Project

5-VARIOUS DEPARTMENTS

Purchase department

Stores department

Engineering department

Production department

Quality department

Marketing department

Sales department

Finance department

Accounts department

HR & Personnel department

Research & Development department

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5.1 PURCHASE DEPARTMENT

Requisition stage

All the important departments shall be provided with material requisition notes. They

continuously develop alternative solve of supply and investigate they assibilated of attentive type

of material reduce last or to improve upon the effectiveness of the material.

The purchasing of all products ensures optimum cost / benefits performance as well as to

ensure minimum transaction and warehouses costs. They maintain and develop a qualified

purchasing including evaluation and control.

The department should clearly indicate the detailed specifications of the item / item

requiring purchase in the requisition.

Preserving requisition

On receipt of the requisition for a particular item, the purchase in charger shall verify the

quantity available in store. Purchase in charger shall also take into consideration the item that is

already ordered and are in pipe line.

They maintain and improve warehouses control to ensure an optimum flow in logistics

with balance between turn ones rate and size of stow as well as minimizing waste, scrapping and

transactions costs.

Other details

The purchase department is responsible of raw materials and spare parts.

A new supplier is requester in the “supplier’s assessment form” and send to the

prospective suppliers.

The capabilities are evaluated and approved by the information provided by the head of

purchase department.

Processing enquiries and raising purchase order related to purchasing.

Registering a new into the approved list.

Requirement is forwarded to purchasing authority though “purchase indent” approved by

appropriate section in charge of machine shop.

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The store department verifies the raw materials in stock, rises indents forwarded to the

purchase departments.

Purchase order is checked for adequacy of data provided and signed by approving

authority.

The purchase specification is taken from the document “purchase specification of basic

raw materials” and “list of critical spare spares” and enquires.

The purchasing authority selects a supplier’s form the approved list and process the

purchase order.

Purchasing regulation is printed in the purchase order.

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5.2 STORES DEPARTMENT

The storage of different materials is in one particular location. The store keeper maintains

every records of purchase. All materials are stored in the room. The store keeper maintains a

register like store material receipt book. In this book each and every activity of enter and exit of

the product are entered in an effective way. This book contains name, particular, delivery and

note numbers. This book gives effective information about movement of goods and gives about

its process.

Stores Department Process

Material issue book

The material should be issued from stores immediately and after requisition, materials

supply is taken into this register. According to the production pattern, i.e., count of yarn in this

case, they issue the materials. Store keepers gets copy of material, individual card has been

allotted.

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MATERIALS RECEIPT BOOK

MATERIALS ISSUE REGISTER

STOCK REGISTER

Stock register

Stock register was also maintained by the storekeeper and the stocks have also been

maintained in effective manner. The stocks have been entered in separate book in detailed

account by the store keeper, in this register it shows the records of remaining stocks, required

stock in an accurate way prepared by the store keeper.

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5.3 ENGINEERING DEPARTMENT

The engineering department review whether the customer technical requirements can

be met in the “contract review sheet for enquiry” taking guidance from “foundry

capability document”.

If the customer requirements are within the capability and decided as feasible by

engineering department.

The engineering department and machine shop conducts a technical review to find out

if there are any differing requirements.

The observations are recorded in contract review sheet.

Control plan is prepared by the engineering department and issued to the quality control

dimensional, quality control lab, melting section, molding section, service sourcing and

sales department.

The copies of the revised / new drawing are stored in the “visual source safe” software

by engineering department.

The old drawing is kept in “absolute drawing file” by the department for future

reference or return to the customers.

The revised or new drawing number is entered into the “drawing control register “.

The department sends an advice to the production department asking to stop the

production if the drawing revision affects the product.

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5.4 PRODUCTION DEPARTMENT

Production is a process through which raw materials are covered into semi finished goods

which in turn is converted into finished goods. The sales department prepares the monthly

schedule based on the customer schedule and one copy is passed by the production planning

department for execution. The estimation of the raw material is authorized by the head of this

department. The moulds and cores requirement is checked for sufficiency. If any shortage of

capacity is noticed, action is taken to augment the production capacity. The service sourcing

department verifies the adequacy of the capacity supplied and issues the monthly schedule for

the in-housing. In case of the shortage of capacity alternate arrangements are decided by the head

of the production and service sourcing department. The machine capacity is studied against the

requirement s and the extant of outsourcing is decided. All the implementation of production

process during labor shortage is done by the production heads of the department. The monthly

schedule is sent to production planning department of respective unit.

Names and uses of products

Some of the products produced in the company are,

Rocker liver

This product is used as an engine components and it has 25 to 30 products.

Cam shaft

It is used in the engines of two wheeler vehicle and has 25 to 30 types of products.

Crank shaft

This is used in the three wheeler for the rotation herd while running

Cam follower

This is used an engine components in the vehicle like truck, marine etc.

Hydraulic housing cast

It is a hydraulic application used in solenoid valves and control valves.

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Distributor block

It is used as the hydraulic motor application.

Control cover

It is a earth moving application used for fork lift.

Filter head

It is a hydraulic application used in the filter head.

Housing brake lever

It is used as engine components and for the efficient working of the brake lever.

Piston

It is used in the refrigerator for the compression. The most frequent customer is Godrej

Ltd.

Product and process:

It is continually improved by reducing the variation of their characteristics.

They have a strong metallurgic base and experience.

Metallurgical quality of the product is S.G.Iron and it has been acclaimed by their

overseas customers.

The basic requirement of process is taken up for capability measurement.

The priorities are based on the importance of customers, economical feasibility, technical

constrains etc…

The advanced testing equipments like microscope attached with image analyzer software

melt lab and endoscope spectra meter, ultrasonic magna flux and trimos vertical

measuring equipments are used.

They have 400 product productions in their company.

These products has 400 varieties.

All the products are used only for the vehicles.

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5.5 QUALITY DEPARTMENT

The main aim of the quality department is to maintain the quality of the product. The

foundry has formulated a quality systems and assurance to bring about improvement in all areas.

All the products which directly affect the quality of parts shall be subject to inspection

and for testing by authorized company inspection perusal.

Procedures

1. Raw material inspection

In a foundry the inspection for raw material are taken.

2. In process inspection

The parts produced or procured by the company shall be inspected and tested as required

thought out their intermediate stages of manufacture by authorized company inspection

personnel.

3. Final inspection

The final inspection and testing shall be performed is approved ITP and quality

assurance procedure QA poof.

All works operations, including those sub contracted and non conformance correction

have been completed and all acceptance. All products observed during final inspection to be non-

confirming shall be identified and processed in accordance with quality assurance procedure.

Objectives

Controlling the quality of products throughout various stages.

Interaction with customers regularly to understand their needs and to incorporate their

requirements.

Continuous up gradation of human resource through training programmers.

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Other details

Indo shell cast private limited is strongly committed to retain the supremacy in our

segment of business by achieving “total customer delight”

The company achieved by the supplying casting of customer requirements at right cost on

time and every time.

Effective team work.

Providing a clean and safe work environment.

Optimizing the inventory turnover.

Improving people productivity by good production capacity.

Reducing the cost of poor quality.

Promoting the concept of defect prevent.

Carry out socio-environment.

Control

At Indo- Shell Cast, quality starts right from the selection of the resources. Aided by stringent

quality checks and controls in every stage of the process, the Process drastically reduces the risk

of final inspection, enabling mitigation of the quality costs.

The head of each functional area identifies the various quality records to be generated and

maintained by this functional area against each of the applicable procedure for this

functional area.

These identified records are listed down at the end of each procedure.

All the quality records are retained generally for a period of one year.

The various records formats are approved and controlled as per documents control

procedures.

The calibration related records are maintained for the lifetime of the equipment.

The pattern and Cirebon related records PPAP records and APQP records and product

plus one year.

The sale department takes the responsibility of informing the various departments

concerned well in advance account such contractual requirement.

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5.6 MARKETING DEPARTMENT

The marketing activity is associated with buying and selling a product or service. It

includes advertising selling and advertising products to people.

People who work in marketing department of companies try to get the attention of target

audience by using slogans, packaging design celebrity endorsement and general media exposure.

The four ‘Ps’ of marketing all Product, Price, Place and Promotion.

Procedures

Market operation

It is a common practice for an entire organization marketing activities such as advertising

sales and market research to be grouped together is a marketing department.

The organization that develops and performs its product and marketing activities with

aim of satisfying the needs of its customers is oriented.

Marketing removes the imbalance of supply the surplus of deficit arras, through better

transport facilities.

Market details

Enquiries are received and registered in the “entry register” by the marketing department.

Based on the cost estimation sheet the quotation is prepared and send to customers.

The marketing department verities and amended the price master.

If order is not received in three months duration, a reminder letter is send to the customer

by the marketing department.

Quotations are sending by the marketing department.

The entire requirement is done by this department to the customer.

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Customer Communication

Sale executives / sales representative shall meet the consignee agents / distributors /

stoutest / dealers on the regular basis to canvas order.

Order taken or received shall be communicated to marketing manager / market

development manager as well as to office manager. Necessary documentation shall be

done.

The office manager shall write down the order details in the order from available in the

office. The procedure details data of order taken, order number, name of sales

representative / executive etc. shall be filled in the order from.

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5.7 SALES DEPARTMENT

Sale department is basically is service oriented department. It deals with the

dealers, customers and manager. Their proceedings are receiving the order and distribute

the materials according to the customer’s requirement.

Responsibilities of sales manager

To ensure a clear sale strategy is in place for demand and that it is communicated to the

sales term efficiency and reviewed regularly.

To constantly review and maintain confirmed provisional and offered business in line

will all turn down to ensure the right business has been taken at the right line for the right

price.

Analysis and reporting of actual performance venues competitors.

To work with the head of sales and marketing and the senor sales manager to compile and

implement the sales and marketing strategy and be active in 5 years planning process.

To support the development of the sales and event terms ensure consistent and

professional sales practices through the development.

Due to the sales operation flexibility is a key requirement for this role. The role will in

volume working line weekends and evening in order to fulfill appointments and customer

requirements.

Sale details

New orders are received by the sales department and register in the “order entry

register”.

The result of contract review is sati’s factory and order acknowledgement letter is sent to

the customers by this department.

Whenever customer requirement are received by verbal means the sales department

writes a confirmation letter to the customer.

Stock in head and work in progress stock is informed by the sales department.

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Packing

At Indo Shell Cast, Superior Products, Sound Quality Control Process matches with Excellent

Delivery Systems. Packaging is custom designed to suit the specific requirements of the

domestic and international supplies. Many crucial factors like Seaworthiness, Shelf life, Rust

Prevention, Pest Control, Termite Control, Size of the package, handling systems at customer

end are considered to ensure proper delivery.

Delivery

The delivery is made after the package of each product.

The machined casting are applied with preventive coating and stored under covered area.

Approved list is maintained for the delivery of the products.

The product is delivered throughout the world.

The company using the airways from Delhi, Mumbai and Bangalore.

It also uses waterways from Trivandrum, Tuticurin, and Chennai.

Clients

Our service ensures a long-term customer relationship; our list of satisfied clientele proves our

quality service.

Domestic customers:

Bajaj Auto Limited

Volvo

Maruti

Ashok Leyland

Hindustan Transmissions

Godrej

Tempo

Rexroth Bosch group

Vickers

Autotech

SAI hydraulic motors

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International customers

Italy Steprava

Gnutti Carlo Italy

Minigears

FMC Energy Systems

Drell Borg Automating-Italy,UK

Jackup vehicle system,USA

Catterpilor

Poclaine Hydraulics

Parker Hannifin Hydraulics

Bosch Raxroth

Indo Autoshell America

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5.8 FINANCE DEPARTMENT

Finance is the life blood of every business. The head of the finance department is

Mr. Ganesh Kumar. The cashier prepares the budget for every month and presented to the

managing director for approval and the amount is drawn from the state bank of India

accordingly.

Business finance refers to money and credit employed in business. It involves

procurement utilization of funds so that business firms may be able to carry out their operations

effectively and efficiency. It includes all types of funds and it is important to all type of

organizations. It involves estimation of funds. It is also concerned with raising funds from

different sources as investment of funds for different purposes.

Finance is requiring to each and every department, also it is required in each and every

stage in the production process.

The cashier is in charge for this department. He is responsible for need of working capital

funds. The finance department arranges funds to meet the financial commitment of the

department in the organization.

Creditors

For the credit purchase of stores materials and consumables the payments are made once

in 30 days and other raw materials. The payments are made according to the arrival as per the

terms and conditions.

Debtors

The outstanding is collected from debtors against delivery or after days as per the sales

contract and the amount is remitted to the bank.

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Purpose

To take care of responsible for all accounting and financial activities of the project are

including receivables/payables.

To drive and upgrade process and system to give the best of functional support in project

to meet financial and business objectives on sustained basis.

The bank balance of each and every day is maintained. The bank balance statements and

the gain stock statement is maintained a submitted to the director on every day. The

accounts of the company are fully computerized. The daily transaction vouchers and bills

are verified and signed by anyone of the director of the company. Then the signed

voucher and bills are entered in company records.

The transaction which occurs daily are recorded in their respective books of original

entries are maintained.

Annual reports

The cash is maintained by the cashier all the amounts received and spend are entered in

this cash book.

The bank book is also maintained in the company, it is the amount received from the

customer or order and it’s recorded in the bank book.

All the purchase transactions are recorded is the purchase book. In this organization only

the cash purchase book is maintained.

All the sales transaction re-recorded in the sales book.

Ledger is prepared once is a year regarding assets and liabilities expenses and incomes

and expenditure and balance sheet.

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5.9 ACCOUNTS DEPARTMENT

Accounting reports are maintained by the accounts manager, with the help of clerk

assistance. All the financial information is recorded in this department. Every week the sales

manager use to submit the sales information and accounts to the accounts clerk. The material

purchase information and accounts are also given to the accounts clerk.

The material purchase in charger also inform about the purchase for positioning them to

prepare ledger. Separate accounts are cash and credit dealings are maintained.

Function

Finance planning

Working capital management

Day to pay management of funds

Negotiation with banks and others

Purchase bill passing

Internal data

The concern maintains various kinds of accounting books in the company.

They are as follows,

Day book

Subsidiary book

Voucher

Day book

Day-to-day transactions are recorded in day book and it is used for future verification.

Purchase record

Mixing

Production

Stores ledger

Sales

Cash book

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1. Purchase record

From whom the raw material has been purchase.

Quality and quantity of variety of product.

Date purchase.

2. Mixing

Date of mixing

Quantity of variety

Variety of product

3. Productions

In this production book the details about day to day production activity such as of

production, the type of manufacturing produced etc., are entered.

4. Sales

In sales book the details entered are data of sales, quantity of sales, rate of sales and

also entering the name of the receiving party, details of any given etc….

5. Cash book

Cash book is maintained for recording the cash receipts and cash payments.

6. Attendance register

It is the book, which is maintained by the company for attendance of the labor per

shift.

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5.10 HR & PERSONNEL DEPARTMENT

The head of the human resource and personnel department is Mr. N. Devaraj. The human

resource personnel department is concerned with the most effective use of people to achieve

organization and industrial goals. It is the way of managing of people at people at work. So that

they give their best of times capability to the organization. The human resource and personnel

manager solves if any problem arising between the management and workers group. The human

resource department acts as intermediaries between the both. The various credit and incentive

plan are given by human resource and personnel department. The credit facilities are arranged by

the help of various banks, according to the type of loan.

A separate file is being maintained for each worker and the activities of each worker is

such as attendance, application for leave, casual leave, sick leave, any notice to the worker are

noted in the file on the respective workers.

This department which carries employee oriented activities such as maintaining ESI, PF,

etc.., in the organization. They strive to good productivity by motivating employees.

Functions:

Calculation of working time with recruitments. Selection and placement. The wages and

salary administration is controlled by this management. It involves job evaluation and employees

benefit measures for training and development.

Recruitment

The employees are recruited on the basis of certain conditions like educational

qualification; technical know-how etc. training will be given to employees who are not familiar

with their job.

Attendance

For attendance, a card is maintained, and is inserted into a machine while an employee

entered the company. Attendance allowance is given to motivate the regular workers for their

full attendance.

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Salary

Salary for every employee is given on this 5th day of every month. Two copies of salary

slip are prepared, one copy is given to employee and another one is within the office for further

reference.

Salary is calculated along with basic pay. Dearness allowance, house rental allowance

conveyance allow, production bonus etc...

Bonus

Bonus is the amount which is given by the employee according to the profit and loss of

the company. It is given 8.33% of profit is shared among the employee.

Over time

Over time allowance is given to the employees for his work over the actual work time. It

is given double the pay for only workers. It is given on the day of 15th every month.

Shift timings

1st shift (morning) 8.15 AM to 4.15 PM

2nd shift (half-night) 4.15 PM to 12.15 AM

3rd shift (night) 12.15 AM to 8.15 AM

No of employees

Total permanent employees are 231,

Department Employees

Sales - 2

Marketing - 2

Purchase - 3

Development - 12

Production - 21

Quality control - 12

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Maintenance - 3

HRM - 27

Finance - 6

IT - 1

Top management - 3

Engineers - 48

Commercial staff - 41

Operators & inspection - 139

Salary details of the employees

Department Salary

Sales - 5000 to 25000

Marketing - 8000 to 20000

Purchase - 7000 to 35000

Development - 12000 to 20000

Production - 5000 to 39000

Quality control - 10000 to 39000

Maintenance - 3000 to 32000

HRM - 10000 to 39000

Finance - 6000 to 35000

IT - 8000 to 32000

Top management - 20000 to 70000

Engineers - 8000 to 40000

Commercial staff - 4000 to 20000

Operators & inspection - 10000 to 25000

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Employee Motivation Programme

Indoshell Cast believes in constantly upgrading skills of its employees, driving perfection

at work. There are many programs for employees to develop both curricular and non-curricular

activities. Indoshell constantly identify individuals / teams with exceptional performance get

them to share ideas with the rest. The company ensures through frequent meetings a fair

exchange of ideas of development in each of the fields.Employees are constant updated on

technology, market, and the latest developments in the field. All these make the employees get

involved in work thereby giving better productivity. Dedication of the Indo Shell Cast team and

its unity create a synergic work environment.

Indo Shell Cast is running various schemes and adopting various beneficial measures to

motivate its workforce. Some are given below. In addition to the statuary welfare measures like,

ESI, Provident fund etc, they are doing the following measures:

1

.

Meeting the first month educational expenses of the children of employees every year and

liberal assistance for higher education.

2

.

Meeting the specialized medical treatment for deserving employees.

3

.

Free medical insurance scheme for the employees who are not covered under ESI

4

.

Helping the employees to overcome any emergency personal problem.

5

.

Blood test and grouping for all employees.

6

.

Eye test for all employees and provision of corrective treatment and spectacles.

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7

.

Arrangement of blood donation for employees and their relatives in case of any emergency.

8

.

Arranging for soft loans through co-operative bank to the employees.

9

.

Provision of uniforms, shoes etc.

The employees of Indo Shell Cast undergo vigorous training through programs conducted

within the Campus. Various steps are taken to ensure that every employee is quality conscious at

every stage with latest technical know-how and technological advancements. Special emphasis is

on personality development and building healthy co-employee relationship.  

Welfare Activities

1. Three sets of uniform dresses are being issued for once in 2 years for all employees.

2. One pair of shoes for all employees.

3. Medical facilities are being extended to all employees at our factory dispensary.

4. Provided rest shed for employees.

5. Lockers provided to all employees.

6. Bonus payment is adopted for all employees under productivity linked bonus scheme and

performance bonus scheme.

7. Festival advances for all employees.

8. Company picnic scheme.

9. Incentives scheme.

10. Insurance for all employees.

11. Provident fund scheme for all employees.

12. Education advance for employees son/daughter.

13. Group personal accident policy – 24 hours coverage for all employees.

14. Sick leaves are introduced for the employees.

15. Moped loan scheme to employees.

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5.11 RESEARCH AND DEVELOPMENT DEPARTMENT

Indoshell cast has a R&D facility with latest testing and measuring instruments for

making advanced researches in metallurgical aspects such as Gating system design, failure

analysis and foundry process with the involvement of rich knowledgeable professionals.

With the aid of R&D activities, Indoshell Cast has developed and fine-tuned the following process.

Magnesium treatment for nodularizaion with cored-wire for ductile iron production

Producing impeccable compacted graphite iron economically

Developed ADI treatment methods to achieve desired properties without adding any expensive alloying elements

Effective gating system has been developed to produce safety critical parts

Developed various core making techniques suitable for hydraulic parts

Developed new method for automatic inoculation

Designed & developed indigenous mould making machines suitable for parts up to 50 kgs

Develop various customer specific grades like Ductile Iron 900-5 etc

Exploring various avenues in various cost saving projects with enhanced quality of the products in various manufacturing process such as thermal reclamation of resin coated sand, hot coating process, application of producer gas etc.

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6-SWOT ANALYSIS

SWOT analysis acts as a tool for enhancing the company’s growth through its strength &

opportunity and further helps to identify the challenges in order to draft its strategic plans.

Strength

The location of the plant is situated at sidco industrial estate.

Creates lot of employment opportunities.

Strong market position.

Clients all over the world.

Weakness

Takes lot of time to get the government approval.

Lot of procedures and rules for getting job done.

Opportunity

Unexpected rural market.

Growing domestic demand.

Threat

Thread of competitors.

Iron prices are rising invariably.

Global economic slow down.

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7-OBSERVATIONS

Every employee in the organization got their respective roles and responsibilities from

their HR manager. It is also agreed by majority of the employees.

Motivation and support are regularly provided to the employees by the HR manager and

the top authority.

Due to the training program provided by the organization, the organization’s productivity

has also increased. It is also provided at a free of cost.

The biggest achievement of the HR manager is wages and bonus settlement to the

employees and providing sufficient manpower to the production.

The training programs conducted by the HR department are: 5S awareness, Kaizen

method, Model machine concept, Why-Why analysis, presentation skills and TS 16949

awareness.

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8-CONCLUSION

I conclude that training in Indoshell Cast Private Limited was of great use to me and

benefited a lot from the practices study of the subjects. My study period very useful and will help

a great in my future career. This Company works with efficient staff and workers. The

relationship between the management is cordial. I once again thank my professors and

management staff members of Indoshell Cast Private Limited.

I understood the functions of each and every department and it is also know that all the

transactions are recorded in a proper way, which is useful for the management for further

verification each of the department is interrelated to the other, yet having its own autonomy.

The training was just a preview of what is in store for me when I step into the industry.

This institutional training has immensely helped me in study of the organizational structure. It

has enabled me in successful fulfillment of the objective of my training program.

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9-BIBLIOGRAPHY

Books

1. M.Y.Khan and P.K. Jain,(2001),Third edition, Financial Management, Tata McGraw Hill

Publishing Company Limited, New Delhi.

2. VSP Rao,(2009) Second edition ‘Human Resource Management’, Excel Books

3. Dr S N Maheshwari, Dr S K Maheshwari and Sharad K Maheshwari, “A Textbook of

Accounting for management”, VIKAS Publishing house Private Ltd, Noida, Second Edition

(2010).

Websites

3. http://www.indoshellcast.com/

4. http://www.foundryinfo-india.org/

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