SRI KRISHNA COLLEGE OF TECHNOLOGY

An Autonomous Institution, (Approved by AICTE and affiliated to Anna

University)
Accredited by NAAC with “A” grade
Coimbatore, Tamil Nadu

SCHOOL OF MANAGEMENT

SUPPLY CHAIN AND LOGISTICS

MANAGEMENT

Industrial Study Report

Submitted By

ASHIKHA E
727821TPMB023
 Rubrics for Supply Chain Field Activity

Accomplished
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All required All required Most of the required Missing

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(5)
detailed and is well-written. uninformative. and/or no
informative abstract.
abstract.

Proper formatting, Proper formatting Some formatting errors Multiple

sections clearly withlabeled or missing sections formatting
Organization(5) labeled,well- sections errorsor missing
organized, sections.
professional style.

All of the Most of the requested Some requested topics Multiple topics
Content: requested topics topics are good in absent or details lacking. lacking or
Supply chain process are covered in gooddetail. insufficient
(Inventory, good detail. details.
Procuremnt,
Designing,
Operation cycle)
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ACKNOWLEDGEMENT LETTER

3
 ABSTRACT
The Field attachment program from which this report is produced is a part of
continuous assessment for the award of Master’s Degree in Management at Sri
Krishna College of Technology, Coimbatore.

This study was conducted at Greens Gears Private Limited which is located at
Coimbatore on 12th May 2022.

The main objective of the study is to completely understand the Production Process
in a Manufacturing sector. Greens Gears is manufacturing wide range of gear boxes
for various applications such as machine building, construction, process industry etc.

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 TABLE OF CONTENTS

S.NO TITLE OF CONTENTS PAGE NO

1 CHAPTER-1
6
COMPANY PROFILE

2 CHAPTER-2
9
PRODUCTION PROCESS

3 CHAPTER-3
16
SUPPLY CHAIN AND LOGISTICS MANAGEMENT

CHAPTER-4
4 26
CONCLUSION

5
 CHAPTER - 1

COMPANY PROFILE

A Gear is a rotating circular machine part having cut teeth or, in the case of a cogwheel or
gearwheel, inserted teeth, which mesh with another toothed part to transmit torque and speed. The
basic principle behind the operation of gears is analogous to the basic principle of levers. In simple
words, Gears can be defined as the machinery in a vehicle that turns engine power into a movement
forwards or backwards.

Gear Box is a contained gear train, or a mechanical unit or component consisting of a series of
integrated gears within a housing. In fact, the name itself defines what it is — a box containing
gears.

Greens Gears Private Limited is an ISO 9001 Certified Company, established in the
year 1991. We have been in the business of manufacturing Industrial Gears and Gearboxes since
our inception almost two decades back with Quality as our prime aspect. Our constant quest for
innovations and extensive research has resulted in our strong design and development capabilities
as well as integration of wide range of products like Industrial Gearboxes.

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ABOUT THE COMPANY

Greens Gears Private Limited formerly known as Greens Technology Corporation was
established in the year 1991 with an aim to manufacture quality gears and its allied products. In
1994, Greens started manufacturing Worm reduction gear boxes with “Greens” as its brand name.
The main principle of greens is to manufacture quality gearboxes and to supply them in time to
have the satisfied customers. With dedicated partners and qualified and skilled workers greens
grow steadily to have the capacity to manufacture worm reduction gearboxes up to 14” Center
distance.

Greens Gears Private Limited also designed and manufactured a lot of custom built gear boxes
with spur, helical, and worm gears as per the customer requirement. With the expansion of its
customer base, Greens also expanded its production capacity by adding new machines and
identified qualified suppliers. A trained and dedicated quality control team has ensured the quality
of the product and timely delivery. It has been regular practice in Greens to adopt the latest trends
and techniques in production and acquire the latest software’s for drawings and inventory control.

Adopting the quality management system is another mile stone in the company’s growth the
company was awarded ISO 9001 Certification in December 2003. The brand name Greens is
registered with Trade mark registry.
The sole motto of Greens will remain as to Supply Quality products on time.

QUALITY POLICY

The quality policy of Greens Gears Private Limitedis to design, manufacture and consistent supply
of standard and customized products on time with international quality level, to satisfy our
customers. They shall continuously attempt to improve our quality, service and delivery through
the implementation of efficient quality management system at all levels.

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QUALITY OBJECTIVES

• To increase delivery performance

• To increase customers satisfaction level
• Reducing Inhouse Non-Conformances

FEAUTURES

• Optimum Design and Robust Construction

• Centrifugally Cast Worm Wheels
• Hardened and Profile Ground Worms
• Custom Built Gear Boxes 1/8
• Ratio 5 to 4900:1

ABOUT THE STUDY

The Main Objective of the study is

i. To have a practical exposure to the industry.
ii. To explore different types of warehousing, supply chain and logistics management in the
industries.
iii. To have a look over various supply chain operations being used in the
industries.
iv. To know about, warehousing of the products is done in industries.
v. To explore the safety measures taken by the industries.
vi. To have a look about present demand in supply chain of the industries.

8
 CHAPTER – 2

PRODUCTION PROCESS
PRODUCTION FLOW

A gear is a rotating machine part having cut teeth, which mesh with another toothed part
to transmit torque. Geared devices can change the speed, torque, and direction of the power source.
Gears almost always produce a change in torque, giving a mechanical advantage through their gear
ratio and can also be considered a simple machine. There are several types of gears, among them
the simplest type of gear is the Spur gear. They consist of a cylinder or disk with teeth projecting
radially. Although the teeth are not straight sided, the edge of each tooth is straight and aligned
parallel to the axis of rotation. These gears mesh together correctly only if fitted to parallel shafts.
No axial thrust is created by the tooth loads. Spur gears are excellent at moderate speeds but tend
to be noisy at high speeds.

IMPORTANCE

Gears are very much important in our day to day life. Clocks, bicycles, automobiles and
heavy duty industrial machines all rely on common gears and without these, we wouldn’t be able
to live the modern, convenient lives we live today. Spur gears are generally seen as best for
applications that require speed reduction and torque multiplication, such as ball mills and crushing
equipment. Examples of high-speed applications that use gears despite their high-level noise
include, consumer appliances such as washing machines and blenders. They are often used in
aircraft engines and trains.

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MACHINING VS NON-TRADITIONAL MACHINING

Contrary to traditional machining, non-traditional machining does not use a cutting tool to
remove material instead uses various forms of thermal, mechanical and chemical energy. Non-
Traditional machining involves high capital cost, complex equipment set-up and skilled labor.
Tooling costs are generally higher for non-traditional machining processes as compared to the
traditional ones. Another limitation of Non-Traditional machining process is that it is not suitable
for every material economically.

PRODUCTION PROCESS :

GATHERING OF RAW MATERIAL:

After the selection of the material, the next step is to gather the raw material from which
the spur gear is to be manufactured. Raw material can be gathered from different manufacturers or
material suppliers.

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CASTING (OPTIONAL):

Casting is a manufacturing process in which a liquid material is usually poured into a mold,
which contains a hollow cavity of the desired shape, and then allowed to solidify. The solidified
part is known as casting, which is ejected or broken out of the mold to complete the process. If the
raw material is not available in cylindrical form, raw material (cast iron) gathered will be casted
in the form of a cylinder.

SAWING:

Sawing is a process wherein a narrow slit is cut into the work piece by a tool consisting of a series
of narrowly spaced teeth, called a saw blade. Sawing is used to cut off is used to separate work

11
parts into two or more pieces or to cut-off unwanted parts. Typically, the materials used for the
making of saw are High Speed Steel (HSS), Carbon Steel, High-speed Edge, and Tungsten Carbide
tipped blades. Carbon Steel was chosen as the material for the saw blades because of its general
utility for a small lot and low cost. The raw material brought from the suppliers will be cut in the
specified number of parts i.e. 100 parts, and sizes with the help of sawing machine. The thickness
of the stock after sawing would be 15mm.

TURNING:

Turning is a cutting operation in which a single point cutting tool removes material from a
rotating workpiece to generate a cylinder. Turning operation is performed on a machine tool called
Lathe. Various types of turning operations can be performed such as Facing, Contour turning,
Chamfering, and Threading. Conventional turning will be applied to the parts, in which the tool is
fed longitudinally at a certain depth of cut to reduce the diameter of the stock. The outer diameter
of the stock after turning would be 60mm.

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POCKET MILLING:

Milling is a machining operation in which the workpiece is fed past a

rotating tool with multiple cutting edges. Cutting tool is called a milling cutter.
Typically, two types of milling operations exist i.e. Face and Peripheral
Milling. In face milling, the cutter axis is perpendicular to the surface being
milled whereas in peripheral milling the cutter axis is parallel to the surface.
Pocket milling is a type of end milling, which is used to create shallow pockets
in flat surfaces. Pocket milling will be used to create shallow circular pockets of 5mm on each face
of the stock leaving a thickness of 5mm.

DRILLING:

Drilling is an operation used to create round holes in work pieces. Cutting tool for drilling
operation is called a drill bit and machining tool is called a drill press. Drill bit comes in various
sizes in order to create holes of different sizes. Two types of drilling holes exist i.e. Through holes
and Blind holes. Through holes are the ones in which drill exists opposite side of the work piece
whereas blind holes are the ones in which the drill doesn’t exit the opposite side of the work piece.
In this project, after pocket milling drilling operation will be used to cut 8 holes of 6mm, 8 holes
of 15mm and 1 hole of 12mm in the center as shown in figure 1.2. All holes will be through holes.

HOBBING:

Hobbing is a machining process for gear cutting, cutting splines, and cutting sprockets on
a hobbing machine. It is a special type of milling machine. The teeth or splines of the gear are
13
progressively cut into the material by a series of cuts made by a cutting tool called a hob. It is the
most widely used gear cutting process for creating spur and helical gears. If a spur gear is being
produced, then the hob is angled equal to the helix angle of the hob, if a helical gear is being
produced then the angle must be increased by the same amount as the helix angle of the helical
gear. Compared to other gear forming processes, hobbing is quick, inexpensive and quite accurate,
thus it is used for a broad range of parts and quantities. After drilling, hobbing operation will be
applied to the stock to generate spur gears with a vertical length of 6mm.

GEAR BROACHING:

Broaching is a machining process that uses a toothed tool, called broach. There are two
types of broaching: linear and rotary. Broaching can be used to generate external as well as internal
gears. In this project we will use gear broaching process to generate internal gear with 34 teeth in
the work pieces after the hobbing process.

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MACHINING:

The most common form of gear machining is cutting metal by tools called hob. The hobbing cutters
rotate and mesh with gear blank like a meshing gear therebygenerating teeth profile on blank.
Other processes like gear shaping, milling, andbroaching also exist. For metal gears in the
transmissions ofcars and trucks, theteeth are heat treated to make them hard and more wear
resistant while leaving the core soft and tough. For large gears that are prone to warp, a quench
press is used.

FINISHING PROCESSES:

Gear-tooth shaving, grinding, honing and lapping is the finishing processes that provide tooth
profile correction, accurate tolerances and surface finish. Gearhoning machines produce teeth to
reduce the surface roughness of the toothprofile. Gears are lapped on gear-lapping machines after
they have undergone heat treatment.

QUALITY CONTROL:

Overall gear geometry is inspected and verified using various methods such as coordinate-
measuring machines, white light scanner or laser scanning. Metal composition is testes at blank
stage. Other tests like teeth skin hardness etc. are done as per requirements. Important dimensional
variations of gears result from variations in the combinations of the dimensions of the tools used
to manufacture them. An important parameter for meshing qualities is backlash. Precision gears
are inspected by a method where meshing gear vibrations are recorded showing variations with a
high resolution as the gear was rotated.

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 CHAPTER – 3

SUPPLY CHAIN AND LOGISTICS MANAGEMENT

Supply chains can be employed to connect data or ideas, link people via communication
systems, or focus on the manufacture of a tangible product. But the end goal of any type of supply
chain is a satisfied customer. In product manufacturing, the supply chain facilitates the transfer
and transformation of raw materials into finished products. From there, the manufacturer transports
and distributes the products to a retailer or directly to a consumer. Customer satisfaction in product
manufacturing rests on creating a high-quality product at a reasonable cost and in the requested
time frame.

Easier said than done, of course, but all successful supply chains develop and constantly
revisit their parameters for making sound decisions on costs, price, quality and speed in every step
of the manufacturing process—from materials and labor to delivery and storage.

It starts with the cost of raw materials. But quality and sourcing matter, too. Materials have
to arrive on time and in the desired quantities to the facility that produces the product. A breakdown
in just one part of the supply chain can bring everything to a grinding halt.

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MANUFACTURING ESSENTIALS: SUPPLIERS AND GOODS

In order to deliver a product to market on time and on budget, you must collaborate with
suppliers. Manufacturing a product in the global marketplace almost always means that raw
materials will have to be moved from one location to another—and that the various components
of an end product will be procured from different suppliers.

If that’s the case, you must consider the size and weight of the items being shipped and the
distance between locations. Then you have to compare shipping times and rates and negotiate for
the best deal.

Fortunately, technological advances make it simple and fast to map out the quickest routes for
drivers, choose the most fuel-efficient delivery vehicles, and maintain precise purchase and order-
processing systems. All of which save time and money.

MANUFACTURING ESSENTIALS: LABOR AND EQUIPMENT

Raw materials are integral to product manufacturing, obviously, but they are far from the
only component. Without labor inputs, you just have a stack of materials—fabric that needs to be
sewn into clothing, wood that’s waiting to be built into furniture, and metal that is useless until it’s
engineered into machinery. Simply put, you need good workers. But while people drive labor, the
manufacturing equipment they use can’t be ignored, either. A supply chain management team
works closely with designers and engineers so that the workers building the products know what
parts and assemblies are available to them and are kept up to date on usage.

The team has to decide when and how to make a capital investment in equipment so that
workers can be safe, effective and efficient in their jobs. In some cases, that could mean owning
the entire distribution system. In others, all services may be contracted out. Your product
manufacturing likely will fall somewhere in the middle.

Finally, product manufacturing—like every other process in the supply chain—involves

plenty of coordination, collaboration and decision-making. A robust organization constantly

17
motivates itself to improve speed, raise quality and lower costs as it turns raw materials into
finished goods ready for use.

SUPPLY CHAIN MODELS

The supply chain involves all of the logistics of producing and selling commercial goods.
It entails the entire process beginning with resource acquisition, then continuing through to product
development and delivery to the vendor. It’s the process by which manufacturers secure the
resources to produce products and how those products are delivered to the point of purchase.
Sustained, quality management of supply chains is necessary for every company to remain
competitive and for the global economy to stay healthy. To properly manage and protect supply
chains, one must be aware of the six different models that can be employed.
Imagine a business as a well-oiled machine: the supply chain would be the oil that keeps it
running.

The Continuous Model

A continuous model is a supply chain built for continued, scheduled delivery of goods.
This model ensures a continued, steady cadence of products and resources. It only exists in an
environment with supply and demand stability, typically with mature supply chains for established
brands, and requires minimal variation in the customer demand profile. PepsiCo is a well-known
example of a continuous supply chain model. The company’s family of drinks and foods maintains
a large customer base with little to no variety in demand no matter the season or market conditions.
PepsiCo has set up the logistics of its delivery system to continuously receive ingredients to
produce its food and beverages, and likewise continuously restock vendors.

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The Fast Model
A fast model is most often used by businesses that manufacture finished products with a
short market lifecycle, making it the most common for the delivery of products considered to be
trendy. This model applies when a business changes its products frequently, delivering them to
market before a trend loses its relevance. One example is Nike. A leader in active-wear fashion,
Nike frequently sets up delivery systems of new supplies and information to create and then sell
new shoes and other apparel before that particular trend’s time has passed. A short time later, the
company will set up a new fast supply chain for the next wave of trendy products.

The Efficient Model

The efficient chain model is best for businesses that are in highly competitive environments
and must strive for high efficiency in their delivery logistics to retain a competitive advantage.
This model prioritizes proper inventory management and maximizing output from production
equipment and labor. General Mills uses an efficient chain model as it develops products relatively
similar to its competitors and sells to the exact same audience as the competition. With tight
competition and thin margins in the breakfast cereal market, General Mills knows that a lot of its
profit will be found in reducing costs along the supply chain while ensuring vendors can keep their
products in stock.

The Agile Model

There are four components a supply chain must have to be considered an agile model:
virtual integration, process alignment, a network base and market sensitivity. Virtual integration
requires the business to track market demand changes in real time. Process alignment is about
sharing supply chain responsibilities across the business. This is achieved by keeping a co-
managed inventory, utilizing collaborative product design and running all parts of the supply chain
in sync with each other. Network-based means that an equal contribution is made by every actor
in the supply chain. The market sensitivity component changes the rate of production immediately
with any changes in demand. This model is a great fit for businesses that exist in markets with a
high degree of demand variation. Such is the case for fashion company ZARA. ZARA exhibits
agility by keeping its designers vigilant in the spotting of new trends. As soon as ZARA’s designers
identify a potential trend, they immediately draw up sketches and order new materials.
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The Custom-Configured Model
Essentially, a combination of the agile and continuous flow models, a custom-configured
model is ideal in scenarios where multiple product configurations are required. Whenever there
are consumer customization options, it’s likely that a custom-configured model is in use. This can
be seen in a company like L.L. Bean, which invites customers to customize their backpacks before
placing an order. The market for backpacks stays pretty consistent, aside from the demand spike
in the late summer, but L.L. Bean has to be prepared for when one feature of customization
becomes particularly more or less popular.

The Flexible Model

The flexible model provides businesses the ability to meet peaks of high demand as well
as long periods where demand is low. There are three components a supply chain must have to be
considered a flexible model: part segmentation, accurate stocking algorithms and flexible
planning. This is ensured through diversifying suppliers and incorporating automation on factory
floors. Staples’ paper and writing utensil products are produced and delivered via a flexible supply
chain. Staples anticipates high demand during back-to-school season and stocks its stores with
excess notebooks, paper, pens, pencils, rulers and other school supplies. The company also must
ensure that it has some stock, albeit less, of those products year-round. This is achieved through
flexibility: having multiple suppliers, many of whom are on seasonal contracts, and perfecting the
stocking algorithm so that the company produces only what will be sold in the offseason.

WAREHOUSING
A warehouse is a building that stores products for stocking, packing, and shipping preparation.
Warehouses are central locations that manage both inbound and outbound products. Maintaining
a warehouse is crucial for any business that sells physical goods or receives products from a
wholesale marketplace.

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WAREHOUSE OPERATIONS

A customized storage building, a warehouse enables a business to stockpile goods, e.g., to

build up a full load prior to transport, or hold unloaded goods before further distribution, or store
goods like wine and cheese that require maturation. As a place for storage, the warehouse has to
be secure, convenient, and as spacious as possible, according to the owner's resources, the site and
contemporary building technology. Before mechanized technology developed, warehouse
functions relied on human labor, using mechanical lifting aids like pulley systems.

Breaking it down, warehouse operations cover a number of important areas, from the receiving,
organization, fulfillment, and distribution processes. These areas include:

• Receiving of goods
• Cross-docking of goods
• Organizing and storing inventory
• Attaching asset tracking solutions (like barcodes) to assets and inventory
• Integrating and maintaining a tracking software, like a warehouse management
system
• Overseeing the integration of new technology
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 • Selecting picking routes
• Establishing sorting and packing practices
• Maintaining the warehouse facility
• Developing racking designs and warehouse infrastructure.

STORAGE AND SHIPPING SYSTEMS

Some of the most common warehouse storage systems are:

• Pallet racking including selective, drive-in, drive-thru, double-deep, pushback, and

gravity flow
• Cantilever racking uses arms, rather than pallets, to store long thin objects like
timber.
• Mezzanine adds a semi-permanent story of storage within a warehouse[35]

• Vertical Lift Modules are packed systems with vertically arranged trays stored on
both sides of the unit.
• Horizontal Carousels consist of a frame and a rotating carriage of bins.
• Vertical Carousels consisting of a series of carriers mounted on a vertical closed-
loop track, inside a metal enclosure.

A "piece pick" is a type of order selection process where a product is picked and handled
in individual units and placed in an outer carton, tote or another container before shipping. Catalog

22
companies and internet retailers are examples of predominantly piece-pick operations. Their
customers rarely order in pallet or case quantities; instead, they typically order just one or two
pieces of one or two items. Several elements make up the piece-pick system. They include the
order, the picker, the pick module, the pick area, handling equipment, the container, the pick
method used and the information technology used. Every movement inside a warehouse must be
accompanied by a work order. Warehouse operation can fail when workers move goods without
work orders, or when a storage position is left unregistered in the system.

One of the most important factor to be considered while designing a warehouse storage
plan is the Product Volume. The Products which has high demand and the ones that has to reach
the customer or the next workstation in a short span of time has to be kept in places like low storage
racks or even near primary aisles, which greatly minimizes the distance to be moved and thus the
time consumed. Opposingly, the less frequent moved products can be placed somewhere distant
from the primary aisles or even the higher storage racks.

Material direction and tracking in a warehouse can be coordinated by a Warehouse

Management System (WMS), a database driven computer program. The development of work
procedures goes hard in hand with training warehouse personnel. Most firms implement a WMS
to standardize work procedure and encourage best practice. These systems facilitate management
in their daily planning, organizing, staffing, directing, and controlling the utilization of available
resources, to move and store materials into, within, and out of a warehouse, while supporting staff
in the performance of material movement and storage in and around a
warehouse. Logistics personnel use the WMS to improve warehouse efficiency by directing
pathways and to maintain accurate inventory by recording warehouse transactions.

SAFETY IN WAREHOUSE

Warehousing has unique health and safety challenges and has been recognized by
the National Institute for Occupational Safety and Health (NIOSH) as a priority industry sector in
the National Occupational Research Agenda (NORA) to identify and provide intervention
strategies regarding occupational health and safety issues. Creating a safe and productive
warehouse setting starts with a culture of safety. This culture should be reinforced by the managers
at all levels, especially executives and owners. Creating a safe working environment begins with

23
a safety plan that covers all parts of the warehouse and applies to all employees. Owners and
managers should expect to put resources of time and money toward safety and willingly build these
costs into the overall budget.

Employers should always remember that safe employees are more productive and more
likely to remain loyal to the company. If employers take care of their employees, their employees
will take care of their jobs. Signs and stickers are the most cost-effective and functional way of
keeping your warehouse organized and safe from hazardous situations.

Regular training and inspections should be done to ensure that all employees are knowledgeable
in fire safety processes and that all fire safety measures are in place and functioning as required.

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LEARNING OUTCOME
The Major outcome of the study is
i. Had a practical exposure to the industry.
ii. Got a chance explore different types of warehousing, supply chain and logistics
management in the industries.
iii. Had an opportunity to have a look over various supply chain operations being
used in the industries.
iv. Got to know about, how warehousing of the products is done in industries.
v. Explored about the safety measures taken by the industries.
vi. Known about present demand in supply chain of the industries.

SUGGESTIONS & RECOMMENDATIONS

The company has not yet implemented any kind of Automation and Digitization. When I
enquired about that, their response was that automation can be implemented if the company is
running as a continuous production system. Since it produces variety of Gears, they cant
implement neither Robotics nor IoT Activated devices. But in long run, its better to control all the
machines and production unit using IoT devices and storage of customer and supplier data using
Cloud Based systems for future Perusals.

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 CHAPTER 4

CONCLUSION
Greens Gears Private Limited also designed and manufactured a lot of Worm
Gearbox, Helical Gearbox, Mechanical Gearbox, Worm Wheel Gear Set and more as
per the customer requirement. With the expansion of its customer base, Greens also
expanded its production capacity by adding new machines and identified qualified
suppliers. A trained and dedicated quality control team has ensured the quality of the
product and timely delivery. It has been regular practice in Greens to adopt the latest
trends and techniques in production and acquire the latest software’s for drawings and
inventory control. Adopting the quality management system is another mile stone in the
company’s growth the company was awarded ISO 9001:2008 Certification in December
2003. The brand name Greens is registered with Trade mark registry.

"The sole motto of Greens will remain as to Supply Quality products"

With well over two decades, They have earned a good reputation over 1,500 clients with 35,000
trouble free running units in India and abroad. With the best-of-breed manufacturing amenities,
They cater products to all major industries including:

• Sugar Mills
• Paper Mills
• Rice Mills
• Cement Plants
• Tea Plants
• Plastic Industry
• Material Handling
• Textile Industry and
• Special Purpose Machine

26
PHOTOGRAPHS

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