Professional Documents
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1. INTRODUCTION
Automation is the control of machines and processes by independent systems through the use
of various technologies which are based on computer software. Industry implements
automation to increase productivity. Automation of operations may encompass the
automation of a single operation or the automation of an entire factory.
Today’s highly increasing competitiveness over the industry demands high quality and most
consistent products with a competitive price. To address this challenge number of industries
considering various new product designs and integrated manufacturing techniques in parallel
with the use of automated devices.
One of the remarkable and influential moves for getting the solutions of above mentioned
challenge is the industrial automation. The development of technologies made it possible to
introduce industry automation systems into almost all manufacturing fields. Industry
automation of production processes enhances labour efficiency and allows cutting net cost
and improving product quality. Moreover, it extends the equipment service life, saves
consumables and raw materials, and improves production safety as a whole.
Industrial automation utilises various industrial communication devices such as
programmable logic controllers (PLC’s), programmable automatic controllers (PAC’s) which
are used to control the industry. In industries, control strategies use a set of technologies
implemented to achieve the desired result, making automation systems necessary in
industries.
Industrial automation involves usage of advanced control strategies like cascade controls,
modern control hardware devices as PLC’s, sensors and other instruments for sensing the
control variables, signal conditioning equipment to connect the signals to the control devices,
drives and other significant final control devices, standalone computing systems,
communication systems, alarming and HMI (Human Machine Interface) systems.
Industrial automation is the use of various control devices like PAC’s / PLC’s, used to have
control on various operations of an industry without significant intervention from humans and
to provide automatic control performance. In industries, control strategies use a set of
technologies which are implemented to get the desired performance or output, making the
automation system most essential for industries.
Industrial automation improves the rate of production through superior control of production.
It helps to produce bulk by significantly reducing product processing time with better quality.
Therefore, it produces a large number of results.
Integrating several processes in an industry with automated machinery, minimises cycle times
and effort. Due to automation, consistent and reliable product quality can be maintained with
greater automation compliance by adaptively controlling and monitoring industrial processes
at all stages, from the laboratory to the industrial level.
The automation can completely reduce the need to manually check for various process
parameters. Making the use of automation technologies, industrial processes automatically
adjusts process variables to define values using control techniques. The complexity of
operating processes is reduced with industrial automation.
There are many different reasons to automate. Increased productivity is normally the major
reason for many companies desiring a competitive advantage. Automation also offers low
operational variability. Variability is directly related to quality and productivity. Other
reasons to automate include the presence of a hazardous working environment. Some
businesses automate processes in order to reduce production time, increase manufacturing
flexibility, reduce costs, eliminate human error, or make up for a labour shortage.
Although automation can play a major role in increasing productivity and reducing costs in
service industries - as in the example of a retail store that installs bar code scanners in its
checkout lanes - automation is most prevalent in manufacturing industries. In recent years,
the manufacturing field has witnessed the development of major automation alternatives.
Some of these types of automation include:
Numerically controlled (NC) machines are programmed versions of machine tools that
execute operations in sequence on parts or products. Individual machines may have their own
computers for that purpose; such tools are commonly referred to as computerized numerical
controlled (CNC) machines. In other cases, many machines may share the same computer;
these are called direct numerical controlled machines.
Flexible manufacturing systems (FMS) are comprehensive systems that may include
numerically controlled machine tools, robots, and automated material handling systems in the
manufacture of similar products or components using different routings among the machines.
Job Boss Automation is all about creating an automated machine shop with the help of CNC
machines to provide accurate machining solution. The firm is planned to be equipped with
machines such as Horizontal Machining Centre (HMC) and Vertical Turret Lathe (VTL) at
the first phase. To ensure the quality, a Co-ordinate Measuring Machine with is also to be
equipped to maintain the standard of machining at all point of time.
The history of Job Boss Automation starts from late 1980’s, where Mr. Muthukumar started
his own machine shop in the name of Job Boss along with few of his colleagues from
Lakshmi Precision Tools.
The company became one of the pioneers in the area of milling process at conventional
machining with the support and help from his team. Their parent company has been in Joint
Venture with various reputed firms for providing machining solutions on both standard and
non-standard components at greater accuracy and higher quality standards.
Their lists of customers are endless, as they have done various special applications machining
process such as developing various critical valve components, developing fixtures for the
critical components etc..,
They are proud in creating and developing various skilled workers in machining process and
they add more value to our firm by their workmanship.
The Company has now gone bigger step by entering into CNC machining sector and the
execution stages are in process. As a company involved in automation of other company’s
machines and processes they strive to investigate and utilise new or improved technologies
within their own business concern.
To listen to their customers and continually strive to provide perfect service, distribute
quality products and offer technologically advanced solutions.
To treat their employees with dignity and respect and to provide a safe and pleasant
work environment.
To act in partnership with their suppliers as they promote their lines in their
marketplace.
To educate their employees on the application of their products.
To make a fair profit to assure the company’s continued growth and financial
stability.
1.6 VISION OF THE COMPANY
Their vision is to be the market leader in the design, distribution and implementation
of industrial automation systems. They will confront this challenge by developing
innovative marketing, engineering and customer service strategies to meet their
individual customer’s changing needs.
They will accomplish this goal with a well-educated and highly motivated staff that
thrives on personal growth and satisfaction through teamwork & creativity.
They will assure their longevity through well driven defined financially prudent
customer driven planning.
1.7 PRODUCTS :
Dishwashers :
Dishwasher is a machine used for cleaning dishware and cutlery automatically. The
mechanical dishwasher cleans by spraying hot water, typically between 45 and 75 °C
(110 and 170 °F). Job Boss Automation produces dishwashers and sells them at
affordable prices.
CMM Measuring Machine :
Coordinate measuring machine (CMM) is a device that measures the geometry of physical
objects by sensing discrete points on the surface of the object with a probe. Job Boss
manufactures these CMM’s on an order basis.
CNC machines are now benefiting from automation to make more precise parts and are
aiding emerging technologies by producing quicker parts. Job Boss manufactures these CNC
milling devices for the industrial purpose.
Switch Gears :
Job Boss is one the largest manufacturers of low voltage system assemblies. Their range of
custom-built low voltage systems comprises Power Control Centres, Main Distribution
Boards and Control Panels.
CHAPTER - 2
ORGANISATIONAL CHART
Managing Director
(Mr. Karthikeyan)
General Manager
Store Service
Manager Manager
CHAPTER – 3
FUNCTIONAL DEPARTMENTS
Organisations are built about a group of functions, each of which provides support for the
operations of the business. Functional departments each serve a specific purpose with an
organisation to achieve its objectives.
The various functional departments present in Job Boss Automation are as follows :
Finance Department
Marketing and Sales Department
Human Resource Department
Quality Control Department
3.1 PRODUCTION DEPARTMENT
Machinery Level: In this level various sensing and actuating devices controls the
manufacturing process.
Cell or Group Level: This is another automation level at which operation of a group
of machines within manufacturing cells are co-ordinated.
Plant Level: This automation level performs the activities of production monitoring,
control, and scheduling. HMIs employed at this level facilitate to control all the
manufacturing process variables remotely.
The automated production systems can be classified into three basic types:
Fixed automation,
Programmable automation
Flexible automation
Fixed Automation :
It is a system in which the sequence of processing (or assembly) operations is fixed by the
equipment configuration. The operations in the sequence are simple in nature. It is the
integration and coordination of many such operations into one piece of equipment.
The programmed commands are contained in the form of cams, gears, wiring, and other
hardware. Programmed commands are not easily changed over from one product style to
another.
This production method is usually adopted for assembling machines and for certain chemical
processes.
Programmable Automation :
In this the production equipment is designed with the capability to change the sequence of
operations to accommodate different product configurations. The operation sequence is
controlled by a program, which is a set of instructions coded so that the system can read and
interpret them. New programs can be prepared and entered into the equipment to produce
new products.
Automated production systems that are programmable are used in low and medium volume
production. The parts or products are typically made in batches. To produce each new batch
of a different product, the system must be reprogrammed with the set of machine instructions
that correspond to the new product.
There is no need to group identical products into batches; instead, a mixture of different
products can be produced one right after another.
The program is coded in computer memory for each different product style, and the machine
tool is controlled by the computer program.
Flexible automation :
A flexible automated system is one that is capable of producing a variety of products or parts
in a virtual manner. There is no production time lost while reprogramming the system and
altering the physical setup i.e., tooling, fixtures, and machine setting.
The system can produce various combinations and schedules of products instead of requiring
that they be made in separate batches. The reprogramming of the equipment is done in an off-
line manner.
In Job Boss Automation the production is done through an automated production line. The
automated production line consists of a series of workstations connected by a transfer system
to move parts between the stations. Each station is designed to perform a specific processing
operation, so that the part or product is constructed stepwise as it progresses along the line.
Machineries used :
• Supervisory Control and Data Acquisition (SCADA) - operate faster
This department helps in maintaining the required tools , spare parts and materials required
for the production process. The stores manager maintains a systematic record for all these.
The stores department make available a balanced flow of raw materials, components, tools,
equipment and other stores required for operation.
The stores department receive and issue materials after physical inspection and proper
identification. The stores department also does :
Stores accounting
Stock control
Help in standardisation of tools and other components
Notification when stocks are running low
Details of deliveries rejected on inspection
Certification of invoices for quantity and quality
Procurement of items urgently required in case of breakdowns
Listing of obsolete, surplus and scrap materials for disposal
In Job Boss Automation there is a specialised software for noting down all the above
mentioned functions.
3.3 SERVICE DEPARTMENT
Service is an economic activity where an immaterial exchange of values occurs. Job Boss
Automation is involved in after sales service and this service is further divided into two
categories called in-service and out-service.
In in-service the service for damaged products is done within the company itself, here the
customer sector brings their damaged products to the company directly and get their products
serviced. Free services is also been provided by the company in some special cases (warranty
and guarantee).
In out-service , the complaint of each customer is been noted/filed and the expert team from
the company is been sent to the customer’s place and satisfactory service is been provided.
The service engineers from Job Boss Automation does the repair work of the faulty
machineries in the client’s place itself.
3.4 FINANCE DEPARTMENT
The finance department provide accurate bookkeeping and accounting services to the entire
organisation.
The finance department assist the business organisation with essential bookkeeping and by
maintaining systematic records of the daily transactions.
The authorised capital of Job Boss Organisation is Rs.50,00,000 and it’s paid-up capital is
Rs.50,00,000.
BILLING :
The process of sending invoices to the customers for sales or services is known as billing.
The finance department collects the necessary data from the sales department about its
customers and does the billing process. The billing clerk assess the shipping details , verifies
the prices , adds the taxes for the bill that is to be made.
In Job Boss Automation the billing clerk gets the approval from the sales department and the
finance manager once the bill is been drafted. The billing clerk gets the approval of these
authorities.
3.5 MARKETING AND SALES DEPARTMENT
A product is an item that is built or produced to satisfy the needs and wants of the
customer sector. The product can be in the form of services also.
Dishwashers
Tools for machineries
CMM measuring service
Milling works
Switch gears
Low voltage systems
Job Boss Automation ensure to have the right type of product that is in demand. In
Job Boss Automation most of the products are been customised based upon the needs
of the customer groups.
The marketer does an extensive research before providing machining solutions. These
products have a certain lifecycle that includes the growth phase, the maturity phase
and the sales decline phase.
The price of the product is the amount that a customer pays for buying a certain good/
service. Price is also a very important component of a marketing plan as it determines
the firm’s profit and survival. Adjusting the price of the product has a great impact on
the entire marketing strategy as well as greatly affecting the sales and demand for the
products manufactured.
The organisation usually considers the following factors while fixing the price of the
product that is been produced :
Market penetration pricing is a pricing strategy that sets a low initial price for a
product. The goal is to quickly attract new customers based on the low cost. The
strategy is most effective for increasing market share and sales volume.
Neutral pricing :
In neutral pricing , the prices of the products are set by the market forces. The
major benefit of a neutral pricing is that it works in all four stages of a product
lifecycle.
Place is a very important part of the product mix. We have to position and distribute
the product in a place that is accessible for all the buyers. This always comes with a
deep understanding of the target market.
The various promotion tools obtained by Job Boss Automation are as follows :
Event Marketing :
Relationship Marketing :
Direct Marketing :
Marketing channels are channels used by any company to reach their end customers.
These channels are generally interdependent on each other and interact with each
other so as to ensure that the product reaches from the company to the end customer.
The route that the product takes on its way from production to the consumer is
important because a marketer must decide which route or channel is best for their
particular product.
Sales is the activity that involves in providing products and services in return for the money
paid by the customer sector. Sales is also referred to as the act of completion of a commercial
activity.
The main function of a sales department is to effect sales. It is concerned with the transfer of
ownership or merchandise on terms satisfactory to both the buyer and seller. This has to be
done at the lowest possible cost.
The sales team deal with customers and generate orders. The techniques used to generate
sales varies between organisation. Marketing plays a very important role in increasing the
sales of the manufacturing concern. The marketing department generates the target group and
the potential customers list.
In Job Boss Automation the marketing department helps in promoting the products
manufactured by the organisation. The marketing department helps in creating an awareness
about the company’s products to their target audience.
The sales manager sells out the product through agents, wholesalers, and directly to the
customers itself. Sales are made to different parts of the country as well as across different
nations also. These goods are sent either through ships or roadways.
When there is a bulk sale the organisation also provides certain trade discounts to its
customer sector.
3.6 HUMAN RESOURCE DEPARTMENT
The Human Resource department plays a key role in helping companies deal with a fast-
changing environment and the greater demand for quality employees. Human resource
department performs human resource management strategies.
Human resources is the company department charged with finding, screening, recruiting and
training job applicants, and administering employee benefit programs. HR responsibilities
include compensation and benefits, recruitment, firing, and keeping up to date with any laws
that may affect the company and its employees. A HR department helps to maintain a
company's core values and culture.
The workforce is the labour pool in employment. It is generally used to describe those
working for a company.
Working time is the period of time that a person spends at paid labour.
Job Boss Automation works from 9.30am to 6.30pm.
The employees also have overtime duties for which they get paid for from the
organisation.
The employees are permitted to take two paid casual leaves per month and they also
provide certain allowances for those who take sick leave.
The job vacancy is announced by Job Boss through the following sources :
External Recruitment :
Direct Walk – Ins
Newspaper advertisements
Consultancies
Employee Referrals
Job Portals
Internal Recruitment :
Promotions
After the vacancy is announced, the screening process takes place. After the preliminary
screening is done the resumes are reviewed by the officials of the human resource
department.
Then there’s a direct interview for the candidates who are shortlisted. Job Boss Organisation
provides job opportunities on the basis of :
Educational qualification.
Technical knowledge.
Usage of automotive machineries.
Once the interview is conducted the effective candidates are been selected.
The human resource department then issues the offer letter to those candidates who are
selected. The candidates are given a period of 10 days for joining the organisation from the
date of issuing the offer letter.
Employee Welfare :
Labour welfare refers to the efforts made by the employers to improve the working and living
conditions over and above the wages paid to them. In its widest sense it comprises all matters
affecting the health, safety, comfort and general welfare of the workmen, and includes
provision for education, recreation and other schemes.
Canteen facilities.
Restroom facilities.
Uniforms are provided to all the employees who are working there.
At times interest free loans are also been provided by the organisation to its
employees.
Certain medical allowances are also been provided to the employees from the
organisation.
Bonus on special festivals are also been provided to the employees.
3.7 QUALITY CONTROL DEPARTMENT
Quality control is a process by which entities review the quality of all factors involved
in production. Quality control requires the business to create an environment in which
both management and employees strive for perfection.
The key duties for a quality control technician, are to prepare inspection plans and
instructions, select sampling plan applications, analyse and solve problems, prepare
procedures and perform audits.
Quality of the output is usually compared with the standards/benchmarks setup by the
organisation.
Quality control involves testing of units and determining if they are within the
specifications for the final product. The purpose of the testing is to determine any
needs for corrective actions in the manufacturing process. Good quality control helps
companies meet consumer demands for better products.
Collecting the right data is essential to quality control. Inspectors define statistical
techniques, determine what data needs to be collected through inspection or process
monitoring, and analyse results. They interpret the data to identify problems or trends
as a basis for planning remedial action.
Quality control technicians plan corrective and preventive actions to maintain quality
standards.
In Job Boss Automation there are quality control inspectors. These quality control
inspectors inspect the output and tests all the parts of the tool or component.
The quality control department records their inspections through test reports and
submit that to the top level authorities and the production department. Quality control
inspectors weigh or measure finished goods also.
Sorters separate goods according to length, size of the tools and spare parts.
Quality control inspectors rely on a number of tools to do their jobs. Inspectors testing
electrical devices use voltmeters, ammeters, and ohmmeters to test potential difference,
current flow, and resistance of the electrical devices produced in the organisation. Inspectors
in the firms monitor the equipment, review output, and conduct random product checks.
The quality control inspectors have the authority to accept or reject products as necessary.
They usually keep a record of problems they find and may send defective products back for
repair.
CHAPTER – 4
SWOT ANALYSIS
STRENGTHS :
Provides services across more than 5 countries.
Products recognised for innovation and excellence.
Adopts plant wide optimisation technique to achieve productivity and
efficiency.
Has flexible, scalable automation solutions to lower cost to design.
Provides flexible overall solution with higher levels of standards.
WEAKNESSES :
Intense competition in the automation field.
Lesser margins (financial instability can hurt operations).
OPPORTUNITIES :
Research and Development.
Huge Investments by emerging markets in technology and automation.
THREATS :
Rising cost of energy.
Rising cost of raw materials.
Lack of Skilled labour.
CHAPTER – 5
CONCLUSION
This summer internship training at Job Boss Automation helped me learn about the various
functional departments present in the manufacturing concern. It also taught me about the
work culture and gave me an understanding about how to handle the dynamic business
environment.
This internship training helped me acquire knowledge about the automation field. It also gave
me an opportunity to interact with experienced staff members in the organisation and gain
few subjective knowledge from them.
On the whole this internship training was a meaningful experience where I got to know about
the functions and operations of the manufacturing enterprise.