ,9< ($M ,91 ($M ,, ($M 19< ($M 191 ($M 1, ? ($M 1,! M$M 1!1 M$M 1 ,! @.@%& 24TTI'? M.2HI'% @?19, 39 @?111

TR!INING CENTRE
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This 4nit vie"s H&3 as one of the primary concern as a measure to increase productivity and enhance (ocial (tranding. The company has a "ell established training system by personnel of high technical and management s+ills. The H&3 @rogrammes underta+en by them include the follo"ing71 1.
.

Management $rientation @rogrammes (upervisory 3evelopment @rogrammes 2ustomer Training @rogrammes to e*uip the customer for the optimum @eriodic a"areness Training programmes for employees relating to safety, Multi1s+ill Training to Machine $perators. Induction and in plant Training to 6resh recruits and Transferees. .pprentice Training @rogrammes under the .pprentice .ct. @ro/ect guidance in Management and Technology to students. Industrial familiari)ation training programmes for engineering college

9. -. . <. B. E. 9. students.

utili)ation of HMT Machines. *uality .dvanced Technology, Information Technology etc.

THE M!R%ETING NET'OR% OF HMT MTL LTD


The Machine Tools Mar+eting 3ivisions "ith its head *uarters at #angalore and having a "ide net"or+ of &egional and 3ivisional offices spread throughout India caters to the mar+eting needs of this 4nit at the primary level. To co1ordinate the mar+eting activities at the unit level and to offer technical support to Machine tools mar+eting, a strong sales and services team is constituted at unit level. HMT;s ma/or 2ustomers include 3efense, &ail"ays, .utomobile and other %ngineering Industries in various sectors.

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M!IN INL!ND COMPETITORS FOR THE UNIT/S PRODUCTS


1. Mysore Kirlos+er Ltd. ,. .2% 3esigners. 9. '2 Machines @rivate Ltd. -. La+shmi Machine 5or+.

M!IN FOREIGN COMPETITORS FOR THE UNIT/S PRODUCTS


1. ,. 9. -. . <. B. E. 9. 1!. 11. $+uma, Aapan. 'ori sai+i. 2o. Ltd Aapan. Tu+isama, Aapan. Mu)a+, Aapan. I+egai, Aapan. ?3M, ?ermany. 2hurchill, %ngland. %rnault Toyota, Aapan. Lictor, Tai"an. Tuma, Korea. %M.(, ?ermany.

'ELF!RE ME!SURES IN HMT. %!L!M!SSERY

1. 2ompany Muarters are provided to employees.

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,. (ubsidi)ed Transport facility is provided for employees residing outside HMT To"nship. 9. 2ompany sponsors a central "elfare association. This association has four subsidiary clubs, .rts and 3ramatic 2lub, (ports club, (ocial club, %ducational society.

0U!LITY POLICY
HMT MTL I( committed to T$T.L 24(T$M%& (.TI(6.2TI$' by the supply of M4.LITF @&$342T( .'3 (%&LI2%( Through7 2ontinuous improvement of technology of products and processes. Innovation and creativity. %ffective implementation of *uality management system. monitoring the effective reali)ation of *uality ob/ectives and periodical revie" of its suitability

'H!T IS 1+S2
# S SEIRI1 (ort out unnecessary items in the "or+ place and discard them. & S SEITON G .rrange necessary item in the good order, so that they can easily pic+ed for use. J. place for everything and everything in its place;. ( S SEISO1 2lean your "or+place, completely so that there is no dust on the floor, machine and e*uipments. ) S SEI%ETSU G Maintain high standard of house+eeping and "or+ place organi)ations at all times.
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+ S SHITSU%E G Training to follo" good house+eeping disciplines, autonomously.

ISO 3444* INTERN!TION!L ST!ND!RDS FOR 0U!LITY M!N!GEMENT


?ood *uality system consists of sound technical and administrative procedures for assuring *uality. M. offers more scope for reducing costs prere*uisites and characteristics of good *uality assurance and *uality management. The challenge to a developing nation is to motivate processors and manufacturers to adopt and implement these standards and to establish a credible nation *uality registration scheme, "hich "ill be recogni)ed by trading partners. In a increasing number of mar+ets and industries third party *uality assessments and registration is becoming a pre re*uisite for doing business. I($ 9!!! registration is considered the minimum acceptable level for supplier and those "ho cannot demonstrate this minimum level may not only have difficulty in selling in certain mar+ets they may be barred from those mar+ets. 'ot only must a defendant be able to demonstrate that this product is "ell designed and conforms to all standards and regulations, but he must be able to demonstrate that the product is manufactured consistently "ithin a system that conforms at least t"o internationally acceptable standards.

IN !DDITION. ISO 3444 SERIES ST!ND!RD !LSO*5


a"areness. Motivates %=porters. (ets a base line %stablishes reasonable standards for ?overnment @rocurement. 6ocus Training and @rofessional 3evelopment. (ets general mar+et procedure for regulating health and safety. &educes time consuming audits by consumers and regulators. &aises level of motivation, co1operation, "or+manship and *uality

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Improves efficiency, reduces scrap and re"or+

T6e 7o88o9i : to;ic" i t6e ISO 3444 "erie" o7 "ta dard" are ac6ie<ed =y t6e com;a y*5 #$ ISO 3444* Muality management and *uality assurance standards section and use.
&$ ISO 344#* Model for *uality assurance in designKdevelopment, production Installation and servicing ($ ISO 344&* Model for *uality assurance in production and installation )$ ISO 344(* Model for *uality assurance in final inspection. +$ ISO 344)* ?uidelines on development of *uality management system to minimi)e costs and ma=imi)e benefits.

PRODUCT PROFILE

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PRODUCT PROFILE
HMT Machine Tools Ltd., Kalamassery ma+es tools used to manufacture other machines. The main products produced in HMT MTL, Kalamassery are Turning, Machine centers, ?ear cutting, (pecial purpose machines, #roching, 3rilling and milling machines, 3ie casting machines and @lastic In/ection Moulding Machines, @resses and @ress ba+ers, .utomation solutions, @rinting machines, 2'2 2ontrol (ystems, @recision #all scre"s, ?@Ms, 2onventional Machines. The need of these machines is to globali)e the machine tools industry of India to cater to the rising e=pectation and re*uirements of automobiles, rail"ays, defense, aerospace and other engineering industries to give the re*uired boost to manufacturing sector. #eing an integral sector, gro"th of machine tools industry has an immense bearing on the entire economy, especially India;s manufacturing industry. It is even more crucial for the development of the country;s strategic segments such as defense, rail"ays, space and automatic energy. (ome of the important machines produced in HMT Machine tools, Kalamassery are sho"n belo"

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MACHINE TOOLS Ltd, Kalamassery.

Figure 1 STALLION HS WHITE CNC TURNIN

CENTER

Figure ! NH !!"!#"$! CON%ENSIONAL MACHINE

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MACHINE TOOLS Ltd, Kalamassery.

Figure $ AUTOMANN !# CNC LATHE

Figure & CRAFTMASTER 'ig' ()eed )reci(ion *+t'e

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MACHINE TOOLS Ltd, Kalamassery.

Figure , STALLION 1--S

Figure # SOM 1$# PRINTIN

MACHINE

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MACHINE TOOLS Ltd, Kalamassery.

Figure . SUPER TURN !- CNC TURNIN

CENTER

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Figure / STALLION !-- TURNIN

CENTER

Figure 0 SOM ,$# PRINTIN

MACHINE

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FUNCTIONAL DEPARTMENTS

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FUNCTION!L DEP!RTMENTS
6or the smooth functioning of a company each section concerning a specific /ob is distinguished into departments. In HMT Machine Tools Ltd Kalamassery there are mainly fourteen departments "hich are under the control of the ?eneral Manager. The different departments in HMT Machine Tools are

No$
1 , 9 -

FUNCTION!L DEP!RTMENTS
H4M.' &%($4&2% 3%@.&TM%'T 6I'.'2% 3%@.&TM%'T @&$342TI$' @L.''I'? 3%@.&TM%'T (.L%( 3%@.&TM%'T 6$4'3&F .'3 @.TT%&' (H$@

< B E 9 1! 11 1, 19 1-

@4&2H.(% 3%@.&TM%'T 2$&@$&.T% @L.''I'? MTK M.'46.2T4&I'? MTK .((%M#LF @MK M.'46.2T4&I'? @MK .((%M#LF @4#LI2 &%L.TI$'( 3%@.&TM%'T (.6%TF 3%@.&TM%'T (%24&ITF 3%@.&TM%'T

CENTRE FOR MBA, KANNUR UNIVERSITY !

MACHINE TOOLS Ltd, Kalamassery.

Hu1+n re(ource de)+rt1ent

HUM!N RESOURCE DEP!RTMENT


CENTRE FOR MBA, KANNUR UNIVERSITY !!

MACHINE TOOLS Ltd, Kalamassery.

Human resource management 8H&M: is the strategic and coherent approach to the management of an organi)ationDs most valued assets 1 the people "or+ing there "ho individually and collectively contribute to the achievement of the ob/ectives of the business. The terms 0human resource management0 and 0human resources0 8H&: have largely replaced the term 0personnel management0 as a description of the processes involved in managing people in organi)ations. In simple "ords, H&M means employing people, developing their capacities, utili)ing, maintaining and compensating their services in tune "ith the /ob and organi)ational re*uirement. Human resources management is done by the @ I . department, some of the functions "hich are done by the @I. are 1. &ecruitment ,. (election 9. Training -. 5or+ing hours1 %ight hours a day . Leaves 1 82asual leave, %arned leave, Medical leave, (ic+ leave, maternity leave ,special leaves 1 education leave, e=amination leave, blood donation leave,: <. Holidays18 1, holidays and t"o optional holidays: B. 5ages E. .llo"ances1 8shift allo"ance, house rent allo"ance, "ashing allo"ance, daily allo"ance, traveling allo"ance, child education allo"ance : 9. #asic benefits 1 8provident fund, retirement, pension and mediclaim:.

In HMT .ctivities in the H& department can be classified as o o o Industrial &elations @ersonnel 5elfare activities

I d>"tria8 Re8atio "


CENTRE FOR MBA, KANNUR UNIVERSITY !"

MACHINE TOOLS Ltd, Kalamassery.

This department can be regarded as the system of rules regulating employment and "ays in "hich people behave in the organi)ation. 5henever a conflict ta+es place, it is the duty of this department to loo+ into the matters and ta+e correct action. The industrial relation officer acts as a liaison "ith legal advisors. The company has been en/oying peaceful industrial atmosphere for as long time. The company has the co1operation of employees in almost all the activities. HMT has under gone a restructuring in ,!!1. In this process, the e=isting business group structure "as abolished and changed its identity as a holding company named HMT LT3. 5ith three subsidiaries vi). HMT M.2HI'% T$$L( LT3, HMT T&.2T$&( LT3 and HMT 5.T2H%( LT3. The other subsidiaries "ill continue to e=ist.

TR!DE UNIONS IN HMT %!L!M!SSERY


In this unit there are at present four ma/or trade unions namely,

HMT %M@L$F%%( 2$'?&%(( 8I'T42: HMT %M@L$F%%( 4'I$' 82IT4: HMT %M@L$F%%( 6%3%&.TI$' HMT 5$&K%&( 4'I$'

The ?M of the unit meets the trade union leaders once in every month, to hear them and appraise the overall situations of the company. It is natural that interest of the management and trade unions differ on certain issues. In any industry the mass production can be achieved only by ta+ing into the confidence of the trade union leaders and utilise them in a positive "ay and to achieve the target through good industrial relation.

CENTRE FOR MBA, KANNUR UNIVERSITY !#

MACHINE TOOLS Ltd, Kalamassery.

FUNCTIONS OF HR DEPARTMENT Recr>itme t


The recruitment of management trainees in engineering and other area li+e finance, mar+eting, personnel etc. "ill be made centrally by corporate personal director. &ecruitment function includes t"o methodsN 1. 2ampus recruitment ,. &ecruitment through opens in .ll India advertisement.

Promotio
. common promotion policy and rules for "or+man of HMT is a long felt meet. .n integration of the company needs of multi1s+ills of the present and future "ith the aspirations of the "or+man for an assured career path consistent "ith their s+ills had become imperative in vie" of the changing technology product mi= diversification etc in the company.

LE!VE PROCEDURE
%mployees are eligible for earned leave, sic+ or commuted leave, maternity leave and special leave. 6or the leave and its administration the employees are classified under category1 .1 %mployees covered under %(I #11%mployees not covered under %(I 8up to deputy manager:
#,1Level of managers and above.

2L1 1! days for J.; and J#1; categories and B days for J#,; categories is allo"ed in each calendar. Fear unutili)ed leave lapses at the end of the calendar year. Sic? 8ea<e J.; 1 E days J#1; 1 1! days J#,; 1 1! days

CENTRE FOR MBA, KANNUR UNIVERSITY !$

MACHINE TOOLS Ltd, Kalamassery.

In HMT presently there are -9 employees including officers, directt employees and indirect employees. Em;8oyee" $fficers 3irect employees In direct employees Total N>m=er ,19 1 , 991 -9

WELFARE PROGRAMME
2ompany Muarters7 1 3rin+ing "ater and electricity at subsidi)ed rate. Transportation7 1 .t subsidi)ed rate. 2anteen facility $utpatient medical facilities, one dispensary .rts and 3ramatic club (ocial club %ducational society (ports club Medical benefit policy

T6e time "c6ed>8e o7 t6e em;8oyee" are mai 8y di<ide i to t6ree

HMT Grie<a ce Redre""e8


CENTRE FOR MBA, KANNUR UNIVERSITY !%

MACHINE TOOLS Ltd, Kalamassery.

O=@ecti<e"
The ob/ectives of grievance procedure for officers is to provide on easily assessable machinery for settlement of grievances of officers and to adopt measures so as to ensure e=peditions. (ettlement of grievances of officers leading to increased satisfaction on the /ob and resulting improved productivity and efficiency in the organi)ation. Proced>re 1. %ach unit has a grievance committee consisting of production chief, account chief and @ersonal 2hief of the unit. The personal chief being the convener of the committee. ,. The aggrieved person should submit his grievance in "riting to the convener grievance committee. 9. The convener should collect all related relevant data regarding the said grievance. -. ?rievance committee then should call the assigned officer "ithin 1 days of receipt of the grievance and discuss said grievance "ith him. 5ithin a "ee+ there after the grievance committee should record its findings.
#. The findings of grievance committee should be communicated to the assigned

officer by the convener "ith a copy to the 3epartment Head for ta+ing necessary action arise out of the findings of the grievance committee. <. If the aggrieved officer is not satisfied "ith the findings of the grievance committee he may prefer an appeal to the unit chief. The unit chief should convey his decision "ithin 1 days of the receipt of the appeal. The decision of the unit chief is final.

DEP!RTMENT CH!RT

CENTRE FOR MBA, KANNUR UNIVERSITY !&

MACHINE TOOLS Ltd, Kalamassery.

)M

A)M *HR+

A)M*HRM+

,y.C-.e/ E01r

Ma0a1er.Tra.0.01

SE)

SMO

SET

,y.Ma0a1er

,y.E01r

Ass.st.E01r

O//.2er *3el/are+

O//.2er *IR+

O//.2er*4R+

O//.2er*HR+

CENTRE FOR MBA, KANNUR UNIVERSITY !'

MACHINE TOOLS Ltd, Kalamassery.

Fin+nce de)+rt1ent

FIN!NCE DEP!RTMENT
6inance is the science of funds management. The general areas of finance are business finance, personal finance, and public finance. 6inance includes saving money and often
CENTRE FOR MBA, KANNUR UNIVERSITY "(

MACHINE TOOLS Ltd, Kalamassery.

includes lending money. The field of finance deals "ith the concepts of time, money, ris+ and ho" they are interrelated. It also deals "ith ho" money is spent and budgeted. $ne facet of finance is through individuals and business organi)ations, "hich deposit money in a ban+. The ban+ then lends the money out to other individuals or corporations for consumption or investment and charges interest on the loans.

DEP!RTMENT CH!RT
5)M*F+

,MF*S+

,MF*B+

Ma.0 a62s

OBS

C7028rre0 2e

Cas-

4F

IBS

3a1es

A6Cs 7//.2er

A6Cs 7//.2er

A6Cs 7//.2er

A6Cs 7//.2er

A6Cs 7//.2er

A6Cs 7//.2er

A6Cs 7//.2er

" Sta// 580.7r 7//.2er ! Sta// 1 580.7r 7//.2er 1 Sta// 580.7r 7//.2er

! Sta//

T6e ma@or 7> ctio " o7 t6e 7i a ce de;artme t


.ccounting the transactions carried out by the company and to prepare

monthly and annual financial statement.


CENTRE FOR MBA, KANNUR UNIVERSITY "1

MACHINE TOOLS Ltd, Kalamassery.

.rrange finance for "or+ing capital re*uirements, capital addition and

other day1 to1day needs. 5or+ing capital management. Liaison "ith financial institutions and #an+s. #udgetary control.

F> ctio " o7 t6e Sectio " o7 t6e Fi a ce De;artme t


%very organi)ation irrespective of its si)e relies on its financial health for its survival. It is thus no surprise that public sector organi)ation li+e HMT has a full1fledged account section.

IBS AI 9ard Bi88 Sectio B*


The entire bill that re*uires payment to be made by the company are sent appropriately through the section. It includes purchase bills, e=penses bills, and sundry creditor;s management.

OBS AO>t9ard Bi88 Sectio B*


The entire bill that re*uired payment to"ards the company is sent appropriately from this section. It includes debtors management, in"ards management, invoice generation. %tc.

Fi a cia8 Co c>rre ce*


@urchase of ra" material and incurring of any other e=penditure can be done by only "ith the concurrence of finance department.

Pro<ide t F> d*
This section arranges recovery of provident fund from the employees salary. The present statutory minimum recovery is 1,>. The employees are allo"ed to contribute
CENTRE FOR MBA, KANNUR UNIVERSITY "

MACHINE TOOLS Ltd, Kalamassery.

higher *uantum voluntarily. The company can also contribute 1,> of each employees salary. The amount contributed by the employee and the employer along "ith interest is paid at the time of retirement or resignation or separation of employee.

'a:e "ectio *
This section prepares the payroll every month on the basis of master roll given by the time office. The pay roll preparation is computeri)ed. This section also deals "ith advances to employees including four advances.

Ca"6 Sectio *
This section +eeps the cash day "or+ and ban+ day boo+. The payment vouchers prepared by the in"ard billsection "ages and other sections are sent to the cash section for paymentt. The salary to the "or+ers and supplimentary payroll for the basis to all employers are made by the cash section. 5hen the payments are received from the customers against invoices or as advance then the che*ue, drafts etc are presented to the ban+ by this section. 2ash section is responsible for ensuring that the cash credit doesnot e=ceed the limit.

Time O77ice*
. punching machine is +ept in the administration building "hich records the time and a card is punched into it. The section is used to monitor attendance of the employee.

Co"t a d Materia8 "ectio *


This section estimates standard and actual cost of machines manufactured by the company. It prepares data for the fi=ation of selling price is furnished by this section. It
CENTRE FOR MBA, KANNUR UNIVERSITY "!

MACHINE TOOLS Ltd, Kalamassery.

maintains computeri)ed sore ledger and stoc+ statements. It also prepares annual budgets on the basis of production programmes, sales programmes and capital budgets. This section is responsible for all MI( and also prepares monitoring reports.

Mai acco> t"*


This section complies the various transactions accounted by other sections. This section prepares final account. They also prepares balance sheets, budget for the year.

So>rce o7 Fi a ce
The head office that is situated at #angalore does these activities. They are issuing e*uity shares @rofit K loss of HMT M.2HI'% T$$L( LT3. K.L.M.((%&F during last five years

Fear ,!! 1,!!< ,!!<1,!!B ,!!B1,!!E ,!!E1,!!9 ,!!91,!1!

@rofit 119.B! crores 1,!. 9 crores 19.,9 crores 9.91 crores !.!<99 crores

CENTRE FOR MBA, KANNUR UNIVERSITY ""

MACHINE TOOLS Ltd, Kalamassery.

CENTRE FOR MBA, KANNUR UNIVERSITY "#

MACHINE TOOLS Ltd, Kalamassery.

PRODUCTION AND PLANNIN DEPARTMENT

PRODUCTION !ND PL!NNING DEP!RTMENT


In any #usiness $rgani)ation, @roduction activities must be related to mar+et demands as indicated by the continuous stream of customer;s orders. 6or ma=imum effectiveness this must be done in such a "ay that customer;s demand is satisfied .#ut at the same time, production should be carried out in an economic manner. The process of
CENTRE FOR MBA, KANNUR UNIVERSITY "$

MACHINE TOOLS Ltd, Kalamassery.

developing this +ind of relationship bet"een mar+et demand and production capability is the function of production planning and control

DEP!RTMENT CH!RT

M2

3 M4E5

D M4E5

PMD4PL5

MTD4PL5

Sr6ER ER D76 ER ER A((t6 ER T"R T"R T"R T"R

The production @lanning 3epartment is the most vital lin+ bet"een production design and production department. This department provide necessary facilities and technical +no" Gho" for the manufacture of the product. @roduction re*uires optimum utili)ation of natural resources, men, money, material and machines. #ut before starting the "or+ of actual production, @roduction planning have to be done in order to anticipate possible difficulties and decide in advance has ho" the production should be carried out
CENTRE FOR MBA, KANNUR UNIVERSITY "%

MACHINE TOOLS Ltd, Kalamassery.

in the best and economic "ay. The @rinciples of @roduction @lanning lies in the statement 1Fir"t ;8a yo>r 9or?. a d t6e 9or? 7or yo>r ;8a 2$ The role of @roduction @lanning 3epartment at MTK is as belo".

#B De"i: a d de<e8o;me t de;artme t


Pre;are"* specifications 3ra"ings @roduct List Inspection (tandards Pre;are"*

Test 2harts

&B Prod>ctio P8a

i : De;artme t

$peration Layouts %stimate (tandard Time assemble 6lo" 2harts. @roduction scheduling

&elease papers for manufacture.

#B Prod>ctio De;artme t
Ma >7act>re"* components .ssemble of machines

2ontrol @roduction .ctivities

Prod>ctio "ectio "

P8a

i : De;artme t

at MT%. com;ri"e" t6e 7o88o9i :

@roduction @lanning and %stimation1@@@, @@% @roduction @lanning $rdering G @@$ 2entral @roduction @lanning and 2ontrol G2@@2

F> ctio " a d Re";o "i=i8itie" o7 Pre ;8a

i : Per"o

e8

1. Identify in1 house manufacturing, outside manufacturing and brought out components ,. @repare $peration Layouts for all in1house manufacturing 2omponents. 9. Identify and initiate action for all special tooling
CENTRE FOR MBA, KANNUR UNIVERSITY "&

MACHINE TOOLS Ltd, Kalamassery.

-. Maintain special tool data . 2o ordinate and implement design alterations <. @repare list of assembly operation, assembly flo"chart etc. B. Intimate for part programming of 2'2 operations E. 2omputeri)e the data related to part list data 9. .ttend shop problems related to production 1!. 2o ordinating all activities related to computeri)ation of @@@ function. 11. .rranging and ensuring the availibility of all *uality formats related to @@@ function.

Prod>ctio ;8a

i : Orderi : APPOB

1. Issue (eries "ise manufacturing papers to production shops ,. 2o ordinate activities "ith various department for effective control of production

Ce tra8 Prod>ctio P8a

i : a d Co tro8 ACPPCB

Handed over the manufacturing papers along "ith ra" material to shop @@2.

Fi i"6ed Part" Store"AFPSB$

CENTRE FOR MBA, KANNUR UNIVERSITY "'

MACHINE TOOLS Ltd, Kalamassery.

&eceipt, storage, control and issue of manufactured component1small parts and sheet metal items.

F> ctio " a d Re";o "i=i8itie" o7 PPE Per"o

e8

%stimation of standard time for all manufacturing Kassembly operations identified in operation layouts and assembly list of operations. .ttending shop complaints regarding standard time .uthori)ation for special time in /ob cards .rranging for time studyK.ctivity sampling.

F> ctio " a d Re";o "i=i8itie" o7 O77ice S>;er i te de t #$ &$ $6


Typing of operation layouts, statements, letters etc. Maintaining all office files including leave records. 3istribution of all correspondence, circulation of notice etc.

SELLING PRICE ESTIM!TION 1 MATERIAL COST *&a" materials7 steel, 2astings and others 8#ron)e
,.luminum #rass etc including allo"ance for re/ection ,material charges: 1 a: #$@ 8#ought out @arts:7 Indigenous, (ub contract 8$utsourcing: and imported 8Including allo"ance for re/ection Hmaterial handling charges.

CENTRE FOR MBA, KANNUR UNIVERSITY #(

MACHINE TOOLS Ltd, Kalamassery.

1H1 8a: OTotal Material 2ost.

2 CONVERSION COST
, 8a: M.'46.2T4&I'? 8Including allo"ance for re/ection, ra" material, change manufacturing conditioning, inefficiency: ,8b: .((%M#LF 8including .llo"ance for re/ection ,Inefficiency etc and machine painting , 8aHb:OTotal 2onversion 2ost # C& Atotal material cost Htotal conversion cost:OTotal 3irect 2ost

($SPECIAL COST
aB =B cB 3evelopment cost 8including design ,engineering charges etc.: @attern cost (pecial Tooling cost

98aHbHc:DTota8 S;ecia8 Co"t 1H,H9 O6actory 2ost

)$ +$

ADMINISTRATIVE OVERHEADS PACKING AND FORWARDING CHARGES

1H,H9H-H O2ost $f production

,$ E$

SELLING EXPENDITURE AT UNIT FINANCIAL CHARGES

CENTRE FOR MBA, KANNUR UNIVERSITY #1

MACHINE TOOLS Ltd, Kalamassery.

F$ 3$

MARGIN SALES COMMISSION

1H,H9H-H H<HBHEH9 O@ro/ected (elling @rice

!NNU!L OPER!TING PL!N


.nnual operating plan 8.$@: for the current year is prepared from the mar+et survey and sales forecast during the end of the previous year. .$@ is converted into production rolling plan for 9 months based on the firm orders in hand and "or+ in progress. $rder list material "arrents are issued to production department based on the firm order details 86$3: and details of li+ely order 83L$&: issued from the sales dept.design "ill issue the assembly group list for the machines. 'e" assembly groups "ill be released from design and supplimentory order list and material "arrant is issued to production for the same. @roduction planning is done in an economic manner for the planned product mi= to achieve the annual target.

LO!D C!P!CITY !N!LYSIS L$.3 2.@.2ITF .'.LF(I( is a vital step in production planning because from such an analysis the follo"ing vital information are gathered. The total of each machine should "or+ in order to achieve the production target of the year. This is the PL$.3Q on the machine group. 8eg7 turning, milling, grinding etc.:. The total time that "ill be available in each machine group found by considering the total number of "or+ing days, the number of "or+ing hours per day, the total number of "or+ers and such other factors. This is the P2.@.2ITFQ of each machine group.

CENTRE FOR MBA, KANNUR UNIVERSITY #

MACHINE TOOLS Ltd, Kalamassery.

#y comparing the L$.312.@.2ITF of each machine group 8hence this name L$.312.@.2ITF .'.LF(I(: "e can identify the shortage or surplus hours on each machine group and production programme can be planned accordingly, L$.3 2.@.2ITF .'.LF(I( is thus first and the foremost step in

planning the production programme in an year. The annual operating plan for the year is collected and detailed description of each product is furnished. The steps involved are calculating the standard hour load in each machine group is follo"ed by steps by arriving eventually at the actual hour load. .fter comparing the load and capacity in each machine group, areas of shortage or surplus are identified.

CENTRE FOR MBA, KANNUR UNIVERSITY #!

MACHINE TOOLS Ltd, Kalamassery.

SALES DEPARTMENT

S!LES DEP!RTMENT I'T&$342TI$'


(ales and servicing activity is a most important function in fulfilling the ob/ectives of the organi)ation and needs of the customers. It has the activities of selling the machines as

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MACHINE TOOLS Ltd, Kalamassery.

per customer re*uirement and maintain the customer satisfaction through its after sales activities.

SCOPE
The scope of the process mapped are sales, servicing and despatch of HMT Kalamassery product.

OBJECTIVE
To create and sustain customers in the line "ith the *uality policy of the company and provide after sales service to achieve total customer satisfaction. HMT Machine Tools, Kalamassery has a sales department. The machines are manufactured only as per the order from the customer. If any order cannot be accepted, then the company has to be intimated "ithin B days. .fter B days, "ithin 1!11- days, HMT has to inform the customer;s orders accepted in its legal format.

DEP!RTMENT CH!RT

CHIEF OF SALES

S+*e( 1+c'ine too*(

S+*e( Engg6

Ser8icing 9 S)+re( PMD 9 MTD

S+*e( PMD

De()+tc '

PROCESS
The customer gets into contact "ith &egional office and specifies all the re*uirements as to its productions, delivery date price and other details. These details are then conveyed to the sales department. The order is discussed in detail "ith the
CENTRE FOR MBA, KANNUR UNIVERSITY ##

MACHINE TOOLS Ltd, Kalamassery.

production department and "ith financial department for appropriateness of design time, constraint, design, financial concurrence etc. .fter the feasibility of the design is confirmed by both the department, it gets into @roduction and after inspection and other formalities are despatched to the customer at the re*uired rate. The payment is made to the sales department. This after sending the re*uired commission to the regional office sends the rest of the cash to the financial department.

S!LES ENGINEERING C6ie7 o7 "a8e" e :i eeri :


(ubmission of offers for 2'2 Lathes against en*uiries and collection of technically and commercially clear orders. %=ecution of orders in coordination "ith related departments.

Re";o "i=i8itie" PROPOS!L


?eneration of en*uires in liaison "ith regional K)onal mar+eting offices. @reparation and submission of standard and tooled up officers for 2'2 lathes. Interact "ith customers regarding clarification re*uired on these offer. 6ollo" up of offer for the receipt of orders. (crutiny of orders and obtaining technical and commercial amendments, if any re*uired @ut up for unit chiefs sanction ,if the prices accepted vary from the approved prices. @reparation of drafts details of firm order for obtaining assembly group nos. K stoc+ nos. from design department. @reparation of tooling layouts and follo" up for customers approved in case of tooled up offers.
CENTRE FOR MBA, KANNUR UNIVERSITY #$

the

offers

submitted

and provided

MACHINE TOOLS Ltd, Kalamassery.

any.

.ssociate "ith tooling trials and incorporate corrections in tooling layouts if

EGec>tio
Issue of details of li+ely orders K details of firm orders "ith assembly group nos. K stoc+ nos. &e*uest Krelease of tooling layouts for detailed tool design Initiate manufacturing Kprocurement of tooling after detailed design tool selection 2orrespondence "ith mar+eting office Kcustomer regarding technical details , trial materials, inspection etc. 2oordinate "ith all concerned sections and technical "or+ up to despatch of the machine

Ser<ici :
&esponsibilities and authorities of chief of servicing 2ommissioning and servicing of machine supplied by MTK in targeted item either by deputing engineers for unit or by co1coordinating "ith the corresponding regional offices, servicing of out of "arranty machines on changeable basis. S;are" F> ctio * e=cecution of spare parts orders from MTK products from customers and HMT regional officers. Re";o "i=i8ity .rranging free replacement spares for rectifying complaints reported during "arranty period of all machines. Monitoring of customers complaints and to provide technical adviceK suggestionsK classifications "herever re*uired.

CENTRE FOR MBA, KANNUR UNIVERSITY #%

MACHINE TOOLS Ltd, Kalamassery.

&eceive customers en*uiries for spare parts for MTK products, scrutini)ed and issue of *uatations. Issue order acceptance against purchase orders received. Issue proforma invoice for payments. &eceive payment vouchers from account dept and issue delivery vouchers to accounts dept for clearance. 2ollect items against customers order and for"ard to despatch section "ith items "ith identification tag for proper pac+ing and despatch to customers. 6ollo" up of serie issue, materials issue and operation se*uence in the shop floor. @lanning of spare parts re*uirements. 2orrespondance "ith customer and regional offices regarding spares activity. (ubmission of spares activity dates to mar+eting division, corporate planning. 6ollo" up "ith customersKregional officers regarding pending payment. @rocessing of HMT regional offices and unit spares transfer intends. 3ocumentation of sectional and customer records.

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MACHINE TOOLS Ltd, Kalamassery.

FOUNDRY AND PATTERN SHOP

6$4'3&F
6oundry industry is the mother industry for all types of industrial, agricultural and consumers products. The developments in this industry therefore are bound to have a far
CENTRE FOR MBA, KANNUR UNIVERSITY #'

MACHINE TOOLS Ltd, Kalamassery.

reaching affect on the production in all other sectors. Though the casting processes are based on techni*ues that are age old and ama)ingly simple in principle considering the effectiveness of the results achieved the metal casting industries have become the +ey industries in the "orld today. 6oundry industries based on casting principles. 2asting is a process I producing metal parts of desired shape by pouring molten metal in to a prepared mould and then allo"ing the metal to cool and solidify. This solidified metal is +no"n as casting.

HMT FOUNDRY
The foundry attached to the machine tools division to manufacture all cast iron and spheroidal graphite iron re*uired for machine tools and printing machinery division and can also underta+e /ob orders. %stablished in 19<E "ith @$LI(H design, it is semi mechanised foundry producing heavy duty grey and (? iron , castings for machine tools and printing machines using means fre*uency induction furnace for melting and resine bonded sand for moulding and core ma+ing.

OBJECTIVES OF FOUNDRY DIVISION


In any business organi)ation, production activities must be related to mar+et demands as indicated by the continuous stream of customer orders. .ggregate planning is carried out in an economic manner for ma=imisation of production. 6rom the annual operating plan, rolling production plan for three months is made. $b/ective of the foundry division is to achieve the annual production target in an economic manner by the timely supply of castings to the production shop and the outside customers.

This can be achieved by 1: &educing percentage re/ection of casting in foundry.

CENTRE FOR MBA, KANNUR UNIVERSITY $(

MACHINE TOOLS Ltd, Kalamassery.

,: 9: -: :

&educing percentage re/ection of castings at customer;s end. &educing energy consumption. Increasing yield percentage. &educing production loss by T@M.

STEPS INVOLVED IN M!%ING ! C!STING


Ma+e the pattern out of "ood, metal or thermo coal. Incase of sand casting select, test and prepare the necessary sand mi=tures for mould and for ma+ing. 5ith the help of patterns prepare the mould and necessary cores. . mould is a container having a cavity of the shape to be cast and core is a body "hich is employed to produce a cavity in the casting. Melt the metal to be cast. @our the molten metal in the mould. &emove the casting from the mould after the metal solidifies. 2lean and finish the casting for priming. Test and inspect the casting. &emove the defectors if any salvage. @asting is ready for shipping.

Di77ere t acti<itie" o7 Fo> dry


@attern ma+ing (and preparation

CENTRE FOR MBA, KANNUR UNIVERSITY $1

MACHINE TOOLS Ltd, Kalamassery.

Moulding Metal preparation @ouring Knoc+ out 6inishing Inspection

P!TTERN SHOP
. pattern may be defined as a model of anything, so constructed that it may be used for forming an impression called mould in sand or other suitable material. This mould, "hen filled "ith molten metal that solidify, forms a reproduction of the pattern and is +no"n as casting. The process of ma+ing a pattern is +no"n as pattern ma+ing and the person "ho ma+es the pattern is +no"n as pattern ma+er. The s+illed pattern ma+er must combine an ability to reach a blue prints, visuali)e the finished products understand each step in the moulding and casting process. He must bridge the gap bet"een designer and founder and must also have the s+ill to transmit "hat he envisions into the "ood or metal replica of the final part.

F> ctio " o7 Patter


. pattern prepares a mould cavity for the purpose of ma+ing a casting core prints, runner, gates, rises are the parts of the pattern. It helps position of cores. . good pattern,
CENTRE FOR MBA, KANNUR UNIVERSITY $

MACHINE TOOLS Ltd, Kalamassery.

prevent all defects in the castings, properly constructed pattern minimi)e overall cost of the casting.

SELECTION OF P!TTERN M!TERI!L


The follo"ing factors assist in selecting proper pattern material The number of casting to be produced. The desired dimensional accuracy and surface finish re*uired for the casting. 'ature of moulding process. Method of moulding. (hape, comple=ity and si)e of the casting. 2asting design parameters and the comple=ity of the casting part. Type of moulding materials. The high probability of changing the casting and hence the pattern is near future, The chance of repeat orders.

M!TERI!LS FOR M!%ING P!TTERNS IN HMT


5ood Thermo coal Metal @laster @lastic 5a= .raldite resins

DEP!RTMENT CH!RT

DE SFP CENTRE FOR MBA, KANNUR UNIVERSITY He+87 P+ttern $! ('o) 1ou*di 9Tec'no*o ng AE M+inte n+nce

MACHINE TOOLS Ltd, Kalamassery.

DEPUTY CHIEF SUPER%ISOR 4FY5

SFH Productio n

Engr 1ediu1 1ou*ding DE reen (+nd 1ou*din g AE Me*ting

EFL P8a i : H 7e8ti : D76 EN 6 Re)+ir 9 1+int+ n+nce

DE )*+nning 9 :e*ting

DE 1+teri+* (

O::ice r

CENTRE FOR MBA, KANNUR UNIVERSITY $"

MACHINE TOOLS Ltd, Kalamassery.

PURCHASE DEPARTMENT

PURCH!SE DEP!RTMENT
P>rc6a"i : refers to a business or organi)ation attempting for ac*uiring goods or services to accomplish the goals of the enterprise. Though there are several organi)ations
CENTRE FOR MBA, KANNUR UNIVERSITY $#

MACHINE TOOLS Ltd, Kalamassery.

that attempt to set standards in the purchasing process, processes can vary greatly bet"een organi)ations. Typically the "ord PpurchasingQ is not used interchangeably "ith the "ord PprocurementQ, since procurement typically includes %=pediting, (upplier Muality, and Traffic and Logistics 8TIL: in addition to @urchasing.

DEP!RTMENT CH!RT
JGM DGM !GM M!N!GERS A&B OFFICE ST!FF OFFICE ST!FF OFFICE ST!FF

Materials engineering is a genetic term coined for the combined activates of material @lanning, belo"7 Materia8" P8a

processing I stores. The functions of these departments are enumerated

i : To forecast and plan for material re*uired for production, maintenance, servicing and spares based on the production program, sales fore cast and re*uest from maintenance, spares and servicing.

To follo" G up "ith purchase department for shortage items, so as to ensure the availability of right materials in right time, and issue of the same to the re*uired department.

CENTRE FOR MBA, KANNUR UNIVERSITY $$

MACHINE TOOLS Ltd, Kalamassery.

P>rc6a"i : The procure the re*uired *uantities of *uality materials at the best possible terms based on the annual production programK&olling assembly program. Store" To ensure that all varieties of materials received forms e=ternal sources are properly identified, stored, pre served and protested from damages occurring due to handling or environmental deterioration and +ept under safe custody. To +eep proper accounting of all the material transactions. Sco;e The scope includes material planning procurement and storage of all materials as per production re*uirements. Maintains and spaces re*uirement for machine tools, foundry and printing machines. The details of scope are as sho"n belo"7 Material planning I control Lendor *ualification I approval. Maintaining the list of approved vendors Lendor performance evaluation in co1ordination "ith *uality assurance department 2o1ordination "ith vendors for *uality problems and corrective actions. @lanning and procurement of materials as per specified re*uirements. &evie" and release of purchase order &eceipt of incoming materials, co1ordination of inspection of the same .rranging for proper storage "ith proper identification %nsuring proper handling I preservation of materials. Maintaining all relevant documentsKrecords of receipts, issues and storage.

CENTRE FOR MBA, KANNUR UNIVERSITY $%

MACHINE TOOLS Ltd, Kalamassery.

OBJECTIVES
Timely procurement and supply of re*uired materials "ith prescribed specifications and *uality at the most competitive price and terms. 6air, consistent and transparent purchase practices. 2ontinuous search for alternate sources of supply and to develop reliable sources of supply.

CL!SSIFIC!TION OF M!TERI!LS
.ll purchases should be broadly categori)ed into revenue and capital. 4nder revenue, further categori)ation shall be into production and non Gproduction items. The production items shall be categori)ed J.;, J#; and J2; class as per classification adopted by the unitsKdivisions.

MODES OF PURCH!SE Te der "y"tem


It is adopted to procure materials at competitive rates and different types of tenders are in vogue vi). open tender, limited tender, single tender and local purchases through spot offers 8spot tender:. a: $pen tender $pen tender refers to calling of *uotations by advertising tender en*uiries in "ebsite of the company and at last in one reputed localKnational ne"spapers. .ll tender notices are to be approved by the competent authority 8unit chiefKpurchase chief:. $pen tender have to be resorted to for an item "here the estimated tender value of purchase e=ceeds &s , !!!!. The time allo"ed for receiving *uotations against open tender can be fi=ed at a minimum of ,1 days from the date of release of tender en*uiryKnotice. Time allo"ed for receiving *uotations may be limited to minimum 1 days "ith sanction from unit chief. b: Limited tender
CENTRE FOR MBA, KANNUR UNIVERSITY $&

MACHINE TOOLS Ltd, Kalamassery.

Limited tender are those addressed to all parties in the approved list of suppliers for the re*uired items, as per the data base maintained by the purchase department. The time allo"ed for receiving *uotations against limited tenders shall be minimum 1 days from the date of release of tender. 6oreign and local suppliers "ere mode of communication available through %1 mail and fa=, and to meet the urgent delivery re*uirement, en*uiries may be sent by %1 mailK6a=K2ourier "hich "or+s out to be faster and economical. c: (ingle tender (ingle tenders are those addressed to a single party and the reasons for the same are to be clearly recorded in the proposal. This can be resorted to only under the follo"ing conditions and "ith the prior approval of purchase co ordination committee and sanction from the unit chief. 1: The government has canali)ed the supply only through a single source. ,: (uppliers are from government and semi government agencies and controlled agencies "ho have a mar+et monopoly for those products8 %g7 petrol, diesel, L@?, iron ore: and based on the inevitability of the situation. 9: Time limit for obtaining offers may be stipulated based on re*uirement -: $ffers by %1mailK 6a= can be accepted in case of single tenderK proprietary item en*uiries d: (pot Tender This is resorted to only for emergent re*uirements. . team of officers comprising of representatives from purchase, 6inance and 4ser departments proceed to the mar+et and obtain spot offers from local vendors after physically verifying and inspecting the goods and obtaining the assurance that the items are offered e=1 stoc+.

PURCH!SE
@urchase from collaborators
CENTRE FOR MBA, KANNUR UNIVERSITY $'

MACHINE TOOLS Ltd, Kalamassery.

@urchase from foreign suppliers @urchase through long term contract 2ash purchase @urchase "ith specific imprest

PROCEDURES REL!TED TO PURCH!SE FUNCTION


@rocedure to treat re/ected materials %=cess supply 3elivery ahead of schedule 2hange in statutory levies Issue of statutory forms @rice variationK%scalation .vail of 2%'L.T Mode of transport

aB Inland purchase =B 6oreign purchase Re";o "i=i8itie" o7 P>rc6a"e De;artme t


.dherence to guide lines contained in the purchase manual. Maintanance of an updated vendor register system. To issue en*uires K tenders, analyse the *uatations received and prepare comparative statements "ith a vie" to obtain competitive price to HMT. To conduct negotiation "ith tender. To +eep tender bo= "ith loc+ for receiving offers in sealed tenders. Tender bo= shall be opened in the presence of venders and representative of finance department in the case of open tender, limited tender, single tender etc.
To ensure fair opportunity to tenderersKsuppliers and competitive prices and terms

and assured *uality to HMT.


CENTRE FOR MBA, KANNUR UNIVERSITY %(

MACHINE TOOLS Ltd, Kalamassery.

To issue purchase orders in time after obtaining competent authority;s sanction and follo" up for supplies and periodical revie" of pending purchase orders. To follo" up "ith suppliers for timely supply and replacement K settlement of claims and other dues from suppliers or closure of purchase order is ensured. To co1ordinate and assist finance and inspection department in settlement of bills and recovery of dues if any. To submit applications for import clearence and obtain technical clearences and import licenses "here ever applicable. To enter into annual rate contracts "ith committed delivery schedules for standard items, "here ever advantageous to HMT. To enter into service contracts for transportation, customs clearence and maintanace of e*uipment etc. To ensure after1sales service is fulfilled by the supplier during "arrenty and post1 "arrenty period. To effectively plan and control the inventory level. To be alert and responsive to the changes in production programme and change in re*uirement of material. To interact fre*uently "ith purchase department of other units "ith a vie" to sharing of information regarding price, source of supply, payment terms, vendor rating etc. To ensure that insurance claims are prefered in time, for items damagedKlost in transit. (tandardi)ation and computeri)ation of purchase activities and inventory controls. .ll relevant data regarding purchase function should be recorded and maintaining, as re*uired for the internal use as "ell as providing the information as per present provision of right to information act. 'o purchase orders shall be placed against anticipated customer orders e=cept under special circumstances for "hich prior specific approvals of competent authority shall be ta+en 8pro/ect deptK%ngg dept:.

CENTRE FOR MBA, KANNUR UNIVERSITY %1

MACHINE TOOLS Ltd, Kalamassery.

&evie" of sho" cause notice from customers, counter claims from vendors and advance payments for items re/ected subsi*uently. Minimi)e dependency on imports. (erve as an information centre on materials li+e prices, source of supply, specifications etc. to all other unitsK departments. %nsures inventory is at an optimum level. %nsure that the economic and legal interests of the organi)ation are safeguarded at all lengths. %nsure that advanced ne" technologies li+e usage of internet etc are adopted for more effective procurement practices.

CENTRE FOR MBA, KANNUR UNIVERSITY %

MACHINE TOOLS Ltd, Kalamassery.

CORPORATE PLANNIN DEPARTMENT

CORPOR!TE PL!NNING DEP!RTMENT


.s a result of increase in mar+et competition and the changing technologies, it is necessary for an organi)ation to have a planning department in order to meet the competition successfully. 3ue to the liberali)ation all over the "orld, "orld itself become a single mar+et and many organi)ations are coming into this mar+et "ith different strategies. (o to face these challenges from the competitors and to satisfy the needs of the customers they have to plan their strategies in advance and carefully.

CENTRE FOR MBA, KANNUR UNIVERSITY %!

MACHINE TOOLS Ltd, Kalamassery.

HMT, Kalamassery has a corporate planning department. HMT has head office in #angalore and from there planning is done on the basis of the reports submitted there by the planning department of each HMT machine tool units all over the country. 2orporate planning department in HMT have a 3eputy %ngineer and an employee. 3eputy %ngineer is directly reporting to ?MK. F> ctio " 2ompilation of #usiness @lans 2ompilation of operational plans @reparation of short term plans I &olling plans Maintaining and 6urnishing Information to the management (ecretarial function for the unit board. .rrangement of &evie" Meeting71 5ee+ly production and sales revie" 8(aturday: Monthly production and sales revie" 8Fello" card: 5ee+ly target meetings 8Monday:
Monthly production I sales finali)ation meeting 8,<th of every month:

Pro@ect ;8a

i :

o Long term capital #udgeting o (hort term capita #udgeting o 2apital procurement. o Maintaining and famishing information regarding capital procurement to management. o (ending monthly performance report o .rrange for monitory meeting71 Inventory control G monthly %nergy conservation G monthly

CENTRE FOR MBA, KANNUR UNIVERSITY %"

MACHINE TOOLS Ltd, Kalamassery.

DEP!RTMENT CH!RT

G$M D$G$M ENGR OFF SUPDT

CENTRE FOR MBA, KANNUR UNIVERSITY %#

MACHINE TOOLS Ltd, Kalamassery.

MT2 MANUFACTURIN DEPARTMENT

MT% M!NUF!CTURING

Manufacturing is the use of machines, tools and labor to produce goods for use or sale. The term may refer to a range of human activity, from handicraft to high tech, but is most commonly applied to industrial production, in "hich ra" materials are transformed into finished goods on a large scale. (uch finished goods may be used for manufacturing other, more comple= products, such as aircraft, household appliances or automobiles, or sold to "holesalers, "ho in turn sell them to retailers, "ho then sell them to end users G the 0consumers0.

CENTRE FOR MBA, KANNUR UNIVERSITY %$

MACHINE TOOLS Ltd, Kalamassery.

Manufacturing ta+es turns under all types of economic systems. In a free mar+et economy, manufacturing is usually directed to"ard the mass production of products for sale to consumers at a profit. In a collectivist economy, manufacturing is more fre*uently directed by the state to supply a centrally planned economy. In free mar+et economies, manufacturing occurs under some degree of government regulation. Modern manufacturing includes all intermediate processes re*uired for the production and integration of a productDs components. (ome industries, such as semiconductor and steel manufacturers use the term fabrication instead.

Ro8e o7 ma >7act>ri : ;roce""I


1. 3esign I 3evelopment 3epartment7 @repares1Match specifications, 3ra"ings, @arts list, Inspection standard I test chart. ,. @roduction @lanning 3epartment7 @repares1$peration layout, %stimates standard time, .ssembly flo" chart, @roduction schedule. 9. @roduction 3epartment7 @repares1Manufacturing components, .ssembly of machines, 2ontrol production activities. MTK Manufacturing has divided into , parts7 1. Heavy parts. ,. (mall parts. Heavy 3uty @roducts
CENTRE FOR MBA, KANNUR UNIVERSITY %%

MACHINE TOOLS Ltd, Kalamassery.

1: ,: 9: -: : <:

#ed Leg (toc+ Tail (toc+ .pron (addle 6eed #o=

(mall 3uty @roducts 1: ,: 9: -: : <: B: E: 9: ?ears Main (pindle (pine (haft Motor @ulley Head (toc+ @ulley #earing 2overs Hand 5heel Levers #loc+s

DEP!RTMENT CH!RT

CENTRE FOR MBA, KANNUR UNIVERSITY %&

MACHINE TOOLS Ltd, Kalamassery. )M94:

,)9MM:

,CE9S4:

SMN

S)R

SMV

SMH

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M, 1 M, ,

M, 9

M, < M,

M, - M, 9 M,<, M,<!M,<9M,<1

CENTRE FOR MBA, KANNUR UNIVERSITY %'

MACHINE TOOLS Ltd, Kalamassery.

Prod>ctio Faci8itie" !t MT% Ma >7act>ri :


2% '$ M, 1 M, , M, 9 M, M, M, < M, B M, 9 M,<! M,<1 M,<, M,<9 M ,B1 M ,B, M ,B9 (%2TI$' &$4'3( '$' &$4'3( H%.T T&%.T%M%'T L%.3 (2&%5 (@I'3IL%( ?%.&( T4&&%T( .22%(($&I%( H%.LF @.&T( HT2 M.2HI'I'? 2%'T&% 2'2 T4&'I'? 2%'T&% (H%%T M%T.L MTK1.((%M@LF 8?@M: MTK ?@M .((%M@LF 2'2 MTK @&% 6I'.L .((%M#LF

CENTRE FOR MBA, KANNUR UNIVERSITY &(

MACHINE TOOLS Ltd, Kalamassery.

1t; +((e1<*7 de)+rt1ent

MT% !SSEMBLY INTRODUCTION


.mong the subsidiaries of HMT LT3, Machine Tool 3ivision Kalamassery is engaged in producing various types of turning centers, printing machines I cutting machines. .ssembly activity is the +ey function of any organi)ation.
CENTRE FOR MBA, KANNUR UNIVERSITY &1

MACHINE TOOLS Ltd, Kalamassery.

DEP!RTMENT CH!RT

M2

3 M4MP5

3 M4AY5

3 M 4MM5

3 M4D5

DY CHIEF EN

DY CHIEF EN SR EN W

SR EN W

Sr6ER ELECTRICAL ASSEM=LY

SCOPE
The main function of the department is to assemble the machines based on rolling plan applied by sales department to confirm "ith the performance I *uality specified in the design document. .ssembly department "ill offer the assembled machines for in house inspection. It "ill also monitor at different stages of assembly to ensure that a *uality product is delivered to the customer.
CENTRE FOR MBA, KANNUR UNIVERSITY &

MACHINE TOOLS Ltd, Kalamassery.

P>r;o"e
To assemble the machines as per the rolling plan supplied by sales department. To assemble the machines to meet design specification. To complete the assembly of machines as per the dispatch plan. To evolve systems to ma+e the system fle=ible to adapt to the changes in the sales plan. To improve methods I systems to changing needs for mar+et. To assemble the pre1assemblies, group assemblies I final assemblies to match "ith assembly dra"ings I specifications of the machines. To record the non conformities I ta+e corrective actions to prevent recurrence of the problem. To interact "ith departments li+e production, design, tool design, purchase, sub1 contract I sales for continual improvements of the machine. To complete assembly of machines "ithout any shortcoming I problems for the final assembly.

O=@ecti<e
1. Improve performance inde=. ,. Improve efficiency of operations. 9. &educe number of non1conformities in assembly detected during in process I during final testing. -. &educe number of customer complaints o"ing to assembly snags.

Re;o "i=i8ity o7 o77icer" i a""em=8i : "ectio HE!D OF THE DEP!RTMENT OF THE !SSEMBLY

CENTRE FOR MBA, KANNUR UNIVERSITY &!

MACHINE TOOLS Ltd, Kalamassery.

2o1ordinate the activities in the respective assembly areas effectively and efficiently in line "ith the units dispatch and production programme. Maintain discipline and good industrial relations in respective assembly groups. 2o1ordinate the activities in assembly "ith other section li+e design, planning etc. To ensure proper up+eep of assemblies facilities. %ffective leadership in implementation of productivity improvement program. Implement and sustain procedure relating to I($ 9!!1.

CENTRE FOR MBA, KANNUR UNIVERSITY &"

MACHINE TOOLS Ltd, Kalamassery.

P1; 1+nu:+cturing de)+rt1ent

PM% M!NUF!CTURING $#A%2TIL%(


Manufacturing activities is the +ey function of any organi)ation. The main ob/ective of the department is to supply components manufactured based on 3esign and
CENTRE FOR MBA, KANNUR UNIVERSITY &#

MACHINE TOOLS Ltd, Kalamassery.

planning documents and accepted by inspection and Muality control 3epartment to assembly shops at the re*uired time. The manufacturing schedule is governed by the annual production programme and its subse*uent monthly split ups based on the order position and delivery schedule. Manufacturing department in @M3 is divided into 9 parts7 1. Heavy parts. ,. (mall parts. 9. HT2 8Hi1Tech 2entre: (mall parts sections are namely based on the shapes of components they are processing. The sections are &ounds, 'on1 rounds and 2ams, ?ears and &ollers, manufacturing progress. Heavy parts deals "ith processing of heavy components. To maintain orders I discipline in the section. 3o necessary co1ordination "ith other production as "ell as service section for the smooth I harmonious functioning of the section. ?enerate team spirit among employees I supervisory staff I strive for the achievement of company ob/ectives. Initiate disciplinary action "herever re*uired.

CENTRE FOR MBA, KANNUR UNIVERSITY &$

MACHINE TOOLS Ltd, Kalamassery.

P1; +((e1<*7 de)+rt1ent

PM% !SSEMBLY I'T&$342TI$'


.mong the business group of HMT, Machine Tool 3ivision Kalamassery is engaged in producing various types of turning centres, printing machines I cutting machines. .ssembly activity is the +ey function of any organi)ation.
CENTRE FOR MBA, KANNUR UNIVERSITY &%

MACHINE TOOLS Ltd, Kalamassery.

SCOPE
The main function of the department is to assemble the machines based on rolling plan supplied by sales department I to confirm "ith the performance I *uality specified in the design documents. .ssembly department "ill offer assembled machine for in house inspection. It "ill also monitor at different stages of assembly to ensure that *uality product is delivered to the customer. @MK .ssembly is divided into7 1. ?roup .ssembly. ,. @re16inal .ssembly. 9. 6inal .ssembly.

PURPOSE
To assemble the machines as per the rolling plan supplied by sales department. To assemble the machines to meet the design specifications To complete the assembly of machine as per the dispatch plan To evolve systems to ma+e the system fle=ible to adapt to the changes in the sales plan. To improve methods and systems to changing needs of mar+et. To assemble the pre1assemblies, group assemblies, and final assemblies to match "ith assembly dra"ings and specification of the machine. To record the non1conformities and ta+e corrective actions to prevent recurrence of the problem. To interact "ith departments li+e production, design, tool design purchase, sub1contract and sales for continual improvement of the machine. To complete the assembly of machines "ithout any shortcoming and problems for the final assembly inspection.

CENTRE FOR MBA, KANNUR UNIVERSITY &&

MACHINE TOOLS Ltd, Kalamassery.

DEP!RTMENT CH!RT

3 M4PP5

D M4YP5

ONE

ONE

ONE

ONE

ONE

&

1,

P !.ROUP ASSEM =LY

P !.1!,"MOM FINAL ASSEM=LY

P !.1$#"CUTTI > PAINTIN > FINAL ASSEM=LY

P !.PRE ASSEM=LY

P !./ ELECTR ICAL

CENTRE FOR MBA, KANNUR UNIVERSITY &'

MACHINE TOOLS Ltd, Kalamassery.

Pu<*ic re*+tion( de)+rt1ent

PUBLIC REL!TIONS

DEP!RTMENT

P>=8ic re8atio " 8PR: is a field concerned "ith maintaining public image for businesses, non1profit organi)ations or high1profile people, such as celebrities and politicians. .n earlier definition of public relations, by The first 5orld .ssembly of @ublic &elations .ssociations held in Me=ico 2ity in .ugust 19BE, "as 0the art and social science of analy)ing trends, predicting their conse*uences, counseling organi)ational leaders, and implementing planned programs of action, "hich "ill serve both the organi)ation and the public interest.0

CENTRE FOR MBA, KANNUR UNIVERSITY '(

MACHINE TOOLS Ltd, Kalamassery.

$thers define it as the practice of managing communication bet"een an organi)ation and its publics. @ublic relations provides an organi)ation or individual e=posure to their audiences using topics of public interest and ne"s items that provide a third1party endorsement and do not direct payment. $nce common activities include spea+ing at conferences, "or+ing "ith the media, crisis communications and social media engagement, and employee communication. @ublic relations is used to build rapport "ith employees, customers, investors, voters, or the general public. .lmost any organi)ation that has a sta+e in ho" it is portrayed in the public arena employs some level of public relations. There are a number of public relations disciplines falling under the banner of corporate communications, such as analyst relations, media relations, investor relations, internal communications and labor relations.

DEP!RTMENT CH!RT
?M

.?M8H&:

@4#LI2 CENTRE FOR MBA, KANNUR UNIVERSITY &%L.TI$'( '1 $66I2%&

MACHINE TOOLS Ltd, Kalamassery.

$66I2% (4@T.

$66I2% (4@T.

R%&$R $@%&.T$&

&%2%@TI$'

#asically "ith the e=pansion of public relations activities to different types of organisations, the nature of its function have also undergone change. T"enty years ago no public relations practitioner "ould have agreed that communicating "ith its employees is one of the function of public relations department but hardly any practitioner and proffesional today can deny that it is a public relation function. The public relations department should organise press conference at the time of launching a company, ne" product, ne" service and ne" financial year "ith highlights of the acheivements of previous financial year, issue clarification on any controversy regarding company in ne"s papers, manage press coverage of company;s activities from time to time, lobby among govt circles to obtain licenses at the cost of competitors and do liaison "or+ "ith various govt departments to procure faster electricity connections, telephone lines, release of *uotas of ra" materials, etc.

CENTRE FOR MBA, KANNUR UNIVERSITY '

MACHINE TOOLS Ltd, Kalamassery.

#reifly, public relations practitioners "ere loo+ed up on as the .li #aba of the company, "ho should solve all critical problems as and "hen it is confronted by them. The emphasis "as on PManagement by 3riveQ rather than PManagement by $b/ectivesQ. 2oncept of public relations as defined by HMT is P@Q represents performance and P&Q stands for recognition. Hence @& is the art of getting recognition for performance of organi)ation. 6or any big organi)ation it is necessary to have efficient public relations department. The functions of @& department in HMT machines tools limited is as follo"s, (canning ne"spapers every day for information regarding the company or even competitors and it provide a bac+up service to concern departments. This department also has the responsibility of receiving LI@ and arranging other visits including factory visits of students from technical institutions. 2entral registry managers manage the letters and couriers to respective departments. &eception is the frontend of public relations department. 2onference hall is being managed by the @& department. $verall responsibility for all "or+s in public relations and publicity including reception, arranging seminars and conferences of general nature, protocol, photo copying and duplication "or+ liaison "ith media and service li+e tele=, fa=, telephone e=change etc,. This department also conducts some community development activities. @& department has also have the functions of editing, printing and publishing house /ournals in %nglish and Malayalam, releasing advertisements, holding press conference and press releases. Mailing is done by the staff of @&. In mailing they "ill transmit the letter to different departments and also from the departments.

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MACHINE TOOLS Ltd, Kalamassery.

CENTRE FOR MBA, KANNUR UNIVERSITY '"

MACHINE TOOLS Ltd, Kalamassery.

S+:et7 de)+rt1ent

SAFETY DEPARTMENT
HMT MTL is a company "here health and safety, assurance is properly maintained The department "hich helps in maintaining safety has introduced many technical and methodical "ays to reduce the accidents and ha)ards. 6or the safety of employees some statutory tests are made for certain areas such as crane, lift, pressure vessels etc. there are <! fire e=tinguishers placed in several areas for the safety of the "or+ers.

DEP!RTMENT CH!RT

?M

(afety $66I2%&

CENTRE FOR MBA, KANNUR UNIVERSITY '#

MACHINE TOOLS Ltd, Kalamassery.

The main functions include (afety of the organi)ation (afety promotion @revention and precaution of the fire 2hec+ing of the safety instruments 6ire and safety training to the employees Sa7ety mea">re" ta?e 6ire hydrant net"or+ (prin+ler system for spaying "ater in case of fire Insulated sphere and bullets to reduce heat 3eluge system provided for loading and unloading areas of chemical 6ired form process (afety sho"er and eye "ash system are provided 6ire proofing is done T"o generators of 1!!!+" are installed 6irst aid systems are provided 6ire alarm (mo+e detectors 5or+ permit system is practiced @ersonal protective system

HMT HE!LTH !ND S!FETY POLICY The management of HMT Ltd +alamassery is committed to"ards maintaining healthy and safe "or+ing environment for the employees at all levels, "hich along "ith other commitments lead to Total Muality Management, in all spheres of activities.

CENTRE FOR MBA, KANNUR UNIVERSITY '$

MACHINE TOOLS Ltd, Kalamassery.

O=@ecti<e" To create safe and healthy "or+ing environment in the factory and to maintain a"areness among all the employees about health and safe "or+ing habits. Po8icie" The provisions of various enactments "ill be complied "ith for securing health, safety, and desired environmental standards. The health and safety performance of the employees at different levels "ill be revie"ed periodically ad this "ill be ta+en into account for considering career advancement. (afety committees "ill be formed "ith duties and functions defined as stipulated in Kerala factories &ule 19 B. The safety department "ill periodically assess the status of the health and safety measures provided through safety audit and ris+ assessment and implement preventive measures in consultation "ith the safety committees. 'ecessary instructions "ill be given to all contractors and outside agencies entering the premises and they "ill be bound to obey the same for their safety and health. (afety and health a"areness "ill be created by displaying slogans, conducting competitions and training programmes. The safety department "ill ensure purchase, storage and distribution of *uality personal protective e*uipment and insist on the usage of the same by the employees concerned.

Rea"o " 7or > "a7e actio "Jco ditio "

Lac+ of +no"ledge Lac+ of education Lac+ of training @hysical condition @sychological condition 4nhealthy body

CENTRE FOR MBA, KANNUR UNIVERSITY '%

MACHINE TOOLS Ltd, Kalamassery.

I "tr>ctio " 7or t6e Em;8oyee"


(afety is every body;s business. It is every body;s duty to "or+ safety and to do the /ob promptly. &eport promptly and situation affecting the safety of yourself or your fello" employees. %ntering the factory under the influence of li*uors and other into=icants is strictly prohibited. %mployees should +no" the location of the stretchers, first aid bo=, fire e=tinguishers and other such e*uipments. .ll employees should observe and obey all regulatory signs. %very employee, trainee, apprentice and contract laborer etc should consider it as his responsibility to do his part in maintaining good house+eeping at his /ob location. 6irst aid is the immediate and temporary care given to the victim of an accident. 4se the stretcher or trolley if re*uired for ta+ing the casualty to the dispensary immediately. .ir hoses, temporary cables of e=tension etc should not be allo"ed to lie across "al+"ays passages.
Internal vehicles must be driven carefully inside the factory premises and the

speed must not be e=ceeded beyond 1 +mK hr. outside vehicles are not permitted inside the production shop. @ersonal protective e*uipments li+e goggles, gloves, aprons, safety shoes, helmet, safety belt etc supplied by the company must be "orn "hile on duty. .n employee sustaining in/ury on the /ob ho"ever minor it may be, should report it to his supervisor immediately. It should be clearly understood that it is the duty of every employee to protect men, machine and materials of the company. It should be ensured that all contractors labour is complying "ith all regulations, safety codes and safety practices "hile they are "or+ing in the company premises.

CENTRE FOR MBA, KANNUR UNIVERSITY '&

MACHINE TOOLS Ltd, Kalamassery.

.ll dangerous occurrences li+e fire, collapsing of any "all, overturning of cranes etc must be reported by the officer in charge of the section "here it has occurred to the safety department. (afety committees as re*uired under factory rules are constituted in the machine tool, printing machine and foundry divisions. %ach committee is represented by e*ual number of management and employees representatives and meets periodically to discuss the safety matters in the company. %ach employee is re*uested to bring their suggestions to prevent any accident to the committees notice through their representatives. The follo"ing dress code to be follo"ed Long pants and short or full sleeved shirts "ith shirt tails tuc+ed into be used. 'o loose clothing is permitted. Long hair to be tied "ith a piece of cloth or net.

Securit7 de)+rt1ent

CENTRE FOR MBA, KANNUR UNIVERSITY ''

MACHINE TOOLS Ltd, Kalamassery.

SECURITY DEP!RTMENT
(ecurity is one of the important functional aspects of every organi)ation. Its main purpose is to protect the man, material 8ra" material, assembled parts, building and installations: and its assets. This department is direct control of ?eneral Manager. This department consist security officer, (ecurity inspectors and guards 8@ermanent and contract basis:. This department has common lo" on the basis of security standing order and guidelines. 2onfidential matters are handled under direct order of ?eneral manager

DEP!RTMENT CH!RT
?M

2($

(($ CENTRE FOR MBA, KANNUR UNIVERSITY 1((

MACHINE TOOLS Ltd, Kalamassery.

(HI6T IK2 .

(HI6T IK2 #

(HI6T IK2 2

The main function of the security is to protect the company;s property. ?ate pass is provided for all the employees and those "ho enter into the company for various purposes. There are separate gates for man and materials. This department provides patrolling day and night. It is the duty of safety department to flag on the national flag in the morning and flag off in the evening. .t present, 19 permenent staffs are in the department most of them are %= servicemen on contract basis, 9 members are +ept as gate +eepers. The main duty of this department is to chec+ every employee and unrecogni)ed persons are not allo"ed. There are many registers, "hich are maintained in the security department. Material outgoing registers or "hite pass 71 sale of material. ?ate pass 11 The material is sent to other country. ?ate pass ,1 The passing of machinery spare parts "ith in india. Materia8 i comi : re:i"ter

The materials coming into the company are recorded here. The security "ill chec+ *uantity supplier name etc. Too8 re:i"ter Temporary going of material, machinery to different department in the company. This record "ill contain date, time, *uantity etc.

RECORDS M!INT!INED

.ttendance &egister Key &egister


CENTRE FOR MBA, KANNUR UNIVERSITY 1(1

MACHINE TOOLS Ltd, Kalamassery.

3uty &oster .bsents &egister Materials incoming &egister ?ate @ass &egister 85hite 2olor: ?ate @ass &egister 8@in+ 2olor: ?ate @ass 1 &egister 86or inland Materials: ?ate pass , register 8for abroad materials: 2ustomers &egister Lehicle &egister Lisitors @ass &egister 2asual labour &egister Tool &egister $fficers in and out &egister This department aim is to get date for future business from mar+eting department and their data are to be analy)ed and submit it to top management. #efore submitting report they consider the environmental factors for running the business. Its main function is to setup infrastructure facilities for doing business in future.

CENTRE FOR MBA, KANNUR UNIVERSITY 1(

MACHINE TOOLS Ltd, Kalamassery.

F.0d.01s

CENTRE FOR MBA, KANNUR UNIVERSITY 1(!

MACHINE TOOLS Ltd, Kalamassery.

Fi di :"

1. ,. 9. -.
#.

.ll departments are computeri)ed. (pecial training is provided to them. Limited opportunity for /ob rotation. (afety Measures are efficiently used. 5elfare Measures are initiated for employees. @unching card system is used for .ttendance. &esources are not fully utili)ed. Many High technically s+illed and *ualified persons too+ L&(. @romotion is based on the seniority and performance. ?ood "or+ing conditions and "elfare facilities for the employees.

<. B. E. 9.

1!. 3ecision ma+ing is very slo". 11. 2ompany is facing the problem of man po"er shortage. 1,. @resently company is not able to ta+e bul+ orders. 19. Lac+ of professionalism in top level.

CENTRE FOR MBA, KANNUR UNIVERSITY 1("

MACHINE TOOLS Ltd, Kalamassery.

Sugge(tion(

CENTRE FOR MBA, KANNUR UNIVERSITY 1(#

MACHINE TOOLS Ltd, Kalamassery.

S>::e"tio "

1. &eplacement of the e=isting outdated machinery "ith latest. ,. %mployees must motivated by giving promotion and cash incentives. 9. .dopt AIT technology for the effective utili)ation of the resources. -. .void the use of costly machines by trainees and casual labours, this "ill help to reduce scrap and increase the life span of machines. . &ecruit ne" technically s+illed employees. It may be s+illed trainees "ithin the organi)ation or the engineers "ith e=perience from other reputed organi)ation. <. @roper and regular maintenance of plant and machines should be done. B. @rofessional management should be appointed. E. If Kalamassery unit is made as an independent unit, it "ill be more effective. 9. Ta+e effective measures to prevent labour turnover 8s+illed employees:. 1!. Ma+e appropriate changes in the products design and features on the basis of ne" mar+et trends 8mainly printing machines:. 11. Ma=imum utili)ation of available resources.

CENTRE FOR MBA, KANNUR UNIVERSITY 1($

MACHINE TOOLS Ltd, Kalamassery.

S?ot +n+*7(i(

CENTRE FOR MBA, KANNUR UNIVERSITY 1(%

MACHINE TOOLS Ltd, Kalamassery.

S'OT !N!LYSIS STRENGTHS


1. @roducts of HMT are comparatively better in *uality than other Indian manufacturers. ,. 5ell established manufacturing bases 81< manufacturing units and ,, product divisions:. 9. -. . <. B. E. 9. Machines. 11. 6oundry "ith all facilities. (trong technological base. 4nit accredited "ith I($ 9!!! and 9!!1. Highly s+illed professionals and *ualified "or+ force. 3edicated "or+ force. ?ood strength application engineering and tooling. %=tensive mar+eting net"or+. (trong brand e*uity.

1!. 5idest range of machine tools from general purpose lathe to 2'2

'E!%NESS
1. ,. 9.
".

The company "as not able to retain its s+illed employees. The machine of the HMT is high price in the mar+et. Insufficient fund for the company;s e=pansion plan. HMT Kalamassery has to import a lot of valuable ra" material from @olitical interference. $ld plant and machinery. &elatively high average age of employees compared to e=ternal standards. 4nhealthy direct or indirect ratio of employees. Lac+ of young blood in the e=ecution level

outside. . <. B. E. 9.

CENTRE FOR MBA, KANNUR UNIVERSITY 1(&

MACHINE TOOLS Ltd, Kalamassery.

1!. 11.

&ed tappism 3ifficulty in fund mobili)ation.

OPPORTUNITY
1. ,. 9. -. . <. B. HMT can enter in "eb printers mar+et "hich has a good potential. 3iversification of products in the future. 3emand from defense sector. ?ro"th in auto mobile sector. ?ro"ing trend of multinational outsourcing manufactured components from India. .dopt ne" technology for production and mar+eting. %=pectation of increase in %=port.

THRE!TS
1. ,. 9. -. . <. mar+ets. B. E. 9. 6urther liberali)ation leading to huge import. Increasing unhealthy competition. 2ompetition from ne" private firms. High *uality products from technically advanced countries. %ntry of ne" private sectors. Increasing price of steel "hich is a ma/or ra" material. 2ompetition from second hand imported machinery. Increase the cost of production through material cost. @roducts are available at the lo"er price in the domestic and foreign

CENTRE FOR MBA, KANNUR UNIVERSITY 1('

MACHINE TOOLS Ltd, Kalamassery.

Conc*u(ion

CONCLUSION

CENTRE FOR MBA, KANNUR UNIVERSITY 11(

MACHINE TOOLS Ltd, Kalamassery.

?lobali)ation and Liberali)ation has brought us in a competitive environment, "here only the fittest can survive. The success depends upon ho" an organi)ation can cope up "ith changes ta+en place and ho" effectively they can use the organi)ation;s resources so as to achieve an effective output. Management of resources is a vital and central activity in any organi)ation. Management, "hether it is in industry, civil service, defense or in any other discipline is gro"ing comple= day by day. The study conducted at HMT Mac6i e Too8 Ltd. %a8ama""ery helps to understand comple=ity of management functions, apart from class room studies. The study gave an idea about the performance of management functions "hich led to its success. The management, practices gave the real picture of functions li+e planning, organi)ing, staffing, controlling, co coordinating etc. The social responsibility of management, business ethics, strategy, decision ma+ing, organi)ation development techni*ue etc gave the image of professional management. HMT is doing great help to nation by providing very important and essential e*uipment to various industrial concerns.

CENTRE FOR MBA, KANNUR UNIVERSITY 111

MACHINE TOOLS Ltd, Kalamassery.

=i<*iogr+)'7

BIBLIOGR!PHY
Boo?"

CENTRE FOR MBA, KANNUR UNIVERSITY 11

MACHINE TOOLS Ltd, Kalamassery.

Kothari 2 &, 8,!!<:, Research Methodology, 'e" 3elhi7 'e" .ge International @ublishers

4ma (e+aran 8,!!<:, Research Methods For Business:A S ill Building A!!roach, 'e" 3elhi7 Aohn 5iley and sons, Inc.

.s"athappa K8,!! :, Human &esource and @ersonnel Management, 'e" 3elhi7 Tata Mc ?ra" Hill.

Kotler @hilip I Lane Kevin Keller 8,!! :, Mar eting Manage"ent, #$th %dition, 'e" 3elhi7 @rentice Hall of India @vt, Ltd

@andey I M 8,!!9:, Financial Manage"ent, 9th edition, 'e" 3elhi7 Li+as @ublishing House @vt Ltd

'e="ite"

""".machine toolsShmtindia.com """.google.com """."i+ipedia.com """.hmti.com

CENTRE FOR MBA, KANNUR UNIVERSITY 11!