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1.2 Industry Profile
Steel is very important for the development of any economy and is been also
considered as the backbone for the human civilization. Steel level is an important
index for level of social development and also the standard of living of the people
in any country. It is a product of a large and technologically complex industry
having strong forward and backward linkages in terms of material flows and
income generation. All major industrial economies are characterized by the
existence of a strong steel industry and the growth of many of these economies
has been largely shaped by the strength of their steel industries in their initial
stages of development.
The foundry sector is well recognized as one of the supporting industries for the
machinery and the Automobile industry. With the recent remarkable economic
development in Asia, the production of castings as part of process materials in
every engineering industry has been increased; that of the Asia area is the highest
in the world. However the production of costing per capita is only 8.2kg which is
the lower than world average than 13.6, this fact shows that the production of
castings will surely to increase along with an economic growth not only in the
Asian area, but also in developing countries.
The term Cast Iron is a general term for “Grey cast iron” and “Spheroid graphic
cast iron castings”. Since cast iron is easy to manufacture and its manufacturing
cost is low and besides it has various physical and chemical properties, it is used
in large amount in metal products in almost all areas of industries.
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CHAPTER 2
The Shanti Iron & Steel runs under three partners Mr.Shantilal Porwal,
Mr.Kantilal Porwal and Mr.Santosh Porwal. Shanti Iron & Steel is one of the
largest manufacturers of casted machined oil sumps in India. Company is
expanding its area of operation in all the states.
E-MAIL: marketing@shantiiron.net
TELEPHONE: 0831-4218303
EMPLOYEES: 600
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2.2 Background
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2.4 Vision Mission, Quality Policy:
Vision
The company has a vision for the next ten years to pioneer in supplying casting
of highest value at optimum price, which are sub assembly/parts by itself for
OME‟s in automobile, engineering and industrial applications. It wants to be
“Best single source solution provider” for its entire customer‟s casting
requirements.
Mission
The company wants to help their OEM customer to convert from a design to
production parts in grey iron and ductile iron and help in building their products
in shorter time on continual basis. They strive for operational excellence,
innovation, continual improvement and make exciting place to work and
promote talent of their people to ultimate deliver higher customer satisfaction.
Quality Policy
Shanti Iron and Steel will strive continually to improve the effectiveness of the
quality management system through involvement and innovation of the
employees so as to meet the customer requirements, to satisfy internal customer
and enhance external customer satisfaction.
Quality Objective
Reduce wastage
Reduce in variation
Reduce customer rejection
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Health, Safety and Environment Policy
At Shanti Iron & Steel, it is our policy to provide and maintain safe working
conditions and practices that will protect environment through pollution
prevention, resource conservation and health & safety of all the stake holders.
No activity will be considered complete, unless it is performed in a manner safe
to environment and occupational health.
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2.5 Product and Service
Shanti Iron and Steel always is providing better products through its resources,
which will result in high productivity and better quality. The product range
consists of the following items, which are explained below with the help of the
diagrams
Engine Parts
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Exhibit 2.3 Housing- Compressor Part
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2.6 Ownership pattern
PARTNERS
Mr. Shantilal Porwal is the Vice Chairman and also operational aspects of the
company.
Customers
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Exporting Countries
Italy
Belgium
Germany
Finland
Brazil
China
Competitors
New Enquiry: - The customer visits personally or uses any other media like
telephone, fax, email or letter to convey the order to the company. At the receipt
of new enquiry from the customers and log details in enquiry, the foundry
manager will collect all information from the customer and log details in enquiry
register.
Technical aspects
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Delivery aspects
1. If the enquiry turns profitable then the action plan will be made and recorded
in the enquiry register, if feasibility study does not turn to be attractive the
same is updated in the enquiry register.
2. If the feasibility study is accepted, a quotation is prepared and follow up is
made.
3. At the receipt of the order from the customer the foundry and technical
manager will review the order as against the quotation.
4. If any discrepancy arises the same will be resolved for the customer.
5. The Company receives purchase order else a verbal commitment. New
product development will be initiated as per as per product realization chart.
6. The purchase orders are of two types direct order and repeat order types.On
receipt of the purchase order it will be updated in the inward register by clerk
and forwarded to the P&D assistant for reviewing std. weight and rate register.
7. After clearance from the P&D assistant a soft copy is created and sent to
foundry manager.
8. Next the foundry manager with the consultation of the planning and dispatch
department conducts schedule feasibility study and prepare activity chart for
production.
9. If any amendment is received by the customer, are studied by the technical
manager and if feasible then it will be noted as per the customer and updated
in the inward register.
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Introduction to the Foundry
A foundry is a factory that produces metal castings. Metals are cast into shapes by
melting them into liquid, pouring the metal in a mold, and removing the mold material
or casting after the metals has solidified as it cools. The most common metals
processed are aluminum and cast iron.
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2.8 Departments in SIS
Departments in any company play a vital role in the development of the company.
These departments manage all the operations of the company. They are as
follows:
Production Department
Machining Department
Testing Department
Maintenance Department
Purchase Department
Marketing Department
Accounts Department
Quality Department
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PRODUCTION DEPARTMENT
PRODUCTION PROCESS
1. Pattern shop
2. Moulding and sand plant
3. Core shop
4. Fettling
5. Melting
6. Painting
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Production is an art of converting raw materials into finished or semi-finished
goods.
The steps involved in the production process of Shanti iron and steel is as follows:
Sand Plant: - Green sand mould is prepared. In green sand 85% is reused and
15% fresh sand with 5% additives and water is used.
Hand mould: hand mould is done for bigger and heavier casting.
Machine mould: It is done when one batch of machine mould is 500 pieces.
Core making: - Core made manually and it includes oil sand, no bake CO2 and
shell core.
Melting: - in cupola coke is mixed with pig iron, scarp, mild steel, manganese and
lime stone depending on the requirement and is heated at a temperature up to
1400 C, once it reaches that temperature they pour in the moulds made and
temperature is checked again and it should be between 1350 to 1450 C it takes
about 4 to 5 hours to cool down. The capacity of cupola is 7 tones. Once it cools it
is sent to next section called fettling.
Fettling: - fettling is a process where in the casting is cleaned with help of two
machines knock out machine and shot blast machine. The activities like chopping
of extra parts, grinding and inspection is done to check if it meets the
specifications.
Stress relieving
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MACHINING DEPARTMENT
Shanti Iron and Steel has a conventional machine shop where in the machining is
done
1. Vertical Lathe
2. Horizontal Lathe
3. Grinding Machines
4. Vertical Boring
5. Horizontal Boring
6. CNC Machine
7. VNC Machine
8. HMC Machine
Scheduling:-
Shanti Iron and Steel industry uses 2 types of scheduling operations for a
production according to customer requirement.
1. Job Operation: It refers to the manufacturing of the products on the basis of the
orders. They scheduled as per the requirement of the customers. These operations
involve the production of the products I low volume. There is considerable
variation in the materials used, set time etc. in performing these jobs.
Following customers of the industry are given prioritized for job operations:
Objectives
Responsibility
Objectives
Responsibility
DISPATCH DEPARTMENT
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PURCAHSE DEPARTMENT
To keep track of individual material requisition these are serially numbered and
kept in a separate file from purchase register.
The purchase order specifying the SIS material specification no. Name of the
materials grade or type, order quality, delivery schedules and terms and condition
is prepared and countersigned by purchasing assistant. If any deviation in the
purchase material is observed, the same is communicated to the vendor in writing.
HRD is the department, which handles the most delicate section of the the
company. The HRD manager is in charge of the whole department.
Responsibilities
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Organization Process
MARKETING DEPARTMENT
Marketing is the business function that identifies customer needs and wants,
determines which target market the organization can serve the best and design
appropriate products, provide services and set programmed to serve the market
however marketing in much more than an isolated business function. It is the
philosophy that guides the entire organization.
Functions
1. Market their products through personal visit with the help of product catalogue
2. Getting orders from the company
3. Quoting prizes for their services
4. Getting payment terms from their customer and also credit term.
Personal visit
Yellow pages
E-Business
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ACCOUNTS DEPARTMENT
Objectives
Accounts department is responsible for passing the bills to send cheques& cash to
the party. They maintain double entry system of book keeping. The complete
accounting system in SIS is computerized. Following are the following
documents:
1. Purchase account
2. Vouchers
3. Sales register
4. Bills receivable
5. Bills payable
6. Journal
7. Ledger
They prepare financial statements i.e. trading, profit and loss statement & balance
sheet so that they can know their position at any given point of time.
1. Purchase account: Postings is done in the personal accounts everyday from the
purchase book. At the end of the week month the total of the purchase of book is
debited to the purchase account in the ledger.
2. Sales Book: It is meant for recording all sales of goods. It is also known as the
sales or day book. It should be noted that the book records only sales of goods on
credit. The cash sales are recorded in the cash while sales of the articles other than
goods on credit are recorded in the journal.
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3. Vouchers: The Company has two vouchers, they are
5. Bills receivable and bills payable book: Where the number of bills received or
bills issued is large, would lead to saving of time if, instead of journalizing
each receipt of bill, we were to maintain suitable register and record the
transactions there. Two books would be required-
QUALITY DEPARTMENT
Objectives
1. Maintain consistent and correct appraisal of quality of the product at all the
stages of manufacturing till the product is dispatched. Such that the
required quality is achieved, maintained and improved.
2. Develop necessary competence in the department for meeting specific
quality requirements.
3. Reduce wastage in all in-house activity.
4. Reduction in variation.
Safety Conditions
Drinking water and rest rooms
Medical facilities
Canteen facilities
Leave facilities
Bonus payments
Insurance scheme
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2.9 Awards/Certificates
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EXHIBIT 2.12 ISO 14001:2004 EXHIBIT 2.13 ISO/TS
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CHAPTER 3
MCKENSY’S 7S FRAMEWORK
STRUCTURE
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SYSTEM
Inventory Control System: Usually a firm has to maintain several types of inventories.
It is not possible to keep the same degree of items over all the items. The firm should
pay maximum attention to those items whose value is highest.
The company uses the ERP system for the inventory management which helps in
planning their future production schedules accordingly. It helps to track the payments
and flow of finances. ERP system enables the most efficient stocking methods for the
inventory and also helps improve all the internal operations.
STRATEGY
The company has a strategy “To be the first choice for the customers in ready to
assemble castings”.
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SHARED VALUES
With the vision of being vision for the next ten years to pioneer in supplying casting
of highest value at optimum price.
The company is been able to build a long lasting relationships with the customers
based on trust and mutual benefit.
It also charted a challenging career for the employees with opportunities for
advancements and awards.
STYLE
The management of SIS is employee oriented. They receive feedback from the
workers and decide on the change in the strategies. It follows
In the top down approach the management plans the activities and sends it to the
every department, to know whether it is suitable or not and with the consultation
decisions are taken.
In the bottom up approach all the departments of SIS plan the activities or recommend
certain policies for their convenient and sends it to the management for approval thus
decisions are made. In this approach the management takes decisions without
consulting the departments.
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STAFF
The people in the organization are very dedicated and work towards the improvement
of the organization. The skill levels of the workers are work oriented and they
specialize in their respective field of work. Most of the workers are well experienced
and well trained.
There are totally 500+ employees. The duties and the responsibilities of the
employees differ based on the job that is performed by them.
SKILLS
The company as a whole is skilled. The steps taken to improve the skills of the
employees are as follows
1. On Job training
Training for the newly joined employees for 3-5 days.
Induction training to newly joined employees.
2. Off Job training
Class room training
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CHAPTER 4
SWOT ANALYSIS
STRENGTH:
WEAKNESS:
The company is in position where they need man power but it is not able to
find the required man power.
There are vacancies but not able to track the right person for the right job.
OPPORTUNITIES:
High demand.
Permanent and new customers.
Better network of customers and working conditions labor.
THREATS:
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CHAPTER 5
In the four week internship I was able to understand that the subjects that we had
studied were actually put into practice such as the various HR policies that are
made for the employees.
I also learned the recruitment procedure that takes place in the company on a
smaller scale and the various joining formalities that the company takes into
consideration when hiring the employees in their company.
The project offered scope to apply some of the concepts related to SWOT
Analysis and Mckensy‟s 7s framework elaborated in the Management course
undertaken in college.
There was a good working culture in the organization where in all the members
of department are in a good relation with each other.
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BIBLIOGRAPHY
Webliography
https://www.shantiiron.net
shodhganga.inflibnet.ac.in>bitstream
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