Introduction

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CHAPTER 1
Sambhram Academy of Management Studies
INTRODUCTION
INTRODUCTION
Steel is the most important multifunctional and most adaptable material. The steel industry today has made the country proud as never before. The Tatas and the Mittals have made India a great force to reckon not only in the world steel industry but also in the global economy. Steel is an alloy of iron and small percentage of carbon and other elements in varying percentage with the increase in carbon content, the strength, hardness & brittleness of steel increase. Steel compared to other material of its type of low production cost the energy required for extracting iron from ore is 25% of what is needed for extracting aluminum. Steel is environmental friendly as it can recycle 5.6% of elements. Iron is present in earths crust, representing a secure raw material base. Steel production is 200 times higher than as compared to production of ferrous metals put together. Different types of steel are obtained by varying composition. Generally steels are classified as mild steel, medium carbon steel, high carbon steel, and low alloy steel are generally used for steel structure. Iron & steel are the worlds cheapest and most useful metals. These 4 are the durable metals used in making 100s of products from paperclips to cars, machine made of iron and steel help to produce almost everything. We use on daily basis to meet personal needs and domestic requirements. Steel is produced by refining iron and alloying it with other metals. Iron may be through of as fine basis material of steel. Iron & steel industry is one of the worlds most vital industries employing large number of people.
Iron has got its industrial origin in India in 1987, during that period the 1st iron & steel industry in India was in Barracker. Iron works was started in Bengal but the real growth of industry took place only in 1907, when Sri. Jemeshedji Tata started TATA IRON AND STEEL COMPANY LTD.(TISCO) SCOPE OF THE STUDY The Organizational study is carried in Peekay Steel Castings at Calicut in Kerala state. It is concerned with the company strategies, work flow of the departments, functions of each department. It is concerned with sales and distribution of the company, Promotional policies of the company, pricing policies, Business economic research of the company OBJECTIVES OF THE STUDY
A study of organizational activities in all functional areas in an organization
To understand how the departments work To understand the structure of the organization To analyze the SWOT (Strengths,Weaknesses,Opportunities, Threats)
To understand the inter-relation of each department

INDUSTRY PROFILE
BUSINESS ENVIRONMENT ANALYSIS Steel, the recycled material is one of the products in the manufacturing sector of the world. The Asian countries have their perspective dominance in the production of steel all over the world. India being one among the fastest growing economies of the world has been considered as one of the potential global steel hub internationally. Over the years, particularly after the adoption of liberalisation policies all over the world, the world steel industry is growing very fast. Steel industry is a booming industry in the world. The increasing demand for it was mainly generated by the development projects that have been going on along the world, especially the infrastructural work and the real estate project has been on the boom around the developing countries. Steel industry was till recently dominated by the United States of America but this scenario is changing with the rapid pace with Indian steel industry are automobile industry, construction industry, infrastructure industry and container industry. INDUSTRY PROFILE The iron and steel industry uses million tons of material, each year chiefly iron ore, and lime-stone about 250 million tons of these materials are required to produce 100 million tons of steel. In addition, a supply of alloying elements is needed, as well as enormous quantities of fuel, gas, oil, oxygen, water, air and refractorys, or material for lining furnaces. The level of percapita consumption of steel is treated as an important index of the level of the socio economic development and
living standard of the people in any country. It is a product of a large and technologically complex industry having strong forward and backward linkage in terms of material flows and income generation. All major industrial economies are characterized by the existence of a strong steel industry and growths of many of these economies have been largely shaped by the strength of their industries in their initial stages of development. Steel industry in India is one of an upswing because of the strong global and domestic demand. Indias rapid economic growth and souring demand by sectors like infrastructure, real estate and automobile such home and abroad, has put Indian Steel Industry on the global map. According to the report of International Iron and Steel Institute (IISI) India is the 7th largest steel producer in the world. The Indian Steel Industry organized in three categories: - Main producers, other major producers and the secondary producers.
INDIAN STEEL INDUSTRY IN CHANGING GLOBAL SCENARIO
The steel industry in the world which was characterized as a sunset industry two decades ago is experiencing in a vast change in scenario. The fast developing Chinese steel industry has for outstripped the world steel giants--United States of America, Russia and Japan which user leading steel producers are no more in a position to claim that position? China, producing less than a million tons of steel prior to revolution in 1949, has now become the largest steel producer in the
world. During 2005 the global steel production stood at 1132 million tons, showing a rise of 6% over the last year. The countries in South America, CIS (Format Soviet Union) Europe and North America have actually shown negative growth. The Asian continent for the first time produced more crude steel than the rest of the world combined. Major shift has taken place during 2005 with China producing 349 million ones of steel, accounting for 32% of the world steel production increase by 69 million tons, i.e. by 25% Chinese steel output was more than three times that of Japan and four times of USA during 2005. Per capita consumption of steel in the world was estimated to be 170kg during the year 2005. However in India it stood at only 35kg during the same year. Indian Steel production was 38 million tons, which accounted for only 3.4% of the world steel output. In view of the fact that Indian population is 16% of the global population, the population of steel is much lower in India. Although India is the second largest populated country in the world, it ranks eighth in steel population. Steel authority of India Ltd. (SAIL) is ranking 17th among the world's largest steel producing companies. With stiff competition in the global market, the formation of giant companies to reduce cost and add to profitability has become the regular feature in the industry. Merger and acquisition have become the order of the day. The recent attempt of the Mittal steel to acquire Arcelor, a Luxemburg based European company, if succeeds, will make Mittal steel produce over 110 million tons of steel per year, i.e. about 10% of the global steel output.
The 2012 outlook for steel demand is a caution due to the markets continued financial uncertainty and volatility. The global steel sector is expected to grow, although at a lower rate growth will be seen in two different speeds, with emerging economies expected to perform much better than developed countries. The sector is only expected to grow by 2.5% in Europe and around 5.0% in the North America Free Trade agreement region. Chinese steel production and consumption will continue to outperform the rest of the world. The steel sectors in other emerging countries, such as India, Russia, Brazil and South Korea, will continue to grow, although the uncertain economic outlook may have some effect on these economies. In India, however, demand for steel from the domestic sector is creating a positive outlook as India is expected to perform better than most. STEEL INDUSTRY IN INDIA Steel industry in India is an upswing because of the strong global and domestic demand. India's rapid economic growth and soaring demand by sectors like Infrastructure and Real Estate and Automobiles, at home and abroad, has put Indian industry on the global map. According to latest report by international iron and industry, India is the seventh largest producer in the world. The origin of the modern steel industry can be traced to companies like Fried Krupp and Demag AG. The initial plan was an annual capacity 500,000 tons, but this was subsequently raised to one million ton. The capacity of the Rourkela Steel Plant (RSP), which belongs to the SAIL group, is presently about 2 million tons.
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India is among the top producers of all forms of steel in the world. Easy availability of low cost man power and presence of abundant reserves make India competitive in the global set up. The Indian steel sector is contributing to nearly 2% of the GDP (Gross Domestic Product) and employed over 5 lakh people. According to the statement, India became the 4th largest producer of crude steel in the world in 2010 and is expected to become the 12th largest producer of crude steel in the world by 2015. Going by estimate of Rs.4000 crores investments per million tons of additional capacity, intended steel capacity build up in the country is likely to result in an investment of Rs. 870640 crores by 2020. The demand for steel in the country is currently growing at the rate of over 8% and it is expected that the demand would grow over by 10% in the next five years. Domestic crude steel production grew at a compounded annual growth rate of 8.4% in the last few years
Crude steel production capacity of the country is projected to be around 110 million tons by 2012-13
Increase in the demand of steel in India is expected to be 14% against the global average of 5-6% due to its strong domestic economy, massive infrastructure needs and expansion of industrial production Demand of steel in the major industries like infrastructure, construction, housing, automotive, steel tubes and pipes, consumer durables, packaging and ground transportation
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Target for $1 Trillion of investment in infrastructure during the 12th Five Year Plan.
Increased demand of specialized steel hi-tech engineering industries such as power generation, automotive petrochemicals, fertilizers etc. STEEL INDUSTRY IN KERALA The steel industry has made the country proud as never before. The Tata's and the Mittals have made India a great force to reckon with not only in the world steel industry but also in the global economy. The industry is fully optimistic about its future and is keen on tapping the emerging opportunities the world over. The phenomenal GDP growth of the country is expected to benefit the steel industry in a big way. The booming infrastructure and housing sector also fuels the steel sector of more reason than one. However the role and contribution of secondary steel
manufacturing sector has not been fully appreciated or even understood in correct perspective. Lots of misconceptions still rule the roost in this segment. This industry considerably contributes in the recycling of steel there by making available steel products of everyday use to the retail consumer at lower prices. This sector also minimizes the waste and energy consumption when compared to big integrated steel plants. To produce one ton of steel the secondary manufactures require only 1.2 tons of raw materials where as in the case of big primary
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manufactures it is 5 tones. More importantly, the former uses only less energy with lesser pollution and wastages when compared to the latter. This industry used water only for cooling of its machinery and its employment potential is also relatively quite high. As a matter of fact, the economic development is measured in the quantity of domestic consumption of commodities like steel and cement. Recently, the industry is facing serious problems like imposition of import duty on scrap, high excise duty on finished products and escalated power tariff which make the industry non-competitive. Needless to say, Kerala was one of the most industrially rich states in India during fifties. The presence of more than 50 small and medium steel manufacturing units in the state has been contributing extensively for the development of the state. The industrial scenario in Kerala is fast undergoing a renaissance and it is left for the steel manufactures that are operational here to seize the emerging opportunities of growth without determinately affecting the environment. The private sector steel industry in Kerala is only a decade old. A relatively young industrial sector is serving the booming housing sector and is thereby contributing substantially to the states exchequer. With the state housing sector to grow manifold this share is bound to move upwards in a day to come.
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According to industry estimate when the per-capita consumption of steel in the country remains at a low 40kg, in the neighboring China it is a mind boggling 1200kgs. Currently there are several challenges before the steel industry and modernization, technology up graduation, attaining global standards, introduction of better energy conservation measures; enhanced pollution control and good manufacturing standards are just some of the issues that require immediate attention. Currently steel industry faces several challenges due to modernization, technology upgradation, attaining global standard, introduction of better energy conservation measures, enhanced pollution control and good manufacturing standards.
INDUSTRY KEY PLAYERS This is a list of the largest steel-producing companies in the world, mostly based on list by the World Steel Association. This list ranks steelmakers by volume of steel production in millions of tons and includes all steelmakers with production over 10 millions in 2010.
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TOP TEN STEEL PRODUCERS GLOBALLY HEAD QUARTERS
RANKING 2010 1 2 3 4 5 6 7 8 9 10 98.2 52.9 37.0 36.6 35.4 35.0 31.1 30.1 25.8 23.5
2009 77.5 40.2 31.3 30.3 31.1 26.5 25.8 26.4 17.3 21.9
2008
2007
COMPANY
103.3 116.4 33.3 35.4 27.7 34.7 37.5 33.0 23.3 12.2 24.4
ARCELOR LUXEMBOURG MITTAL CHINA
HEBEL 31.1 IRON& STEEL 28.6 BAOSTEEL GROUP
CHINA CHINA
WUHAN 20.2 IRON& STEEL 31.1 POSCO 35.7 NIPPON STEEL JIANGSU SHAGANG
SOUTH KOREA JAPAN JAPAN CHINA
34.0 JFE 22.9
12.9 SHOOGANG CHINA 26.5 TATA STEEL INDIA
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TOP TEN STEEL COMPANIES IN INDIA Rashtriya Ispat Nigam Limited Steel Authority of India Tata Steel Visveswarayya Steels Bokaro Steel Plant Bhilai Steels Essar Steels Limited Jindal Steel & Power KVS Ispat
Jindal Steels Limited
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COMPANY PROFILE
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COMPANY PROFILE BACKGROUND AND HISTORY Peekay Group was established in the year 1942 by Haji P.K. Moidu, a legend of his own time for his uncommon vision. The strong foundation laid down by his extraordinary business acumen and uncompromising integrity has given the group a strong set of values and fundamentals. After the blazing success for the past 65 years, the group has held those values closer than ever and has focused more on its business objectives surpassing conventional paradigms and setting new bench marks. Peekay Steels Castings Pvt. Ltd is a leading steel manufacturing unit with foundries situated in Calicut, Coimbatore and Tamil Nadu. The company manufactures Steel Castings of carbon steel, stainless steel, alloy steels of various compositions and nickel based alloy steel for different types of steel castings in various sizes and weights up to 11000kgs per piece for oil and gas sector transportation, mining, power and other engineering sectors. Peekay Steel Castings (P) Ltd is the flag ship company of Peekay group which plays a vital role in the industrial development of Kerala. The company was incorporated with the Registrar of Companies, Kerala as a private limited company on 09.04.1991. The company employs most modern technology and has installed state- of- the -art machinery and equipment for the manufacture of high
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quality steel quality control laboratory for all types of physical and chemical testing and a radiography enclosure room with Cobalt 60 and Iridium 192 for radiography testing of castings. The entire manufacturing process and service departments are supervised and managed by qualified, experienced and competent personnel. The company constantly upgrades its technology and employs the most advanced technology available in the foundry sector. A fully equipped machine Shop with imported machinery is attached to the Calicut foundry for meeting the growing demand for machined, ready to use castings/components for the oil and gas and other engineering sectors. Both Calicut and Coimbatore foundries together produce 13,200 tons steel castings per annum. The steel castings are exported to various countries of the European Union, notably Germany, France, Italy, U.K, Netherlands, Spain, Belgium, USA, Canada, Japan, Korea, Singapore, and U.A.E. It is the policy of the company to produce consistently castings conforming to customer specifications in terms of quality and delivery. The company holds several certifications and recognitions from renowned international agencies. The steel castings are also sold to large public sector undertakings, defense establishments, 100% export oriented units and large valve manufacturers in India. The steel castings are well accepted by our customers in India and abroad.
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Peekay Steel family has 2500 members. The success of the Company is attributed to the strength and unity of the members of this family. The Company is conscious of their skills, passion, quality, strength and strong values and has a value based approach; indomitable spirit, commitment and hard work have won the appreciation of their customers. Loyalty and values are the basic fabric of their work philosophy. Every employee is a partner in their progress and benefits from their profits. It is proud of its contribution to the success of the company. Peekay Steel has regular in-plant training programme for upgrading the skills of the employees and familiarizing them with the latest technology and manufacturing processes. Very often the employees are also deputed for short term courses conducted by specialised agencies. The company is committed to the health and safety of all members. A separate wing of safety experts are working round the clock to ensure safety measures in the company and also to educate the employees for better work environment. Peekay Group of Companies, being a successful business group in Kerala for the past 5 decades proved their success in Manufacturing, Trading, Food Processing, Rubber Plantations, Health Care, Education and Charity. Peekay Steel Castings (P) Ltd is one of the major divisions of Peekay Group of Companies. Peekay Steel Castings(P)Ltd, has two state -of-the-art foundries located at Calicut (Kerala) and Coimbatore (Tamil Nadu), which produces high quality steel castings, catering to the needs of the major industries in India and abroad.
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Peekay Steel Castings (P) Ltd established in 1991, is a modern state-of-the-art foundry located at Calicut (Kozhikode) in Kerala on the western coast of South India, manufacturing high quality steel castings made of Carbon Steel, Alloy Steel, Stainless steel, Duplex Steel, Nickel Base Alloys etc. in various sizes and weighs up to 15000kgs per piece for Oil and Gas Industry, Hydro/Thermal/Steam/Nuclear Power Generation Plants, Earth Moving Equipment, Transportation and other Engineering Industries. With the recent expansion and upgradation in the foundry, the annual production capacity of Peekay Steel is enhanced to 7200 Million Tones. In the Foundry, moulding is carried out in No-Bake process(Alkaline Phenolic) equipped with high speed continuous sand mixing and reclamation system, fluidized bed cooler etc. The melting department has 3ton, 5ton, 6ton & 12ton induction furnaces with ladle pre-heater. Apart from 3 fully equipped fettling section we have 1MT, 6MT, 10MT (2nos.) oil fired heat treatment furnaces as per API calibrated ceramic fiber lined temperature controlled heat treatment furnaces. Peekay Steel Castings products are exported to the countries of European Union viz. France, Italy, UK, Germany, Spain, the Netherlands etc., USA and Japan. The steel castings are also sold to large public sector undertakings, defense establishments, 100% export oriented units and large valve manufactures in India. The steel castings are well accepted by our customers in India and abroad.
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Growth of Company Founded in 1942 by the visionary of Haji PK Moidu is a story of unstinting dedication to quality. The strong foundation laid down by his extraordinary acumen and uncompromising integrity has forged accompany that remain committed to providing the customer the best. Over the 65 years the group of these cherished values and founded on new business objectives. New venture in it continues to set benchmark. Today the Peekay Group has a turnover of more than USD 120 millions. Features Optimum combination of high yield strength and excellent bend ability. Enables designer to reduce steel consumption and yet obtain extremely safe steel structure.

Excellent weld ability. Superior corrosion resistant. No tendency of embrittlement. Uniform properties throughout length as the entire process is computer controlled.
Nil scale per unit of surface area less than 50% in normal hot rolled bar.
Excellent fatigue properties.

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Can be galvanized with no loss and ductility. Saving in steel consumption as much as 18% while using Fe 500. Best choice for earthquake resistant construction.
MAJOR CUSTOMERS ABROAD ARI-Armaturen Albert Richter Gmblt and Company KG, Germany Control component Inc., USA
Dresser products industrials, France
General Electric Company, USA KOSO Fluid and controls Private ltd Leser GMBH AND Co. KG, Germany Mokveld valves, BV
Nordstorm Audco Inc., USA
SPX process equipment, USA Termomecannica Pompe, Italy Truflo Rona st, Belgium MAJOR CUSTOMERS IN INDIA Advance Valves, Faridabad Alston Projects India Ltd, Baroda Audco India Ltd, Chennai Bharat Heavy Electricals Ltd, Tiruchirappalli Dresser Valve, India Koso Fluid & Controls Pvt. Ltd.,
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Fisher-Xomox Sanmar Limited , Chennai Flow Serve India Controls Private Limited, Bangalore Instrumentation Limited, Palakkad Kent-1 ntrol Pvt. Ltd., Nasik KSB, Coimbatore MIL Controls Limited, Trissur Triveni Engineering & Industries Ltd, Bangalore Tyco Valves and Controls Pvt. Ltd, Chennai
Worldwide Oilfield Equipment, Pune
COMPETITOR ANALYSIS COMPETITORS OF PEEKAY STEEL INDUSTRY DOMESTIC COMPETITORS UP Steel, Uttar Pradesh Simplex castings, Raipur Aruna Machine Tools, Tamil Nadu Kolapur steels, Karnataka Starwire, Uttar Pradesh Sanmar, Trichy INTERNATIONAL COMPETITORS Wenshu, China Fordinex, Italy
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BASIC FACTS ABOUT THE COMPANY Company Name Address Tel Fax Chairman M.D JM.D Sister Concern Working Hours Vision Established on Website : Peekay Steel Castings (P) Ltd : Nallalam, Calicut - 673027 : 0495-2421701 : 0495-2420724 : P.K Ahammad : K.E. Moidu : K.E. Shanavas : Peekay Steel Castings (P) Ltd Coimbatore, Tamil Nadu : 8hrs : To be an engineering conglomerate : 09-04-1991 : www.peekaysteel.com www.peekayrm.com COMPANY LOCATION (CALICUT) Nearest Airports : Calicut International Airport 26 Kms Cochin International Airport 185 Kms Nearest Seaports : Cochin, about 210 Kms Mangalore, about 240 Kms By Road : 6 Kms from Calicut town towards south by NH17 210 Kms from Kochi towards north By Rail : Calicut Railway Station, 5 Kms from factory Quality assurance : ISO 9001-2000 BIS
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COMPANY VISION To be an engineering conglomerate and lead Peekay to new horizons, expanding and diversifying to new industries and cutting edge technologies. A one stop supplier to all the major OEM's globally in terms of ready to assemble machined castings, forging and fabrications requirements globally. COMPANY MISSION To produce 13,200 Tons of Steel Castings in the next financial year.
To serve the customers, with wide range of requirements starting from 0.5kg to 12 Tons single casting from our different plants in different locations
Emerge as one of the top 5 casting manufactures in the world. COMPANY OBJECTIVES Peekay Steel Castings (P) Ltd shall consistently and diligently manufacture products exceeding the expectation of our customers, to remain a leader in casting market by excellence in total quality performance. The foundry is committed to its quality policy and objectives. To achieve this, the foundry had formulated a quality systems and assurance program to bring about improvements in all areas of operations including: Continuous effort to improve product Quality Training and motivation of employees
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Improve professionalism and competence Reduce rejections, rework & wastage and
Conserve energy
COMPANY GOAL Our goal is to provide overall superior service and value for money in every market segment we compete. Anybody can manufacture but very few organizations can excel in serving the customer with utmost integrity and high-end technology products. Every employee is a partner in our progress and benefits from our profits." QUALITY POLICY PEEKAY STEEL CASTINGS (P) LTD. shall consistently and diligently manufacture products exceeding the expectation of our customers, to remain a leader in casting market by excellence in total quality performance. The Foundry is committed to its quality policy and objectives. To achieve this to bring about improvements in all areas of operation including: Training and motivation of employees. PRODUCTS AND MARKETS PRODUCTS Peekay Steel Castings (P) Ltd, manufacturing high quality steel castings made of Carbon steel, Alloy steel, Stainless steel, Duplex steel, Nickel base alloys etc. in various sizes and weighs up to 11000 Kgs per piece for the petrochemical industry, water supply, earth moving, transportation and other engineering industries.
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Product List: Gate valve components Plug valve components Control and special valve components Ball valve components Butterfly valve components Engineering components GATE VALVE A gate valve or sluince valve is a valve that opens by lifting a round or rectangular gate/ wedge out of the path of fluid. The distinct feature of a gate valve is the sealing surfaces between the gates and seats are planner. The gate face can form a wedge shape or they can be parallel. Gate valves are sometimes used for regulating flow, but many are not suited for this purpose, having been designed to be fully opened or closed. When fully open, the typical gate valve has no obstruction in the flow path, resulting in very friction loss. BUTTERFLY VALVE A butterfly valve is a type of flow control device, typically used to regulate a fluid flowing through a section of pipe. The valve is similar in operation to ball valve. A flat circular plate is positioned in the center of the pipe. The plate has a rod through it connected to an actuator on the outside of the valve. Rotating the actuator turns the plate either parallel or perpendicular to flow. Unlike a ball valve, the plate is always present
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within the flow therefore a pressure drop is always induced in the flow regardless of valve position. BALL VALVE A ball valve is a valve that opens by turning a handle attached to a ball inside the valve. The ball has a pole or port through the middle so that when the port is in line with both ends of the valve, flow will occur. When the valve is closed the hole is perpendicular to the ends of the valve, and the flow is blocked. The handle position lets you see the valves position. Ball valves are durable and usually work to achieve perfect shut off even after years of disuse. GLOBE VALUE A globe valve is a device for regulating flow in a pipeline consisting of a movable disk type element and a stationary ring seat in a generally spherical body. These valves are named for their spherical body shape with the two halves of the body being separated by an internal baffle. This has an opening that forms a seat onto which a movable plug cab be screwed in order to close the valve. In globe valves, the plug is connected to a steam which is operated by screw action manual valves. Typically, automated valves use sliding teems. Automated globe valves have a smooth stem rather than threaded and are opened and closed by an actuator assembly. When globe valve is manually operated the stem is turned by a hand wheel. CHECK VALVE A check valve is a mechanical device, a valve that normally
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allows fluid to flow through it in only one direction. Check valves are two- port valves, meaning have two openings in the body, one for fluid entry and the other for fluid exit. There are various types of check valves used in a wide variety of applications. Check valves are often a part of common household items. Although they are available in a wide range of sizes and costs, many check valves are very small, simple and cheap. Check valves work automatically and most are not controlled by a person or any external control, accordingly most do not have any valve handle or stem. The bodies (external shells) of most check valves are made of plastic or metal. PLUG VALVE Plug valves are valves with cylindrical or conically tapered plugs which can be rotated inside the valve body to control flow through the valve. The plugs in plug valves have one or more hollow passage ways going sideways through the plug, so that fluid can flow through the plug when the valve is open. Plug valves are simple and often economical. KEY RESULT ACTIVITIES Customer satisfaction Minimum pollution Quality products and services Maximum productivity
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Peekay Steel Casting (P) Ltd is top in steel industry today. Its the knowledge base and global infrastructure they have built since long time and have helped to make them one of the leading providers of marketing, finance and logistic services to the steel industry. The value both independence and are proud of their reputation in the industry as a dependable, straight forward and long term partner. They are committed to meet the challenges and ever changing demands of todays world wide steel market place by continuously diversifying their product line and service portfolio. They take pride in their long standing relationship with their customer based on continuous supply, competitive pricing, excellent service and reliability CERTIFICATIONS, AWARDS, RECOGNITION CERTIFICATIONS
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ISO 9001-2000 by TUV German company has been certified since 2000
2. AD 2000- Merkblatt by TUV German company has been certified since 2000 3. Certificate of quality system for material manufacturer according to directive 97/23/EG Germany 4. Approval of manufacturer certificate by DNV(DET NORSKE VERTIAS) AWARDS AND RECOGNITION Largest private engineering entity in Kerala Largest exporter of engineering goods from Kerala
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A major contributor to the national exchequer from this part of India The top duty payer and the highest growth rate
Awards in the organized private sector in the Calicut
Central Excise Commission rate for 3 years Dhatu Nayak Award 2004 from All India Induction Furnaces Association First Rolling Mill in Kerala producing 8mm CTD Bar. First Rolling Mill in Kerala with ISO ISI Certifications.
The only Foundry in Kerala producing 11 Tons single piece casting,
The only Foundry in India having all third party and other accreditions under one umbrella.
RENOWNED PROJECTS 1. JGC Hawiyah NGL 2. RAS LAFAN Ethylene Cracker 3. Jubail Chevron Philips 4. RAS GAS II 5. SNAM Kurusaniya 6. Rabigh END USERS
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1. Chiyoda Corporation 2. Japanese Gas Corporation 3. Engineers India Ltd. 4. Kawasaki Ship Building Corporation 5. Mitsubishi Heavy Industries 6. Saudi Aramco FUTURE PROGRAMMES Renovate the canteen Plans for building hospitals as a part of corporate social responsibility Plans for building more quarters for the employees Expansion of capacity production from 475-500 tons to 850-950 tons POLICIES Health Safety and Environment Policy: Peekay Steel Castings (P) Ltd is committed to working safely and protecting health of its employees and others that may be affected by our operations and also minimizes impact of our activities on the environment. Believe that all accidents are preventable. Peekay steel casting (P) Ltd will strive for continuous improvement of its Health Safety Environment (HSE) performance by the efficient management of HSE systems. To achieve these objectives Peekay will:
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1. Provide safe equipment, safe living and working place and health care for its employees. 2. Keep its employees, subcontractors and others that they work at its premises fully aware of hazards and safe work practices. 3. Protect the environment from damage and pollution 4. Allocate required resources and provide training to achieve its HSE objectives 5. Encourage all employees to report unsafe acts, practices and conditions and empower them to stop work if safety is endangered. Environment Protection Policy Peekay steel casting (P) Ltd is committed to the protection of the environment from adverse effects consequent to its activities, to a practicable minimum by protecting and preserving the air, water, soil and plant life. This is achieved by:
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Ensuring that all activities are carried out in conveyance with the relevant environmental legislation of India.
2. Seeking to minimize arising, promote recycling, reduce energy consumption and harmful emissions.
3.
Enforcing procedural controls over generation and disposal of hazardous and non-hazardous waste with particular emphasis on the consumption of electricity, fuel and water.
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4. Promoting awareness to employees to develop prevention oriented work attitude. Communicating the policy, obligations and responsibilities laid down by managements to all employees and making the policy available to the public on request.
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CHAPTER II
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ORGANIZATIONAL STRUCTURE
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CORPORATE STRUCTURE
Peekay Private Limited
Peekay Steel Castings Peekay Rolling Mills Peekay Roller Flour Peekay Private limited Private limited Mills Private limited Constructions
Peekay Estate
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BUSINESS LEVEL STRUCTURE
Managing Director
Joint Managing Director
Manager Purchase
Executive director
Chief Executive Works
CFO
HR Manager
Welfare Officer
Executive HR
Stores in Charge
Assistant Manager Purchase
AGM costing, Indirect taxes
Manager IT
AGM Finance
Head Machine Shop
AGM methods
Manager LSF
Senior Manager melting
Senior Manager moulding
Manager Fettling
Senior Manager Project & Maintenance
Manager Quality Assurance
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DEPARTMENTAL LEVEL STRUCTURE
Chairman Managing Director Joint Managing Director Executive Director Manager Purchase Store Incharge Asst. Manager Purchase HR Manager Executive HR Sales Executive Head Machine shop Engineer Met & De Supervisor Welfare Officer AGM Methods Engineer Prodn. Shop Sr. Supervisor DGM HSE Manager Marketing & Planning Asst. Manager Marketing &Planning Sr. Manger Projects & Maintenance Manager Fetling Senior Supervisor Shift Supervisor Manger-LSF Engineer Production Supervisor Fettling Senior Manager Melting Engineer Melting Asst. Foreman Sr. Supervisor Production Engineer QA Supervisor Scrap movement Executive Planning Executive Moulding Senior Manager Moulding Sr. Supervisor Moulding Asst. Foreman Engineer QC Supervisor Technical Asst. Engineer Maintenance Supervisor Moulding Engineer Heat Treatment Foreman Engineer Inspection Senior Supervisor Supervisor Manager Maintenance Supervisor Electrical Engineer Project Supervisor Mechanical Asst. Foreman AGM-Quality Control Manger QA Junior Manager QA Engineer Testing & Documentation Supervisor Testing Engineer NDT Supervisor Senior Supervisor NDT NDT operator Engineer Welder Manager Indirect taxes Chief Executive Works CRO AGM Coding Export & Indirect taxes Manager Export Executives AGM Finance Asst. Manager Accounts Executive Manager IT
Asst. Foreman
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CHAPTER III
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DEPARTMENTAL PROFILE
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FINANCE DEPARTMENT
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Structure of Finance Department
Chief Finance Officer
AGM Costing, Export Indirect taxes
AGM Finance
Manager Export
Cost Accountant
Accounts Manager
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FINANCE DEPARTMENT Finance is the life blood of the organization. In a firm finance bears as equal position that of production and marketing. Finance activity of the firm mainly concerned with acquiring the working capital it needs for production purpose and employees. It in such activities which produce maximum returns on invested capital. The finance department is responsible for all the financial and accounting activities in the company and it is headed with General manager (finance) assisted by AGM (finance), AGM (costing of indirect taxation), accounts manager, In order to keep records of all financial dealings done by Peekay Steel Castings, it maintains the record related to finance and sends to the head of the company. All the transactions of the Peekay Steel Pvt Ltd. are made through computers. The company wants to know the financial position of their business on a particular date. The business men is not able to remember all the transactions that had taken place in the company mainly chooses computers. They are using the computers in order to avoid any fraudulent activities. Every day sales has been done. All the sales are through bills. Details about everyday sales are clearly entered into the computers. At any moment the details of sales are available to the management. All the transactions are done through banks. Daily sales are done and amount of sales are gone to the bank. Therefore we can understand that all transactions of this company are done through banks.
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The main three functions of finance departments are: Arrangement of Funds Management of Capital Maintaining Capital PEEKAY STEEL CASTINGS arrange the funds through bank loans. By examining the month stock statements the bank sanction the particular amount, 50% to 60% of the sanctioned amount can be availed. Major share hold within the family itself. The amount is raised by 15% of inventory sales revenue of almost 200 MT per day. The Financial accounting software is used for maintaining the accounts. Except the payment voucher, all other vouchers are computerized. Six sectional accountants are the charge of the accounts. The record and the net effect are taken to submit before their respective chartered accountants. FUNCTIONS Recording of the day to day business transactions.
Preparation of various statements regarding stock receivables etc are submitted to various authorities like bankers, insurers etc.
Planning and controlling of the expenses or funds for production. Approving and making payments to different parties or creditors. Receiving payments from customers or dealers from correct time. Raising short term loan or credit from bank and other financial institution.
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Preparation of sales budgets or revenue budgets and expenditure budgets on a quarterly basis.
Preparation and maintenance of costing records. Preparation of fund flow statement and cash flow statement for every month. Timely preparation and filling of financial records.
Preparing and filling of quarterly and final income tax return.
Preparation or implementation of cost reduction and cost control programmes. To collect all some due to the company in time as per sales, orders etc. To make timely payment to the creditors, suppliers, contractors, employees, government statutory bodies, service providers etc.
Timely payment of salary/wage perks to employees as per agreement.
To assist all type of audit work. To manage cash proper to maintain liquidity. To assist all departments in providing all financial administration of all transactions. To make proper entries in books of accounts and extract report like trial balance P&L A/c, Balance Sheet on a time bound basis. To make decisions on capital management, capital restructuring and portfolio management. Planning for future expansion and studying the feasibility of future expansion projects.
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Another important function is the timely payment of all statutory requirement of the organization and payment for procurement of raw materials, transportation, spare parts and also creditors.
BOOKS MAINTAINED Cash Book Bank Book Sales Day Book Purchase Day Book Journal Register Debtors Ledger General Ledger Fixed Asset Register Revenue Income and Expense Register
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HUMAN RESOURCE DEPARTMENT
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Structure of Human Resource Department
JOINT MANAGING DIRECTOR
EXECUTIVE DIRECTOR
CHIEF EXECUTIVE WORKS
HUMAN RESOURCE MANAGER
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HUMAN RESOURCE DEPARTMENT
Human resource of function is an important function among the functions. It is sad so because the formal function can be made to be executed only when there are human requirement. So this function makes facilitate to find out the right qualified persons to the right job at the right time when it is required. Some activities that come under the personnel department are Selection Process, Recruitment Process, Internship Training and Performance Appraisal. The human Resource function is completely job oriented function. In an organization the candidates selected will be on the basis of the required skill of the job and the qualities that are needed for the performance of a particular job will be analyzed by the HR department. And the candidates are being selected on the basis of this. Once selected candidates will be given proper training. If the company is more satisfied with the persons performance, he may be given more packages that could make them committed to their job and to stick in the same company. Human resources are asset of any organization. Therefore managing the human resources are the most important functions of the organization. So it is essential for the organization to fix a separate department for the management of human resources. PEEKAY STEEL CASTINGS PVT LTD. has an efficient human resource department, which is headed by HR Manager. This Department is mainly responsible for personnel functions of the company for resulting in timely action for maintaining smooth industrial relations leading to employee's morale and
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productivity. The personnel department renders all personnel and establishment services to all persons. The company has around 2500 employees. OBJECTIVES To create & utilize an able & motivated work force. To accomplish the basic organizational goals. To establish and maintain sound organizational structure & desirable working relationships among all the members
To identify and satisfy individual and group needs by providing adequate & equitable wages, incentives, employee benefits & social security & measures for challenging work, prestige, recognition, security, status etc.
To provide leadership for management of industrial relation & employees welfare functions of the company. To provide basics for corporate strategies & policies for maintenance of industrial peace & for workers motivation. PERFORMANCE APPRAISAL The performance appraisal, also known as employee appraisal, is a method by which the performance of an employee is evaluated generally in terms of quality, quantity, cost and time. It is the method of evaluating the behaviour of employees in the work spot, normally including both the quantitative and qualitative aspects of job performance.
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Performance Appraisal is usually done once in a while. For technical and nontechnical staffs. Done with the consent of the reporting officer.

A form is given to each employee who is filled by themselves. Ranking method is mainly used for Performance Appraisal, which helps to identify ones on dislikes about the job.
As need identification employee itself suggest what training they need. Salary or wages Compensation or salary becomes a more complicated and strategic issues of all company. In this company the management had really understood the importance of salary in recruiting, retaining and motivating the employees. The company is paying a very good salary to all workers. Salary is paid on the basis of their efficiency. More salary is paid if they are working overtime. Motivation tools In order to motivate the employees to do their work efficiently management of this company has adopted certain techniques. Every year performance appraisal is done by the higher officers and increments are given. Yearly they gives two bonus, insurance, ESI and Provident Fund.
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Work environment It is the policy of Peekay Steels Pvt Ltd, Nallalam, Calicut to attain and maintain high standard of occupational health, safety and environment at its work and comply with the relevant requirement of occupational health and safety. EMPLOYEE COMPENSATION The term employee compensation includes remuneration, incentives and fringe benefits. Employee Benefits Fringe benefits refer to various extra benefits provided to employees in addition to the compensation paid in the form wage or salary. This covers bonus, social security measures, and retirement benefits like Provident fund, gratuity, pension, workmen's compensation, housing, medical and canteen and so on.

Free lunch to all employees. Accommodation to employees working inside foundry.
Retirement benefits like PF, ESI and Gratuity.
Free medical checkup for employees working inside the foundry.
ATTENDANCE SYSTEM Working hours of PEEKAY STEL CASTINGS includes three shifts which consist of 8 hrs per 'shift. The attendance is recorded using biometric attendance machine muster role.
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RECORDS TO BE MAINTAINED Employee personal file, attendance and leave records ISO related documents Safety training records
Department manual
Employee competency model Training Record/Need identification and effectiveness evaluation Performance Appraisal Reports Apprentice Contract form
Certificate (service, salary, residential proof, NOC)
Project/Implant training Categorized Resumes
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PURCHASE DEPARTMENT
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Structure of Purchase Department
PURCHASE MANAGER
PURCHASE ASST MANAGER
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PURCHASE DEPARTMENT Purchasing refers to a business or organization attempting to acquire goods or services to accomplish the goals of the organization. Purchasing is the procurement of the raw materials from source keeping in view of reducing the cost associated with it. The raw material for PEEKAY GROUP mainly consist of high quality scrap, which either purchased through domestic vendors or outside India. The other main raw material sand is purchased from two mines in Tamil Nadu. Organizations have become concerned about the purchasing activities as these have a direct impact on the bottom-line of the company. To handle these activities in a more systematic and structured way many companies all over the world are following a process called strategic sourcing. Through strategic sourcing, organizations are achieving a substantial amount of savings through the adoption of different techno-commercial, cost effective measures and leveraging the knowledge and quality of products and services. At Peekay Steel the approach has been to establish long term relationships with vendors for the procurement of different grades of steel for their customized castings. The raw materials for the TMT bar production is mainly scrap brought imported from foreign countries, especially the Middle East, where there is a significant amount of construction going on. Most of this construction debris comes back to the country and become the prime source of raw materials for TMT bars. FUNCTIONS
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Establish suitable system for identification of sources of materials, quality assurance, inspections and acceptance and bill passing.
Ensure dispatches are scheduled and the same are fulfilled.
Prepare detailed schedules for purchase and their delivery to ensure availability of materials and services as per schedules.
Proper supervision of work of clearing agents concerning customs, excise and other statutory need and ensure smooth transportation of goods.
The timely supply is guaranteed. Maintenance of records and files of purchases. Negotiation or bidding contracts. Maintain better relationship with vendors. Placement and follow up of orders. Determination of the need for raw materials and other supplies.
With the assistance of quality assurance is responsible for the selection, qualification, and disqualification of the company suppliers.
PURCHASE PROCEDURE
The purchase executive classifies and codifies the items which are already present at the foundry.
They determine the requirement of each and every section of production and other departments.
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Then they choose the supplier to keeping in view their past performance and the contracts are entered for specific period for quantity to be purchased at determined rate. Follow up will also be made for the order to ensure the delivery of goods of right quality, in right quantity at a right time. The ordered materials are supplied to store department. It is to ensure the material have the prescribed quality. Then they verify the payments and bills. The store department then recommend for payment. The purchase department also does the function of vendor evaluation which is used for future reference.
The purchase department also does the job of choosing the mode of transport i.e.; whether to go for road, water, rail or air transport.
It all depends on variety of factors like type of material, time available, charges incurred, safety, speed, reliability etc.
Documents maintained by the Purchase Department Enquiry Letter Purchase Order Non Acceptance Report Indent Approved Supplier List
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Comparative Statement Of Quotations Vendors History Card Suppliers Evaluation Form Supplier Assessment Card etc.
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MARKETING DEPARTMENT
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Structure of Marketing Department
General Manager (Business Development)
Branch in Charge
Sales Manager
Executives
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MARKETING DEPARTMENT
Planning and Marketing Department is the backbone of the company. Planning means deciding in advance what is to be done, when it is to be done, and by whom it is to be done. It is an intellectual process of thinking before doing. To plan means to look ahead and check out future course of action. Planning leads the organisation towards clearly specified objectives with clearest possible view of the future. It ends with decision making i.e.; choosing the best alternative from the available future course of action. Marketing Management is an important function which is concerned with those activities that are necessary to determine and satisfy the needs of the customers so as to achieve the objective of business. Marketing begins before actual production takes place. Emphasis is given on product planning and development to match products with market. The primary objective of marketing is to enhance sales through consumer satisfaction. The process of processing an order starts from the marketing department where the enquiry is made by the customer. The specifications provided are passed on to the Methods and Pattern Shop, where the design in created and analyzed using pro-cast, a software which stimulates the casting process highlighting temperature, flow and solidification of molten metal in the cast.
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A modified design which includes remedies to issues related to design flaws or constraints is created which is later sent to the customer for verification. The shop also evaluates the options and takes tock of the amount of work needed to bring out the product. It also looks at the grade of steel and kind of material required making the pattern. The Methods and Patterns shop then pass on the order to the QA (Quality Assurance) department which checks for the) requirements of the order in terms of standards of steel and production process to be followed. They also look at the costs involved in welding and welding standards to be followed throughout the process. If there are certain portions which the company will be unable to meet, this will be reported in writing to the customer through the marketing Department in the form of an Order Acceptance (OA) form. Once the customer agrees to the changes suggested in the order, the OA form becomes a Purchase order for the Marketing Department. This in turn is informed to the different departments concerned through the Management Information System in use. FUNCTIONS 1. Order Processing The marketing and planning department receives purchase order from the customer through e-mail, fax, courier etc. This is forwarded to the director; the same then redirected to Market & Planning department and is then registered in the work order register. The order is then
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scrutinized with respect to quotation, delivery date, grade etc. The order is then distributed to various departments. 2. Monthly planning for pouring and dispatch The department assesses the pending order status. A target is fixed for a month in the production meeting chaired by the director. The department then prepares plan after interacting with the moulding department for day wise allocation of items as per the melting and moulding capacity per day. After making plan it is consulted with the director for approval. The department of prepares 2-3 plans in case one of them is found to be non-feasible. Bill of material is forwarded to purchase and stores department for procuring raw material on time. 3. Handling Drawings The department receives the customer drawing for new order and the copies are then distributed to various departments. 4. Handling Tender Documents The department receives the tenders through e-mails, courier and fax. If unacceptable it is highlighted to customers attracting any change in cost. The tender then distributed to different departments. 5. Handling Customer Complaints To handle the complaints of customers the departments gets the complaints through e-mail and courier and this is then registered. The
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complaint is then sent to quality department for study and hereafter the corrective action is taken. 6. Handling Customer Feed Back A feedback form is sent to the customer once in every 6 months which include rating on product quality, product delivery, customer enquiry, response time, promptness in handling customer complaints, overall customer service etc. The rating is on a 5 point scale which is as follows: Poor Average Satisfactory Very Good Excellent
PRODUCT In the simple sense, a product can be defined as everything the purchaser gets in exchange for his money. It is a bundle of satisfaction that a consumer buys. To most people the term product means a tangible good, e.g. pen, shoe, TV. However, service and ideas are also products. The Peekay steel bars are available in: 8mm
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10 mm 12mm 16mm 20mm 25mm
PRICE PEEKAY STEEL CASTINGS does not have scandalized product. Their products are customized products. The company fixes the price of the product taking into account many factors like price prevailing in the market and competitors price. Sometimes they also take into account quality of the product etc. Thus they follow going rate as well as perceived value pricing strategy. PROMOTIONAL ACTIVITIES A companys product may be super. It may be attractively packaged. It may have reasonable price. It may be built according to customers needs and desires. But people will not by the product if they have never heard of it. People must know the availability of the products, features, price etc. marketers must communicate the product, its features etc. to the right message in the language that is understood by them. There must be proper flow of information from the producer to the consumer either along with the product or well in advance of the
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introduction of the product in to the market. This role is played by promotion. PEEKAY STEEL CASTINGS is manufacturing and selling engineering goods and more over their products are products are customized in nature. Hence the reputation of the company plays a major role in gaining customers. Also the quality of the product, the delivery time have an impact on the customers. Also the speed at which the goods are delivered and qualities at which goods are produced are also taken in to account. The various quality certificates which is held by PEEKAY STEEL CASTINGS, act as a mean to attract customers. Thus these itself act as a promotional tool in attracting customers and word of mouth is the biggest means of advertising in the company. PHYSICAL DISTRIBUTION Goods are produced for sale to the ultimate consumers. When a product has been developed and made ready and its price also determined the next task is its distribution. Distribution refers to bringing the product to the market and giving it to the final consumers Channels of distribution Channels of distribution means the path or network or the pipeline through which the products are made available to the customers, thus providing time and place utility. In Peekay Steel Castings the following channels of distribution is used:
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The sales in Peekay Steels are through the dealers and also by the individual buyers. The sales through the dealers are more than that of individual buyers. Sales through dealers are 80%, where as sales by individual buyers are only 20%. Mostly the sales to dealers are on credit basis. The individual builders and buyers make advance payments. The credits are only given for those known people. For the dealers they are given on credit basis. PEOPLE It is the people that the marketer has to deal with. People may include the people to whom the goods are sold and the people through whom the goods are sold. This factor will be the reason as well as resources for success in the marketing. This company clearly knows to whom the product is to be sold and through whom it should be done. So they have given importance to this factor also.
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PRODUCTION DEPARTMENT
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Structure of Production Department
J.M. Director
Manager Casting
Manager Rolling
Production In Charge
Production In Charge
Production Supervisor Skilled Workers & Apprentice
Production Supervisor Skilled Workers & Apprentice
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PRODUCTION DEPARTMENT A typical casting begins when an order is entered into Peekay steel production control programme. This entry adds it to the production schedule which in turn creates a demand for raw materials. They are scrap and sand. In addition, pattern and core boxes are taken to the pattern shop and prepped for the production run. Typically, the core room reacts first, getting the necessary cores ready for setting as the molds are being made. Next, molds, valves (upper and lower) are made and sent to the assembly area. At the assembly area, molds are flow coated and cores are set in place. The mold is then closed up for pouring. As the assembled molds are being staged on the pour-off lines, a heat is melted in the arc furnace. Molten steel from the furnace is brought to the molds on the pouring lines in a refactory lined pouring ladle. Once poured, the molds are allowed to cool before next being sent to the shakeout. At the shakeout, the castings are seperated from the sand mold. As the castings are removed from the shakeout they are sent to the machine shop where they are finished to the customer specifications.
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MANUFACTURING PROCESS The manufacturing process is classified in five: 1. Pattern Making 2. Moulding and Core Making 3. Melting and Casting 4. Fettling 5. Testing and Inspection 1. Pattern Making Pattern is the principal tool used in casting process. In the process of casting, a pattern is a replica of the object to be cast, used to prepare the cavity in to which molten material will be poured during the casting process. Further, it may be defined as the model of anything so constructed that it may use for forming an impression called 'mould'. Patterns used in sand casting may be made of Wood, Araldite, Aluminium, Shell or Cast Iron. In pattern making wood is most commonly used. It is has many advantages over other materials as it can be easily cut and fabricated in to numerous forms by gluing, bending and cutting. One of the disadvantages is that it is highly affected by the moisture and also the changes in shapes. The major types of patterns are Single Piece Pattern Split Pattern Match Plate Pattern
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Gated Pattern Sweep Pattern Shell Pattern
Skelton Pattern
Machineries used in pattern making Planning tool grinder Wood thickness planer cum surface planer Drilling Machine Band saw machine Belt and disk sender machine Portable saw circular cutting machine Portable zig saw machine Portable planner machine Measuring Instruments
Digital and Electronic Equipment
2. Moulding and Core Making Moulding is the process of manufacturing by shaping pliable raw material using a rigid frame or model called a mould. A mould is a hollowed-out block that is filled with a liquid like plastic, glass, metal, or ceramic raw materials. The liquid hardens or sets inside the mould adopting its shape. Moulding sand, Foundry sand, or Green sand that when moistened or oiled tends to pack well and hold its shape. It is used in the process of sand casting. Properties of moulding sand
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Porosity Collapsity Ability to flow Adhesiveness Cohesiveness Mould Making Process After making pattern from the pattern shop it is arranged properly. Then the box size is selected as per the method card. In method card all the details about the location of the chills, fixation of tie bar etc. is given. Then the top and bottom side of the pattern is cleaned to arrange chills, reinforcement bar and gating system in the pattern. The chills are of different shape and the whole detail of its sizes is given on the method card. Using fresh sand the top half and the bottom of the pattern and is filled and is fixed at suitable places to do the ramming. There are two types of ramming method - pneumatic ramming and wooden ramming. To fill the area in contact with the metal new sand can be used. The remaining section of the box is filled with reclined sand. After setting the sand pre-heating of the mould and core is done by torching. Then coating is applied on the mould using brushes. There are three types of coating: Isomol - White Colour Serakote - Blue Zrakofluid - Green The coated area of the mould is then torched. Then opening running system is covered using cotton piece. After preparing the mould
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it is the time for core setting the wall thickness and core print clearance is checked. Then the mould is closed by joining the boxes by welding and certain weight is put on the moulding box. This is because the weight on the mould will be changing or lifting during the pouring process. 3. Melting and Casting Different types of scraps are used in melting process. Each scrap has its own properties. The different scraps are MS, 316, 304, 430, 410, 2205 scraps. After collecting the scraps from specified area it is lifted with the help of magnetic crane to the place near the furnace. The molten metal has certain percentage of chemical compounds such as C, Mn, Si, P, S, Cr, Ni, Mo, Cu, V, Al, Nb, NE. The induction furnace has to be used in the furnace shop. An induction furnace is an electrical furnace in which the heat is applied by induction heating of a crucible around which water-cooled magnetic coils are wound. The advantage of the induction furnace is a clean, energy-efficient and well-controllable melting process compared to most other means of melting point. The coil acts as the primary and the scraps acts as the secondary. Then the current is passed through this and the electromagnetic induction will be produced. Two hours are taken for fully melting the scraps. Various melting furnaces are used for melting different grades of steel. Each furnace have different kilowatt. Light casting 6 tons - 130KW
Heavy casting 6 tons - 2000KW

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5 tons 9 tons
- 1500KW - 4000KW
Pyrometer is used to check the melting temperature. The melting point of scrap is 1539 C and the maximum temperature is 1600 C then sand inclusions, pinholes, cracks will be produced in the casting. The tapping temperature of Carbon Steel: 1590 C - 1600 C Stainless Steel: 1550 C - 1580 C 4. Fettling Fettling is the process of cutting of unwanted parts, cleaning and finishing the surfaces. This is the process of stripping away any unwanted metal to produce the finished cast product and can include the processes of short blasting are welding, oxy-cutting, dressing, welding, and heat treating. This includes Removal of core in casting
Removal of gates, riser, sprues, and runner from the casting by knocking and breaking with hammer
Removal of unwanted projections Repairing casting to fill up blow holes Straightening the warped or deformed casting
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Fettling Process of Carbon Steel
Knock out machine Gas cut Heat Treatment Shot Blasting & Rough fettling Magnetic particle Inspection Welding Finish Fettling Stress release & radiography Test Welding / Gauging Inspection Despatch
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Stainless Steel Process
Knock Out Machine Gas Cut Are Welding Heat Treatment Shot Blasting Pickling Penetrate Test Welding Finish Fettling Final inspection Despatch
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Radiography Qualified and Experienced Inspectors Radiography exposure hall for Iridium 192 and cobalt 60 source Density meter Film Viewers Radiography is the use of ionizing electromagnetic radiation to view object in a way that can't be seen otherwise. Radiography in general should not be confused with the use of ionizing radiation to change or modify objects; radiography's purpose is strictly for viewing. Industrial radiography has grown out of engineering, and is major element of nondestructive testing (NDT). It is a method of inspecting materials for hidden flaws by using the ability of short wavelength electromagnetic radiation to penetrate various materials.
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QUALITY CONTROL DEPARTMENT
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Structure of Quality Control Department
AGM Methods & QC
Engineer Welding
Engineer Inspection
Engineer NDT
Sr. Supervisor NDT
Senior Supervisor Supervisor
Supervisor
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QUALITY CONTROL DEPARTMENT Quality Control during the Manufacturing Process One of the advantages of quality control becomes effective the need for inspection decreases. Also this minimizes the wastages. In quality control statistical sampling and testing in used before accepting the raw materials. Tests done in quality control The tests are usually done in the lab. In lab two types of testing is done. They are Chemical Testing Mechanical Testing
Chemical Testing Under chemical testing they have moisture testing, sieve testing and other test to inspect the chemical composition of the sand. Moisture Testing A small portion of the raw materials, sand is taken and it is then tested to determine the moisture content. Sieve Shaker After that the sand is the sieved using sand sieve. After this process weight of each sieve is measured. It is to measure the fineness of
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the sand. If the sand is fine then most of the weight is found distributed in last three sieves. Mechanical Testing Under mechanical testing they have compression testing, tensile testing and chirpy testing. Mechanical testing is used to measure the strength, hardness, etc. of mould as well as the TMT Bars. In mechanical testing machines used are universal string machine and chirpy machine. Compression Testing Machine Compression testing machine is designed for test materials under compression bending, transverse and shear loads. Hardness test on metals can also be conducted. Mould Hardness Tester When mould is made a small test bar is also made. This bar is tested to determine the hardness of the mould. To ensure the quality of the product various tests are provided. They are Dimensional inspection Magnetic particle inspection Ultrasonic testing Radiography
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Documents required in control are: Drawing Specification Blue Print Inspection Instruction Test Procedure Operation Sheet Quality Manual
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QUALITY ASSURANCE DEPARTMENT
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Structure of Quality Assurance Department
Manager QA
Engineer Heat Treatment Foremen
Engineer- Metallurgy Engineer Testing & Documentation
Engineer Welding
Supervisor Testing
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QUALITY ASSURANCE DEPARTMENT Quality Assurance quality assurance is that well organized programme for all planned and systematic activity which is necessary to provide adequate confidence to the management. Quality control is a part of the quality assurance and comes under the QA Department. The Methods and Pattern shop pass on the order to the QA (Quality Assurance) department which checks for the requirements of the order in terms of standards of steel and production process to be followed. They also look at the costs involved in welding and wielding standards to be followed throughout the process. Responsibility of QA Department
To prepare issue and maintain quality manual, containing quality policy and up to date description.
To assure the correct product specification is dispatched to the customers. QUALITY POLICY PEEKAY STEEL CASTINGS (P) LIMITED shall consistently and diligently manufacture products exceeding the expectation of the customers, to remain a market leader by excellence in total quality performance. It commits to continually improve its processes, personal and system towards meeting customer satisfaction.
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QUALITY OBJECTIVES To reduce the customer complaints on a continual basis. To educate customers about products. To measure and improve customer satisfaction continually. To reduce piping defects in ingots. To reduce of grade heats.
To bring down percentage of break down of critical machine.
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PROJECTS AND MAINTENANCE DEPARTMENT
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Structure of Projects and Maintenance Department
Chief Executive Works
Manager Project &. Maintenance
Manager Maintenance
Engineer Project
Engineer Maintenance
Supervisor Electrical
Supervisor Mechanical
Assistant Foremen
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PROJECTS AND MAINTENANCE DEPARTMENT
Today, many companies view maintenance as the last controllable function in which they have an opportunity to reduce costs. However, arbitrarily reducing the maintenance budget can lead to lower levels of operating capacity and reliability. Therefore, many companies are attempting to implement a variety of maintenance strategies and tactics. Functions
To maintain existing plant and equipment.
To maintain existing building and premises. Equipment inspection and lubrication. Replacement of worn-out spares. Keeping stock of spare parts. Liaison with the government boards like Kerala State Electricity Board etc. Janitorial Services The maintenance at Peekay Steel Castings (P) Ltd. adheres to following areas: a. Electrical Maintenance In electrical maintenance the maintenance is done on machine and equipments, transport vehicles, material handling equipments, steam
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generators, boilers, compressors and furnaces. Lubricating of machines is also included in it. b. Mechanical Maintenance Under these electrical equipments such as generators, motors, lighting, meters, electrical installation etc.; is maintained. c. Routine Maintenance The routine maintenance includes periodic inspection, cleaning, lubrication and repair of production equipments in their service life. d. Planned Maintenance Planned maintenance helps to determine the condition of inservice equipments in order to predict when maintenance should be performed. This approach offers cost savings over routine or time - based preventive maintenance because tasks are only when warranted.
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STORES DEPARTMENT
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Structure of Stores Department
Stores Store in charge
Store keeper
Store Executive
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STORES DEPARTMENT Types of Stores There are two types of stores: Open Stores In open types stores all the raw materials are kept outside and at the time of production it is simply taken near to the production department. Closed Stores In closed type stores the raw materials are kept in enclosed space. Store Procedures The materials have definite shell life and are consumed before expiry date. It is the responsibility of store person to check the expiry date. If at any time, the raw materials are found to be nearing the expiry date the store in charge is send to renew the concerned.
DOCUMENTS TO BE MAINTAINED BY STORES DEPARTMENT
GEN (Goods Received Note)
Store Requisition Slip Stores Ledger Intent Despatch Note
Miscellaneous
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FINDINGS
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FINDINGS Peekay Steel Castings is the South India's only producer of Steel Casting. As the brand image of the Peekay Steel Castings is a wellestablished and trusted one. Company Enjoys turnover of more than USD 150 million. Company offers Steel Castings in different grades and in high quality under ISO 9001: 2008. Company is the holder of many awards and certification. The organization has a good opportunity in the future as the people in the 21st century are very quality conscious. Even though there is tight competition, the consumers have a preference to Peekay product because of its high quality. The company also has a wide opportunity of product diversification in future. Thus, keeping the commitment towards consumer's company will be able to improve the performance in the coming days.
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CONCLUSION
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CONCLUSION The organization study conducted at Peekay Steel Castings (P) Ltd. has been one of the most informative and rewarding experience for me. This study throws light on the various strategies and tactics the firm pursues to sustain its market share. The Peekay Steel Castings (P) Ltd. is gully export oriented company and making large profit out of it. The ongoing process of maintaining quality of the product has helped the company to secure ISO 9001-2008 certification and various other foreign certificates. The coordination and the cooperation of the employees and between various departments enable the smooth functioning of the organization as the achievement of corporate goal. Moreover the far sighted vision of its promoters and their commitment to quality and customer satisfaction has earned the group a reputation among its customers and clients. This study was really very much helpful to understand the Organizational and Managerial Structure of the company. In addition it also paved the way to understand how well a company can be coordinated, what are the policies to be followed by a company for the same etc. In total, the study was very informative. Thus, the nature of Performance Appraisal and its effectiveness depends a great deal on how human resources in the industry are viewed and treated. People are to be treated as resources of the industry. An
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organization interested in developing the capabilities of its employees, should understand the nature and capabilities required to perform different functions as well as the dynamics underlying the development of these capabilities in organizational content. These capabilities can be considered to fall under four categories. They are:1) Technical Capabilities 2) Managerial Capabilities 3) Behavioural (human) Capabilities 4) Conceptual Capabilities The extents to which the various capabilities are required for the performance of the job differ from level to level in the organizational hierarchy.
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CHAPTER IV
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SWOT ANALYSIS
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SWOT ANALYSIS STRENGTHS Easy power and water supply The promoters hail from reputed background and are of highly means and expensive The company is pioneer in the industry and at present one of the major players Large adaptive labour force Demand based production Storage time of the final product is zero Low accident rates Good employee employer relationship Good feedback system Excellent reputation Use of advanced technology in the foundry
Well-developed quality controlled system in the company
Employees of Peekay Steel Castings are working with highly cooperative minds Low labour cost
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WEAKNESSES Late start Company is not much concentrating on marketing activities
OPPORTUNITIES Availability of raw materials in abundance The steel consumption is found to grow in near future Maximum exploitation of export market
THREATS High competition Government regulations
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CHAPTER - V
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107
SUGGESTIONS
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SUGGESTIONS
Motivate the employees to enhance their work. Enhance the communication between management and workers. Give appropriate training for employees. This will improve productivity of workers. The company should increase the advertisement in different in Exports can create a large level of income. So the company should As Peekay Steel Castings has a high brand image and trust, the It would worthy the company spend more money on promotional The company has large number of workers, thus it is very essential
efficiency and
different medias.
create demand in export market.
company should go for more product diversification. activity. to facilitate promotional activities.
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APPENDIXES
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BIBLIOGRAPHY
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BIBLIOGRAPHY
BOOKS: 1. Edwin.B Flippo - Principles of Personnel management. 2. L.M. Prasad - Human Resource Management.
WEBSITES www.google.com www.peekayrm.com www.peekaysteel.com www.steelindustry.com
MAGAZINES
Company magazines, journals. Company brochures.
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ANNEXURE
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Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

A study of organizational activities in all functional areas in an organization

To understand the inter-relation of each department

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

TOP TEN STEEL PRODUCERS GLOBALLY HEAD QUARTERS

ARCELOR LUXEMBOURG MITTAL CHINA

HEBEL 31.1 IRON& STEEL 28.6 BAOSTEEL GROUP

SOUTH KOREA JAPAN JAPAN CHINA

34.0 JFE 22.9

12.9 SHOOGANG CHINA 26.5 TATA STEEL INDIA

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Jindal Steels Limited

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Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Excellent fatigue properties.

Sambhram Academy of Management Studies

Dresser products industrials, France

Nordstorm Audco Inc., USA

Worldwide Oilfield Equipment, Pune

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Awards in the organized private sector in the Calicut

The only Foundry in Kerala producing 11 Tons single piece casting,

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Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Peekay Private Limited

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BUSINESS LEVEL STRUCTURE

Joint Managing Director

Chief Executive Works

Assistant Manager Purchase

AGM costing, Indirect taxes

Head Machine Shop

Senior Manager melting

Senior Manager moulding

Senior Manager Project & Maintenance

Manager Quality Assurance

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DEPARTMENTAL LEVEL STRUCTURE

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Sambhram Academy of Management Studies

Sambhram Academy of Management Studies

Sambhram Academy of Management Studies