INDUSTRY IMMERSION PROJECT

BATCH 2018 - 20

INDUSTRY PROFILE
2.1 Introduction
India insulated wire and cable market is forecast to grow at a CAGR of 10.3% through 2023,
predominantly on account of growing government investments towards infrastructure
development projects. Development of Smart Cities across the country under Smart Cities
Mission coupled with increasing number of electronic devices per household and
development of manufacturing industries under the ‘Make in India’ initiative, which is
driving demand for power, are expected to boost market demand in the coming years.
Moreover, growing demand for reliable, efficient energy and data communication from rural
areas and tier II and tier III cities and towns would positively influence the country’s
insulated wire and cable market.

India’s wires and cables market has transformed itself, from a small industry majorly
dominated by unorganized players to a large and dynamic sector where organized players
capture 50-55% of market. The industry is mostly volume driven, although it comes with a lot
of technical and quality disturbances. The wire and cable market accounted for 17.5% of the
entire electrical industry in FY’2014, which is expected to double in size over the next five
years. Industry is hugely driven by demand from retail segment, level of investment made by
government. The wires and cables market in India is highly fragmented, with the presence a
number of small and medium enterprises. The organized sector manufactures high voltage
durable and specialty cables, whereas the unorganized sector mainly captures the low voltage
market, where products are mainly differentiated on the basis of price. The intensifying
competition in this industry is expected has put increasing pressures on the various players to
maintain their market shares. The overall wires and cables market in India is expected to grow
at a CAGR of 18.5% during FY’2014 – FY’2019. The GDP generated from construction will
grow at a CAGR of 6.0% during FY’2015 – FY’2019.

2.2 Contribution to economy

2.3 Major Players
The major Players in this industry are,
 Polycab Wires pvt. Ltd.
 Sterlite Technologies Ltd.
INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

 Finolex cables Ltd.

 RR Kabel Ltd.
 Havells India Ltd.

2.4 Industry Statistics

Revenue 40,000Cr
Annual Growth 18.5%
(2014 – 2019)
Employment

2.5 Recent Trends

Green Wires – These wires reduce the loss of current while passing through these wire, where
the resistance of the wire decreases as the diameter of the wire increases. This prevents the
loss of current which intern can reduce the consumption of electricity.

COMPANY PROFILE

3.1 History
3.2 Founder
3.3 Profile
POWER – FLEX an ISO 9001:2008 is a Wires & Cables manufacturing company in India with
a glorious track record of 22 years. Kamadhenu Wires established in 1992, is a leading
manufacturer of wide variety of wires and cables under the brand name POWER – FLEX. From
the inception it has earned itself the reputation as a manufacturer of high-quality wires and
cables. The company takes pride in its ability to go the extra mile for a customer no matter how
big or small the business may be. This has been possible due to the high level of commitment
and dedication shown by its professional and skilled staff coupled with the foresight and vision
of its promoters. Electrical wire and cables are the backbone of any electrical work. Rapid
improvements in technology related to production of wires and cables have led to marked
improvements in production outputs as well as improvement in quality of products.
Kamadhenu Wires has successfully integrated the advances in technology to manufacture
products which have become synonymous with high quality and earned itself the reputation of
INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

a trusted and reliable business partner. POWER – FLEX wires and cables are manufactured at
its state-of-the-art manufacturing facility located in the industrial city of Coimbatore, India.
The systems at the manufacturing facility are certified for ISO – 9001 and the products
manufactured meet the relevant National and International Specifications. POWER – FLEX
has been tested and certified by leading electrical testing laboratories all over the country. It is
testimony to the quality and service standards built into POWER – FLEX that is the preferred
supplier to a large number of OEM’s in different sectors and is approved by leading industries,
project consultants, electrical consultants and architects. We also got CE certification too.

3.4 Vision & Mission

VISSION

We aim to be an important part of the “power of all” vision. We are poised to lead way driven
by a strong set of values, continuous product innovation, value addition and all round corporate
social responsibility that sets us apart from the rest a company, that’s cut out to play a vital role
in tomorrow’s power sector scenario.

MISSION

Our mission is to meet expectation of existing and new customer and improve the response
time, locally and internationally. Provide value for money and to be competitive. Our
competitive edge lies with optimum product design, on time delivery and strives constantly for
the best service to customers. Establish a healthy system for quality assurance and
improvement with emphasis on in-process control. Educate, motive and involve employees in
the fulfilment of quality goals. Quality is the cornerstone of our mission, which means being
customer oriented and committed to excellence and cost-effectiveness.

3.5 PRODUCTS

 FR, FR-LSH, ZHLS &HR PVC

 Single core Power Cable (up to 630 Sq. mm)
 Multicore core Power Cable (up to 24 cores)
 Shielded & Screened cables
INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

 Automobiles Cables
 Armoured Cables
 Submersible pump Flat cables
 Polymer winding wires
 Copper Rounds and Profiles
 Custom made cables

3.6 SWOT ANALYSIS

3.7 FUNCTIONAL DEPARTMENTS

Human Resource
Marketing
Finance
Operations
INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

3.8 FLOW OF INSTRUCTION

PARTNERS

CHIEF
EXECUTIVES

ACCOUNTS HR MANAGER PURCHASE

QUALITY PRODUCTION STORES/ MARKETING

MANAGER MANAGER DISPATCH MANAGER

QUALITY
OPERATORS MAINTENANCE MARKETING
CONTROL
EXECUTIVES
ENGINEER (MECH/ELEC)

HELPERS HOUSE
KEEPING
INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

FUNCTIONAL DEPARTMENTS
FINANCE MANAGEMENT

INTRODUCTION
Finance is one of the basic requirements of all ventures be it personal or professional. Finance
indicates to the monetary resources possessed or borrowed by an company or business venture
to support their functioning.

POWER-FLEX ACCOUNTING
Power-flex wires documents all types of financial activities happening day-to-day and maintain
them up-to-date. From purchase to sales all the activities are recorded using computer
accounting software by designated office accountant team.
Accounts are monitored on regular basis by MD and it is updated regularly by office
accountants. This helps company to keep a track on expenses and hold unnecessary
expenditures.
The company maintains daily expenses using a ledger and all those expenses are carried to
accounting every week by office accountants. All the expenses are recorded using bills after it
is approved by the MD.
The software that they use is TALLY for Accounting and MS EXCEL for recording daily
expenses. At the end of every quarter they file accounts and forward it to the certified
CHARTED ACCOUNTANT (CA) for general adjustments to file returns.
The monthly turnover of power-flex wires is 5 crores (approx.). GST for wires is levied at 18%.
All the GST incurred by the company while sales is completely paid to the Income Tax
Department.

ROLE OF ACCOUNTING DEPARTMENT

The major role of accounting department is responsible for recording the following,

 CASH FLOW TRASNACTIONS

 ACCOUNTS RECEIVABLE
 ACCOUNTS PAYABLE
 PAYROLL
 FINANCIAL REPORT
 FINANCIAL STATUS
INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

MARKETING MANAGEMENT

Marketing is a very necessary activity in any manufacturing industry. It plays a major role in
creating demand and supply. Here, in Power-Flex wires marketing is done by team of marketers
in Bengaluru, Hyderabad and in northern regions like Gujrat, Jodhpur. For govt. projects there
are separate marketing agents who are experienced in marketing.

What do they market?

They suggest their marketers to promote Fire Retardant Low Smoke wires (FRLS) which is
used widely for constructions.

Fire Retardant wires (FR) is commonly used for domestic purposes like individual houses and
commercial buildings.

Zero Halogen Low Smoke wires (ZHLS) is marketed and used in huge projects like apartments,
construction projects, malls, corporate buildings.

How do they do it?

Electrical Consultant is the person who decides the wiring and electricals parts in malls and
commercial buildings and government projects.

He takes the responsibility in choosing quality wires and electrical parts in a building. So, the
marketing executives get in touch with consultants and convince them to buy their products.

If the consultant is satisfied with the price and quality of the wires, he calculates quantity of
wires and what types of wires are needed post which the executives forward the order to
Customer Relations Manager (CRM) and the CRM takes it to production head. For
Government projects is marketed by well-trained marketing executives and on agreement basis
goods are supplied on due date. Price quotation is made in favouring the government projects.

All the types of wires are manufactured under ISO standards except ZHLS wires. It is being
continuously suggested to approve by ISO as it is very useful which is demanded by many
INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

electrical consultants however, it is approved and used by other countries as it doesn’t allow
halogen to catch wire and produces very low smoke.

MARKETING FLOW-CHART

CUSTOMER RELATIONS MANAGER

MARKETING HEAD

B2B EXECUTIVES B2C EXECUTIVES

PROJECTS DISTRIBUTOR

RETAILER

CUSTOMERS
INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

HUMAN RESOURCE MANAGEMENT

WORKING HOURS
The official working hours are from 09.30am to 7.30pm.
Breaks
1.00pm to 2.00pm - Lunch
11.15am to 11.30am & 4.15pm to 4.30pm – Tea Break
Excluding the break, the employees work for an 8:30hrs each day.

LEAVE POLICY
The leave policy of the company varies depending on the levels of management
of the company. The company is off on every Sunday and on all Government holidays.
 Middle level management - They provide monthly 2 days off with pay which accounts
to a total of 24 days off in a year.
 Lower level management - The leave will be permitted on a prior notice and correct
reason is stated.

RECRUITMENT AND SELECTION POLICY

Interview Process
If there is a need for recruitment, the employees are recruited through reference and
advertisement through media. Resumes are collected from the candidates and if the candidate
meet the requirement of the company, then the candidate is called for the interview. Interview
is done as 3 Rounds

 Aptitude Test
 Psychometric Test
 Personal Interview

Aptitude Test
Aptitude and ability tests are designed to assess your logical reasoning or thinking
performance. They consist of multiple-choice questions and are administered under exam
INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

conditions. They are strictly timed and a typical test might allow 30 minutes for 30 or so
questions.
Psychometric test
Psychometric tests are a standard and scientific method used to measure individual’s mental
capabilities and behavioural style. Psychometric tests are designed to measure candidate’s
suitability for a role based on the required personality characteristics and aptitude.
Personal Interview
Interviews usually take place face to face and in person, where the personal attitude and
behaviour of the employee is checked, to suit the company. The final decision of the selection
of employees is taken here by Vice President or the Managing Director.

PROBATION
Any appointment made shall be subject to a probation period of six months. During this
period the work of the employee is noted. After six months the employee is reviewed for his
work and is the work of the employee is satisfied, then he retains in the work. Salary hike is
given after the probation period, depending on the work of the employee.

PLACEMENT AND INDUCTION

All new staff shall undergo induction training to assist them in the process of becoming
integrated to the institution within the shortest time possible. The respective immediate
supervisor in collaboration with the HR Officer shall conduct induction training.

TRAINING AND DEVELOPMENT POLICY

The main objective of any company is to satisfy the customer’s needs. This is done by
delivering the quality product to customer’s on time. The timely delivery of orders to the
customers can be done only if the employees are trained and skilled to perform their work on
time. The newly joint employees are given on the job training for a period of 1-2months
depending on the work assigned to them. They are given training on the safety measures and
on their specific work for a certain period of time to increase their efficiency of work.

PERFORMANCE MANAGEMENT POLICY

The employees are rated based on the efficiency of their work. Every employee’s
performance is noted by the HR manager. The HR manager then report the work of the
employee to the higher-level management for review. Based on the performance of the
employee a salary hike or a promotion or removal of the employee is done.
INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

PROMOTION AND CAREER PLANNING

Promotion is given based on Work, Age and Experience. Work of the employee for the
company should be appreciated and this cannot be only a salary hike it can also be a promotion.
An employee in a same job cannot be paid more than a certain extend. To solve this problem
promotions are given to the workers. Along with promotions the responsibility of the
employees is also increased.

PROBLEMS FACED BY HR
Attrition is the major problem faced by the HR which is the gradual reduction of work
force due to firing of workers, payless experienced, personal health issues or retirement etc.
Workers are important to maintain the continuous production of the company so the HR
manager must select suitable employees who will retain in work for a longer period of time.

OPERATION MANAGEMENT

Copper Bunching

Copper, whose chemical symbol is Cu is one of the most important metal for manufacturing
and related industries. The term Cu has been derived from the Latin word: Cuprum. Copper
has a atomic weight of 29. There are several astonishing properties of copper such as its ductile
nature and resistance to temperature and heat which makes it the ideal element for usage in
mission critical industries and sectors. One of the most important products of copper is copper
wire. Along with tinsel copper wire, this product is the most favoured product of industries and
manufacturing units. In the following article, we will find out more about the manufacturing
process of copper wire and tinsel copper wire.

Step 1: Drawing Process:

In this first step of drawing the copper wire, manufactures take out EC grade continuous cast
copper of minimum 8 mm diameter for kick-start the process of manufacturing the wire. Huge
machines are used for this drawing process to carve different gauge wires.

Step 2: Annealing Process:

INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

Once the drawing out of copper wires is being done, the drawn-out copper wires are put in
electric furnace, usually in a pot for getting it annealed soft wires which can be moulded into
different shape and sizes.

Step 3: Bunching/Stranding Process:

Once the wire has been annealed, it is wound on reels and are accommodated for various
process such as bunching and stranding. With this process, manufacturers can easily get
different shape and sizes of the wire, easily. Once bunching and/or stranding has been done,
the wires are made to pass through nuzzling process for a smooth surface.

Step 4: Tinning Process:

There are basically two processes included for tinning process:

a) Hot dip process:

In this process, the bunched and/or stranded copper wire is made to pass through pickled
tin. The tin is specifically pickled for this unique process. Through this process, tin is
being coated around the wire for best results. Additionally, the wire is also wound on
reels in this process.

b) Electroplating Process:

Generally, there is a separate plant for this process. In this process, there exists a
separate electro plating plant. The hot dipped wire, is made to dip in chemicals inside
this plant. Afterwards, the wire is made to pass through various degrees of electrical
current for the best results.

Step 5: Braiding Process:

The final procedure is the braiding process. In this, the wire is bound on reels and other twisting
machines for the final part. Hence, different copper wires of varied shape and sizes are carved
out for use in industries and manufacturing units.

The machines used for bunching are,

 Kuldip engineering high speed high capacity buncher.

 Kuldip engineering high speed buncher.
INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

 Minimax high speed buncher

 S&S engineering high speed buncher.

Insulation

While choosing electric wires and cables, one must give priority to the quality as a cheap
quality wire may create safety hazards and put many lives at risk. It may cause a fire breakout
if the insulation is of very low quality or may also cause a short circuit. Hence, utmost care
must be exercised while selecting the electric wires and cables.

There are different types of PVC used in my company. The quality of a wire or cable lies in
the quality of the PVC. They produce different types of PVC like FR(Flame Retardant), FRLS
(Flame Retardant Low Smoke halogen), ZHLS (Zero Halogen flame retardant Low Smoke).

FR (Flame Retardant)

Flame Resistant Cable is generally constructed with a PVC outer sheath. It is used for internal
wiring or supply cords in high temperature areas up to 90 ° C. Delta cab is designed to work
also during the fire. The emission of smoke in this situation is free from Corrosive gas and they
have low density to guarantee people safety and protection for equipments.

FRLS (Flame Retardant Low Smoke halogen)

PVC Sheathed Power and Control cables can be hazardous when exposed to fire from an
external source. In addition to the fire spreading rapidly, the black smoke generated lowers
visibility, hindering firefighting and rescue operations. Acidic fumes released from the fire are
corrosive, and can cause damage to sensitive electrical and electronic equipment.

ZHLS (Zero Halogen flame retardant Low Smoke)

ZHLS wires are manufactured using bright electrolytic grade annealed copper which are
bunched together in heavy duty high speed bunchers. Specially formulated Halogen Free Flame
Retardant compound is used to insulate the bunched copper. The insulation and sheath
materials of these cables are composed with polymers on the basis of pure hydrocarbons. The
special polymer has the required physical, electrical and thermal properties. The use of smoke
suppressive chemicals ensures that very little smoke is emitted helping in making evacuation
faster. The absence of chlorine means the non-emission of toxic gases mainly hydrochloric
INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

gases during the fire. The flame-retardant nature of compound retards the spread of fire. All
this ensures a remarkably longer electrical functionality under fire.

Coiling

After manufacturing the wires, the wires will be coiled. The machines used for coiling are

 MDS automatic coiling machines and

 Minimax fully automatic coiling machine.

Testing

After this process the quality of the wires will be checked. In this department, they will check
and test each wires and cables on production. Each and every bobbin they will check and the
quality engineers will pass the material to the next stage. If any wise testing is not passed, they
will reject the material and hold. According ISI Standards, they will maintain all records and
certificates. This department ensures 100 % quality in incoming raw materials as well as
outgoing materials (finished goods). The test reports are also issued to the customers. They use
well advanced machines for testing. They test each and every copper wire over comes its
process. They will check and then only pass to next stage. If the wire fails in any test in any
stage they will not take to next level. They will cancel that production and produce new wires.
Maximum this case will not occur since they have quality raw materials.

Testing methods used in my company are

CONDUCTOR RESISTANCE TEST

Scope To measure the conductor resistance of drawn, bunched or finished cable. Test specimen
Minimum of 1 000 mm of length or the entire drum length. The sample must be in ambient
temperature. Procedure The digital micro Ohm meter is to be kept on for a minimum of half
an hour to warm up the instrument. The required range is selected changing the knob.

The zero adjustment is made by processing zero/operate push button and adjusting the pre-set.

After zero adjustment, the zero/ operate push button is released. The mode of measurement,
pulse/trigger, is selected by pressing / releasing the pulse/trigger pushbutton. The sample to be
INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

measured is connected firmly across the leads. If the trigger mode is selected the trigger button
is pressed for a fraction of a second.

The measured value is recorded. It is advised to start from higher range and come down to the
next lower range. If the lower range is selected the over loading is indicated by blinking of the
display. The measured value is multiplied by the temperature correction factor as indicated in
the table. The actual Resistance is 20 ° C.

HIGH VOLTAGE TEST

Scope

Covers procedure for conducting High Voltage test for single core and multi-Core cables.

Procedure

Switch on the high voltage equipment. Connect the Hi lead of the equipment to the conductor
of the cable / sample to be tested. Connect the LO lead of the equipment to the lead immersed
in the water bath.

Switch on the high voltage by pressing the push button switch. Increase the voltage by slowly
rotating the knob of the variance till the required voltage is reached.

Aller specified time (as per-customer specification or IS specification, slowly reduce the
voltage by rotating the variable knob anti-clockwise till the minimum voltage is reached.

No break down should occur during the test. If the sample fails in test, test/reset lamp glows
and the high voltage trips.

THICKNESS OF INSULATION TEST

Scope

It applies to insulation and sheath.

INDUSTRY IMMERSION PROJECT
BATCH 2018 - 20

Procedure

For core / cable piece: Take 300 mm length of core or cable and measure the diameter over and
below the insulation / sheath at three different points. (At intervals not less than 75mm) along
the length of the specimen using micrometer/Vernier. At each point two measurements shall
be made at right angles. The average of 6 measurements below insulation / sheath shall be
subtracted from the average 6 measurements. over insulation/sheath. The value is divided by 2
to get the thickness of insulation / sheath.

For slice piece: The sliced section of the specimen shall be placed under the travelling
microscope with the plane of the slice perpendicular to the optical axis. Measure the thickness
of the slice at different places starting from the point where it appears to be minimum. The
insulation / sheath thickness is the average of 4 readings. Record the readings.

Packing

After all these processes the goods will be sent for packing. Here Electronic test equipment is
used to create signals and capture responses from electronic Devices Under Test. In this way,
the proper operation of the DUT can be proven or faults in the device can be traced. Use of
electronic test equipment is essential to any serious work on electronics systems.

The wires will be coiled automatically according to the meters we require. If we want 90
meters, when we give the meters, the wires will be coiled automatically and packed.

Dispatch

The last process is dispatch. After all these processes the goods will be dispatched. The
marketing manager will help the company to sell the products in their brand name. He is only
responsible for the dispatch of finished goods.