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Organizational Study Report
Organizational Study Report
INTRODUCTION
1
INTRODUCTION OF THE STUDY
In the modern world of tough competition and rivalry among the companies it
has
become necessary that one should be able to understand each and every aspect of the
functioning of the organization than only concentrating on his work alone. So in
order to
make students aware of the overall working of the organization the university as
well as
the institution has made it mandatory to conduct a detailed study into the working
of an
organization and also to submit a report at the end of the study.
Since the industrial revolution in the early 18th century, the world has
witnessed a
significant growth in the field of infrastructure, industry and allied activities.
In India
after the globalization in 1993, the foreign counterparts started coming to India
and the
need for doing project was realized and now it has become an important component of
economic development. Projects are defined as an economic activity with well
defined
objectives and having a specific beginning and end. The engineering industry is one
of
the second largest components of India‟s manufacturing sector over the year. This
particular sector has registered an average growth of 16% during the last two
decades. It
includes production of the electronic gadgets and machines and drives to run those
machines.
2
To study about the general aspects of organisation.
3
CHAPTER – 2
PROFILE OF INDUSTRY
4
INDUSTRY PROFILE
The United States will remain the largest purchaser over the next 5 years
but
China will experience the largest growth rate. Large investments will be made in a
wide
range & applications from Semiconductor ultra pure water to boiler feed water.
China
will build nearly half of the world‟s new coal-fired plants in the next five years.
All major pump types will experience growth over next 5 years. Demand share
for
different types of pump is given below:
5
The Indian Pump industry has more than 500 manufacturers with worker
strength
of over 30,000 producing about 1.2 million pumps. Indian market for pump is
estimated
to be Rs.25000 million growing at an annual rate of 8%.
6
What are the drivers of pump development?
Mixing: Two or more streams can be connected at the suction of pump & mixing
can be achieved.
7
Injecting: High pressure can be developed by using pump and fluid can be
injected in pipe or tank.
Metering: Pumps can be used as metering device.
Pressure Reducing Device: Rotary pumps can be used for reducing the pressure
in
polymers.
Agitator Pump: Submersible pump keep the solids in suspension & prevent
setting.
Vacuum Generation: Liquid ring vacuum pumps are well known. Dry vacuum
pumps are also developed.
Reactor: When two liquids are to be reacted with very small residence time
then
pump can be used.
Cavitation Reactor: When one liquid and another in vapor form are to be
reacted, the principle of cavitation can be used.
Pumps consume about 30% total power. Pump is an item which will consume more
energy throughout its life if it is not energy efficient. Hence, it is necessary to
improve on
energy efficiency of the pump. Even for small Kw rating it is essential to have
high
8
Energy efficiency because in future, we will likely to use solar energy where pump
efficiency plays vital role.
Manufacturers should arrange training programs for user & consulting engineers.
Manufacturers to ensure “PASS”. (Prompt After Sales Service)
IPMA (Indian Pump Manufacturers Association) should
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CHAPTER - 3
COMPANY PROFILE
10
PROFILE OF THE COMPANY
Vision
To manufacture:
Cost effective value engineering pumps with great quality and provide best customer
service.
To make:
Mission
11
QUALITY POLICY
QUALITY OBJECTIVE
2. Timely delivery.
4. Safety in operation.
Goal
12
INFRASTRUCTURE
The company has a built up area of 4500sq.mts mostly roofed by concrete and
another 10,000 sqmts are used for stocking and parking. Apart from this a land
measuring
about 2.5 hectares is available in the vicinity of the company for future expansion
and
diversification. The company has the unique distinction of constructing a huge pump
for
rain harvesting, the first of its kind in India before anybody could think of rain
harvesting. Assembling arena, conference hall, guest rooms, canteen, TV room and
dormitory are other facilities available in the premises. Trees are planted in the
factory to
have an echo friendly atmosphere. A large testing bench to test pump sets up to
50HP has
been constructed. Modern methods are used for stocking and handling and even the
raw
materials are stored in the stock yard through the palletts. This has helped the
industry to
have an elegant look apart from making the handling easy. The present net worth of
the
company will be around Rs. 600 millions.
The company is installed with all modern and precise machineries required to
manufacture the pumps in high caliber. Most of the works are done in the factor
itself by
using CNC machines. Special purpose machines are used to do jobs of intricate
nature.
Utmost care is taken in the planning stage itself to keep the rejection at the
lowest level
and also to get the job done in minimum time with less effort. Computers are
installed at
every stage to monitor the processes. Generators of adequate capacity are installed
for
uninterrupted power supply. Instruments of high accuracy are used along with
standard
gauges for inspection. Efficient engineers are provided at each level to monitor
and also
to contribute their knowledge for continuous improvement. Testing benches more than
the required are installed for taking care of each and every pump set for its
performance
and longevity.
PRODUCT RANGE:
13
Submersible pumps for bore wells of different sizes ranging from 100mm to
250mm and above. The capacity range of these pumps falls between 0.5 and 2HP
for single phase operations and 3 to 120HP in the three-phase category.
Easily rewindable motor with low friction carbon bearings. Hydraulically
balanced design of impeller ensures long life. Motor designed to withstand wide
voltage fluctuations and operate with high efficiency to minimize the power
consumption, proper selection of advanced engineering materials ensures long
life
and trouble free service. Multi stage pump directly mounted on the motor is
designed for maximum efficiency and low power consumption, Control Panel is
microprocessor based and has built in probe less dry run preventer, over load
protection, water level controller and status indicator.
Open well submersible pumps with capacity range from 3 to 120 HP In the three
phase category is a product with immense popularity for its ease of handling,
high
discharge and trouble free operation especially in the agricultural
sector.Ideal
features are No rigid base plate or bed required. No suction pipe & foot valve
required. No need of pump room. Winding cooled by water and designed to
withstand high. Voltage Fluctuation. Journal bearings lubricated and cooled by
water and needs. No external maintenance. Motor light in weight and can be
easily handled. Noiseless Operation
Amphibian monoblock pumps that can work inside and outside water and hence
can be applied for Critical applications like in well bores, filter point, bore
wells,
dewatering pumps and as a flame proof pump sets.Ideal features are Pressurised
water from the pumping main in used as coolant for the windings. So power loss
due to external fan on the motor shaft is saved. No rigid base plate is
required.
Can be used to pump water from inwell bores and filter point bores. No suction
pipe & foot valve required. No need of pump room. Journal bearings lubricated
and cooled by water and needs no external maintenance.
Centrifugal monoblock pumps For pumping water from wells, rivers & ect., huge
volumes (up to 3600 LPM) . For agricultural irrigation, industrial water supply
&
ect.Ideal features are Totally Enclosed Fan cooled the motor with IP 55
protection. Monoblock construction eliminates misalignments & couplings.
14
Ceramic & Carbon mechanical seal prevents. Maintenance of stuffing box.
Windings designed to withstand wide voltage fluctuations
Induction motor :Prime mover for pumps, compressors, machine tools & ect.
Ideal features are Designed for high over load carrying capacity and withstand
wide voltage fluctuations. Heavy size of bearings ensures long life. Ample size
of
terminal boxes with provision for 90° rotation. Energy efficient with higher
frame
sizes available request.
Domestic open well pumps For pumping out water from shallow wells, Sumps for
houses, factories, gardens and commercial buildings.Ideal features are No rigid
base plate or bed required. No suction pipe & foot valve required. No need of
pump room. Winding cooled by water and designed to withstand high Voltage
fluctuation. Journal bearings lubricated and cooled by water and needs no
external
maintenance. Motor light in weight and can be easily handled. Noiseless
Operation.
Jet pumps For pumping water from 100mm & above bore wells, open wells.
Single phase control panel Suitable for operating submersible pumps with built
in
running and starting capacitors for running the motor.Ideal features are Wide
voltage operating range 130 – 250 Volts. Built in electronic instant over load
protection for total safety. Probe less dry run protection. Built in water
level
control. Status Indicators. Itching switch for staring capacitors.
D.O.L control panel Suitable for operating submersible pumps with built in
running and starting capacitors for running the motor.Ideal features are Total
Protection for submersible pumps. Suitable sized three phase contactors make
(BCH / L&T). Electronic over load protection and current sensing single phasing
preventor Ensures total protection for the pumpsets. Auto start facility when
three
phase current not available. Phase Reversal Protection. Probe less dry run
preventor protects your pump from burn out due to dry running. Status
indicators
indicates the availability of power, if pump is running or stopped due to
overload,
single phasing, dry running or phase reversal. Auto start when three phase
current
available and programmable time delay start and stop facility.
15
Star delta panel Total operating and protection device for submersible
pumps.Ideal features are Total Protection for submersible pumps. Suitable
sized
three phase contactors make (BCH / L&T). Electronic over load protection and
current sensing single phasing preventor Ensures total protection for the
pumpsets. Auto start facility when three phase current not available. Phase
Reversal Protection. Probe less dry run preventor protects your pump from
burn
out due to dry running. Status indicators indicates the availability of
power, if
pump is running or stopped due to overload, single phasing, dry running or
phase
reversal. Auto start when three phase current available and programmable
time
delay start and stop facility.
COMPETITORS
Texmo Industries
Deccan pumps
C R I pumps
Suguna motors & pumps
Indus pumps
Mahendra pump
16
CHAPTER - 4
DEPARTMENTAL STUDY
17
ORGANIZATIONAL STRUCTURE
M.D
G.M
Assembly
in charge MRS assistant
Winding in
charge
Store keeper
(process store)
Packaging
in charge
Store keeper
Painting in (component
charge store)
18
VARIOUS DEPARTMENTS
The various departments in this organization is as follows:
Purchase Department
Stores Department
Production Department
Finance Department
Marketing Department
Quality Control Department
Human Resource Department
PURCHASE DEPARTMENT
Critical components are evaluated using ABC Analysis based on total value.
19
Items are supplied and approved after vendor rating is done and recorded.
schedule and price. For each parameter 10 points are allocated and rated for
individual vendor.
20
THE ORGANIZATION CHART OF PURCHASE DEPARTMENT
Purchase
Manager
Asst. Purchase
Manager
Manager Manager
(Issue) (Receive)
Foreman Foreman
Foreman Foreman
21
STORES DEPARTMENT
STORES INWARDS
The material inward and receiving inspection holds the name of the material
received, vendor details, the purchase order placed, purchase document details. The
Quality Inspection is carried out by the quality engineers and assures the quality
of the
material received. The items found to be defective are sent back.
On the tested ok by the QC engineers, the materials are accepted into stores
and
suitably stored for issue. The materials inward and receiving inspection report is
duly
filed and retained by the stores personnel as a document for future reference.
If the materials are found to be defective, the received materials are sent
back to
the vendor. Rejection goods report is generated by the stores in charge and the
same is
forwarded to purchase department.
Receipt Of Materials
Material Inward And Receiving Inspection
Inspection
Storing Of Materials/Purchase Return And Rejection Goods
Report
22
STORES ISSUE
The production, service and machine shop makes a request entry in the system
to
procure the materials required from stores. The physical stock available in the
stores at
the time of requisition is made known to the requestor so as to decide the quantity
requested. On generation of the request a person physically moves to the stores to
collects
the requests made.
The stores personnel view the request in his system and issue the material
and
data punches the quantity issued as a mark issued. The stocks are immediately
reduced
from the stores by the quantity issued. In the event of nonavailability or shortage
of
materials, the stores personnel indicate the same to the purchase department for
procurement.
The stores personnel are aided with the above reports so as to verify
himself the
correctness of the physical stock at his disposal. The purchase manager also views
the
reports at any given time and plans for regular procurements of those materials
which
have come down the re-order level.
Stores Inwards
Stores Issue
Material Below Rol
The purpose of stores department is to store the raw materials which are
needed
for the various departments in the organization. It is collected with the help of
Purchase
Requisition Slip and the materials are given to the departments according to the
necessity.
23
The materials which are given to the department is lessened from the stores and it
is
recorded. The raw materials are collected and stored in the store room. A minimum
quantity is kept in the stores.
24
THE ORGANIZATION CHART OF STORES DEPARTMENT
Stores Manager
Asst. store
Manager
Store keeper
Store keeper
(component MRS Assistant
(process store)
store)
PRODUCTION DEPARTMENT
The production of the components are carried out using both CNC and lathe
machines. The CNC machines are imported from Korea and are used in case of mass
production and Lathe machines are obtained from Kirloskar. Two CNC machines are
operating in the main unit, one with single spindle and the other double spindled.
In case
of double spindled CNC machine, two separate processes are carried out and two
separate
monitors are there to control them. Auto door function is also there in double
spindled
CNC machine.
25
PRODUCTION IN-PROCESS
Production Planning: This includes acquiring the raw materials from the
stores
department according to the order received from the sales department.
Quality Control: The raw materials should be in good quality as per the
standards set by the company, otherwise the products turned to be poor
quality.
Therefore the raw materials should be undergone the quality control process.
Acquisition And Issue Of Materials : The issue of materials after checking
is
given to the department for the production process
Production: The production process is continued with various steps. They are
as
follows:
Pressing
Welding
Winding
Fitting
Painting
Stocking of Finished Goods: The finished goods are stocked in order to meet
the
orders from the customers and suppliers.
ASSEMBLY PROCESS
The schedule is prepared according to the order. The stocks of the finished
product, store stocks and machined components are taken into account. Based on
the
schedule, production log book entry is done by the production engineer. Pump
assembly details work instructions are also included in the production log book
entry.
26
The pump and motor are assembled based on procedures. The fitter ensures the
perfect functioning of the product. Pump serial No. is generated by the welder
at the
initial process. Then it goes for final inspection
Production Schedule
Pump Assembly Details Work Instructions
Production Log Book Entry
Assembly Of Pump/Motor
Final Inspection
27
PRODUCTION PROCESS
PRODUCTION
PLANNING
QUALITY
CONTROL
ACQUISITION AND
ISSUE OF RAW
MATERIALS
PRODUCTION
PROCESS
PRESSING
WELDING
WINDING
FITTING
PAINTING
TESTING
STOCK OF FINISHED
GOODS
28
THE ORGANIZATION CHART OF PRODUCTION DEPARTMENT
Production
engineer
Machine shop
Winding in in charge & Painting in Packing in
Maintenance
charge assembly in charge charge
in charge
charge
FINANCE DEPARTMENT
The transactions are also accounted as per law in force Sales Tax, Income
Tax,
Central Excise Duty, Tax Deducted at Source and service tax etc. Training will be
provided in computers and accounting packages for the new comers and existing
employees whenever required. Accounts department is also responsible for
maintaining
good relationship with the dealers, customers, suppliers, Government bodies and
public
etc.
29
During the mid‟s the company policies such as dealership policy and
distribution
policy was very attractive, so the dealers were able to easily get done their needs
from the
company so as to cater their customers. The company realized the competitive
markets as
no submersible are in the field. Inorder to cater their dealers and customers the
company
has amended its policy so as to strengthen their services such as timely delivery,
zero
stock at dealer point, twelve hours clearance of serviced warranty and after
warranty
pumpsets. This effectiveness they have achieved by adopting the modern
administrative
tool ISO. Since accredited as an ISO company in the year 2000, the company‟s growth
is
remarkable as the staff, worker and as the whole company itself is driven to the
ISO
system
30
ORGANIZATIONAL CHART OF FINANCE DEPARTMENT
Joint Managing
Director
Administrative
Officer
Manager
Accounts
Auditor
Data Entry
Clerk
31
MARKETING DEPARTMENT
GEECO have a wide dealer network spread all over the country. They are
trained
to provide technical assistance to select suitable pumps to meet the requirements
of
customers. Apart from the umpteen private customers all over the country, they have
regular patronage from various Governments. The main customer is Crompton greaves
The amount for the pumpsets ranges from Rs. 2500 to Rs. 1.5 lakhs. Their
sales
for one month are more than 100 pumpsets. They give 1 year warranty period. Their
main
attraction is the First ISI mark holder in India and First Launcher in Open
Submersible
Pumps.
The companies have only 35 dealers all over India. There will be All India
Dealers Meet and State Dealers Meet for the dealers conducted in each year. The
meet
includes taining, fixing targets, prizes for achieving the target and entertainment
also.
Prizes will be Gold coins and Cash prizes.
32
Max – Rs.1 crore per annum
Marketing
Director
Marketing
Manager
Business
Development Sales Manager
Manager
Sales Executives
33
Feedback Planning
Feedback
Analysis
Feedback Analysis Report
Products are produced according to the right standard as specified by the ISO
Standards.
The quality control takes place in a sequence which is as follows:
Inprocess Inspection: It is conducted during the process itself because this can
lessen
the wastage of the products due to fault or damage. A record is maintained for this
inspection which includes description, operation, quality inspected, quality
rejected
etc…. In every 10 piece the quality of 1 piece is checked.
Inspection approval Card: This is the inspection which is made for the materials
which
have bought from outside like bolts, nuts, bushes, sleeves etc……..
Inprocess Material for Scrap: In this process the rejected materials which are off
less
standard or quality are tested whether it can be reused after reprocessing. The
record is
kept for this also which includes the reason for rejection, quantity rejected,
whether it can
be reprocessed or not.
Quality Control Department also does the Machine Maintenance. The machine
maintenance is recorded on the following basis:
Daily Maintenance: Oiling the machine, pressure maintenance in the machine, air-
condition temperature, applying grease, lubrication of supply system etc…
34
Fortnight Maintenance: Clean air conditioner filters, change coolant water, check
belt
tension etc.
Major faults, sudden accidents, break down which happens in the organization
are
recorded with detail description, reasons, defaults and it is analysed in detail
for further
avoidance of such happenings in the company.
In each stage of the process, quality is checked then it goes to the next
stage so
that damages are much less.
Quality Manager
Quality
Inspector
Foreman Foreman
35
HUMAN RESOURCE DEPARTMENT
The human resource department in the company can be divided into three:
Training
Recruitment
The GEECO pump on the whole consists of 240 workers, 42 staff and in the
managerial level there are 4 senior managers. The workers are both in the contract
basis
and permanent workers. In 240 workers, 120 are contract basis and 120 are company
workers.
Again 240 workers can be classified into skilled, semi skilled, unskilled
workers.
Skilled – 80
Semi skilled – 120
Unskilled – 40
The company workers get incentives for not being absent and overtime. The
staff
apart from this gets festival bonus annually and 15 days paid up leave for 1 year
and they
can encash the leave too. In workers there are 230 men and 10 women and in the case
of
staff there are 31 men and 11 women.
Training
The training manager assesses the need for training with the help of
documented
reports and if he finds necessary, arranges for the training with the confirmation
of the
MD. The suitable faculty handles the class to impart the necessary training.
External
training conducted by reputated institutions, is also attended by the staff on the
approval
of the MD, recommended by manager
The feedback of the training is obtained from the trainee detailing the
faculties
performance, arrangements and other information. This serves as a document of
refernce
for the organization to improve the quality of training in future. The trained
participants
36
are evaluated on their performance by the end of training or after a particular
period and a
report of the same is submitted to the MD.
Requirement Identification
Request Assessment & Approval
Training
Training Report
Training Appraisal
Trainee Report
Recruitment
The training manager assesses the need with assistance from concerned
department authorities and on conformance prepares a document detailing the
required
skills, education, experience etc... And proposes the same for MD‟s approval.
The training manager identifies the suitable candidates and calls for a
personal
interview, by a perusal of CV‟s. The CV‟s are gathered and interview panel is
formed for
the suitable candidates to conduct a formal interview. Selected candidates are
appointed
after the approval of the MD. Candidates, if necessary should undergo training for
a
prescribed period of time.
37
CHAPTER - 5
SWOT ANALYSIS
38
SWOT Analysis
STRENGTH
Good Infrastructure:
The design department uses the most modern CAD solutions to design with
cutting edge technology. The unit is sufficiently support by high precision
engineering tools like CNC machines and special purpose machines. This
enable
us to produce quality products Fully integrated computers that tracks and
controls
the process within the organization helps in reducing the lead time,
effective
utilization of available resources and better customer
relations
management.Various functional departments of the firm are linked through
computer networks, which speedens up processes with accuracy and facilitate
immediate responses to satisfy customer's needs.
Location of the Plant:
The factory is situated on the highways at Kavundampalayam just 3 Kms
away from the main Bus Station and around 6 Kms from the Railway Station.
This makes an easy availability of raw materials from different areas and
customers can also reach the head office to make the orders.
Well equipped Quality Systems:
39
The entire team at GEECO has been trained to focus on quality at every
stage. This has earned it numerous awards of excellence and recognition.
Intra & inter department communication are effective:
The communication procedures used in the company are very effective. They
convey all the informations using notices, memos, letters etc. They also
conduct
monthly meetings to take decisions and to convey messages.
Expertised manpower:
Both the workers and managers are experts in their field with a long
period of
experience. It improves efficiency and helps to increases the productivity
Wide range of products.
WEAKNESSES
40
OPPORTUNITIES
THREATS
Tough competition
They face tough competition from Kirloskar Copeland, CRI Pumps, Sharp
Pumps, Aqua Sub Pumps, Suguna Motors & Pumps, Texmo Pumps and
Mahendra Pumps, who are the major players in the pump industry.
41
CHAPTER - 6
FINDINGS AND CONCLUSIONS
42
FINDINGS
Flat structure.
Healthy intra & inter department communication
Promotional activities are less
The use of safety gadgets such face masks are not compulsory
Less Number of dealers
Less supervision is needed as the company is possessing expertise
employees
The quality control department is having good quality control techniques
and
standards.
Over time allowance is not only for the workers but also for the staff
working
in the company.
SUGGESTIONS
The use of safety gadgets such a face mask should be made compulsory so as to
minimize respiratory problems or diseases.
Promotional activities should be increased so as to enhance better brand
image.
Improve the number of dealers by providing incentives
Company should take initiatives for social activities.
43
CONCLUSION
The study gave a wide exposure towards the practical aspects regarding the
functioning of a manufacturing organization. The training primarily focused on the
identification of various departments in the organization and their respective
roles in the
functioning of the organization. Various information regarding Company Profile,
Products, Production Process, Quality Control, Stores Department, Organizational
Structure of each department were collected. Finally a SWOT analysis was also
performed to identify the Strength, Weakness, Opportunities and Threats of the
company.
44
REFERENCES
http://www.wikipedia.com
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