2014

Report on: Nebula Home Products Pvt. Ltd.

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SR.NO. TITLES PAGE NO.
1 Executive Summary 6
2 Introduction to the Industry 7
3 Introduction to the company/ Departmental Details 8
4 Chapter 1 9-15
- HR Department
5 Chapter 2 16-21
- Production Department
6 Chapter 3 22-23
- Purchase Department
7 Chapter 4 24
- Despatch department
8 Chapter 5 25
- Stores Department
9 Chapter 6 26-27
- Job development
10 Chapter 7 28-31
- Quality Assurance Department
11 Chapter 8 32-33
- Finance & Accounts Department
12 Chapter 9 34-35
- Maintenance Department
13 Chapter 10 36-37

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 - Marketing Department
14 Conclusion & Learning 38
15 Recommendations/ suggestions 39
16 Bibliography 40
17 Appendix

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4
 Company Profile
Nebula Home Products Pvt. Ltd., established in Goa, 1994, is a leading name in the field of
manufacturing and supply of packaging products. Promoters are the Mendes family. They
specialize in design and manufacture of Printed and E-Fluted Cartons.
Nebula Company manufactures packaging products for some of the most well-known
international brands- Colgate, Nestle, Philips, Balsara, Kodak, Pointec and Classmate. The
nebula company are major suppliers of Colgate-Palmolive (I) Ltd. Nebula is a spin-off that caters
100% of the carton requirements for the Colgate toothpaste produces in Goa as well as the other
contract manufacturers for Colgate in Hyderabad and the Colgate plants in Himachal Pradesh
and Aurangabad. The company’s manufacturing plant is self-sufficient. It is equipped with the
most modern manufacturing machinery and equipment required for making E-Fluted Cartons.
The Company has an in-house pre-press with high-end processing and plate-making facilities,
hence providing their clients a one-stop solution.

They also have sister company which manufactures oral care and tooth paste which are dispatch
to Madhya Pradesh , Chennai , Gurgaon ( it’s a product of Gillette and it is dispatch to Gillette
warehouse at respective places) .They also have plant at Baddi in Himachal Pradesh where they
manufacture only sheets here and for further processing it is sent to Baddi plant.

HISTORY:
The group entered into packaging business in Bombay with- M/s. Fit-rite Packaging & P. J.
Packs and Prints. The main product line at that time included Duplex Cartons & E-Fluted
Cartons. The carton units in Bombay were suppliers of Colgate, Hindustan Unilever, Balsara,
Godrej, Nestle and Proctor & Gamble.
In 1992, the group ventured into a manufacturing unit in Goa to make toothpaste for Colgate.
The venture was called Lumena Home Products Pvt. Ltd. In 1996, another manufacturing unit,
by name of Sterling Home Products Pvt. Ltd was set up to make toothpaste for Colgate.

QUALITY POLICY OF NEBULA

“Nebulacommits to supply consistently product and service to meet the expectations of their
customers
To this end they shall continuously strive to improve Quality of their product and service by
increasing productivity and reducing cost by innovative operational techniques and optimum
utilization of the material and machine

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They shall maintain Quality System and shall lay emphasis on maintenance of the safety, health
and environment standards catering to the interest of their customer and society”

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 Organizational structure of NEBULA

DIRECTOR

PURCHASE QUALITY ACCOUNT H.R

MANAGER AUURANCE MANAGER MANAGER
MANAGER

ASST.MANGE OFFICER ECEC.A/C JR.OFFICER

R PURCHASE
EXEC.Q.A
DISPATCH HR

JR.OFFICER DISPATCH SUPERVISOR OFFICER

PURCHSE ASST. A/C

HELPERS HELPERS ASST.Q.A ASST. A/C

MAINTENANCE PRODUCTION BUSINESS

MANAGER MANAGER DEVELOPMENT
MANAGER

SUPERVISOR EXEC.ENG. EXEC.PPC PRE-PRESS

STORE INCHARGE

SUPERVISOR SR. GRAPHIC

TECHNICIAN
DESIGNER

DEPARTMENT JR. GRAPHIC

HEAD DESIGNER

OPERATOR ASST.PRE-
PRESS

HELPERS

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 Human Resource Department

It is management function concerned with hiring, motivating, and maintaining people in an

organization. It focuses on people in organization.
Job Summary
 HR Manager is involved in statutory compliances, plant administration functions,
employee facilities, HR initiatives such as policies, employee facilities and any other
special assignments allotted from time to time.

Job responsibility of HR
 To complete the recruitment and selection process, including salary fixation, salary slips
and arrange the training programs.
 To check out the manpower for various departments, plan for yearly salary budget with
accounts & plant manager. .
 To complete the joining formalities of new employee and co-ordinate to new employee
induction program.
 To maintain a record of attendance management of employees for punctuality and
initiative necessary disciplinary action and maintain department wise overtime records.
 To look after employee benefits such as LTA, medical claims, loans &advances,
insurance claim, gratuity etc.
 To attain trade unions meeting and do settlement.(MOS)l.
Authorities
 To issue office letters & appointment letters to all employee.
 To issue disciplinary letters to employee and take action if needed.
 To officially represent company at various related government department.
 To issue salary/service certificates to employees as per policy.
Recruitment and selection process
Two sources of recruitment: 1) Advertisement. 2) Employee reference
In Nebula when there is vacancy or additional worker is required than therespective head of
department (HOD)sends the requisition to HR department, he gives them the detailed
information about the candidate he is looking for (qualification, position and necessary details).
Once the HR gets to know the basic requirement they search the resumes on their data base
(where the many candidates post their resumes) as their first preference where they would like to
work.

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If the company doesn’t find the right candidate in the data base they go for employee reference
wherein employees are informed about the vacancy and try their reference (friends, relatives
etc.). This way is very effective as the employee knows the candidate company looking for.
Ifstill the requirement is not met than company goes forsocial media that is advertisementthey
post the requirement of the job and other details where they get large number of resumes.
Selection process
Once they find the resumes from any of the above source they areshortlisted on bases of
qualification and experience, the shortlisted candidates are given a call weather they are really
interested in job and those interested are called for interview for first time, where in the
company looks for attitude, confidence level, his resistance to change, based on this they are
shortlisted once this is done the respective (HOD) are informed about the shortlisted candidate
and discuss about the candidate with HOD than the candidate is called for second time and
selected based on necessary skills .
People involved in this process are HR-Manager, Jr. officer-HR, and the respective HOD. The
time taken for the selection depends HOD if he needs very urgently than company has to
compromise with the cost and so on otherwise it is not fixed period of time.
Induction program2
When a new employee joins the company his photo and information is put up on the notice
board. He is given introduction about the company. After that he is given induction sheet where
he is given time and date of visiting each department after each visit he has to take signature of
HOD and submit that sheet to HR department so that all the HOD are aware of new employee.
Training and Development
On the Job training is given. Sometimes the HOD of the department takes session with the
employee and it is mostly job related training. Besides company calls external trainer. Apart
from this the workers are given training on personality development. They mostly emphasize on
the personality and attitude of employee. Nebula always looks for experience worker or with ITI
Background.

Performance Appraisal

Nebula follows rating system. They have to rate from 1-5 i.e. 1 being very poor and 5 being
excellent. Employees are rated accordingly.
They are rated on the bases of KPIs such as – job knowledge, flexibility, cooperation,
productivity, quality, communication skill and judgment, punctuality, attendance and attitude.
Employees are rated on above KPI’s. if any employee stands between 1-10 then the more
training is given to that individual and if employee scores between 41-50 than appreciation
certificate is given.
Policy for late coming and early going staff
1. All the staff must report to their duties on time.

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 2. Staff would be allowed to come up to 8:40 am maximum 3 occasion in a month any
worker reporting late at the 4th occasion i.e. beyond 8:30 a.m. then his/her half day leave
will be deducted from the leave balance or half day wage would be deducted from the
salary. No reason will be accepted except medical reason & accident only. Only the 4th
occasion may be pardoned by the respective HOD.
3. Any staff going for outdoor official duty must submit OD form duty authorized to HR
department one day prior. In case if any staff needs to go out & out during emergencies
on an official outdoor duty than he/she must submit their OD form to HR department to
duty authorized immediately upon their return.
Early going
1. All staffs are expected to work till the end of their shifts.
2. Staffs are allowed to go maximum 2 hours early in a month. If any staff exceeds
his/her early going than half day leave will be deducted from the leave balance or half
day wage would be deducted from the salary. No reason will be accepted except
medical reason & accident only.
3. Any employee leaving early must take a valid authorized exit gate pass & handover to
the security before leaving.
4. Any personal exits during working hours that much time will be deducted from their
early going hours.
5. Staff going out for lunch must take a valid gate pass authorized by their respective
HOD and come with an stimulated time if that much time will be deducted from their
early going hours.
Annual Increment policy

1. This policy is applicable to those employees who had completed 1 year of service in
the company and excluding the training period time. any employee completes his/her
1 year of service between 1st April to 31st march is eligible for increment because the
increment is made in financial period that is from 1st April to 31st march..
2. The annual increment completely depends on the performance appraisal conducted by
specific department and the company has the right to withhold the annual increment
or give marginal increment to their staff based on the performance.
3. No employee has the right to expect their annual increment year after year. The
increment is applicable from 1st April of every year.

Minimum wages
 Rs.215/- unskilled workers
 Rs236/- semi-skilled workers
 Rs266/- skilled workers
 Rs287/- highly skilled workers
 Rs256\- clerical

Salary structure for staff

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Basic
FDA (fixed Dearness allowance) - 30% of basic
HRA (House Rent Allowances) - 40% of basic
Education Allowances- 25% of basic
Conveyance allowances- 25% of basic
Total Gross

Deductions:
Provident Fund (PF)
Employees Contribution: 12% on Basic Salary
ESI(employee state Insurance): 1.75%

Salary Structure for workers:

Basic:
FDA
VDA Depends upon
HRA the grades
Education Allowance
Conveyance Allowance
Washing Allowance: Rs 145 fixed

Deduction:
Labor Welfare Fund= Rs 5
PF 12% of basic salary
ESI 1.75% of gross salary
Allowances provided

 Meal allowances: 60 Rs meal Coupon if employees works for extra shift also if
employee attend work on Sunday.
 House rent allowance(HRA)
 LTA( leave travel allowances) – it is given once in a year
 Medical allowance paid once in a year .

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  Those whose salary(staff) is above 15000 are given medical allowance and below
15000 are given ESI

ESI(employee state insurance)

 Employee share is1.75% gross salary, Employer share is 4.75% gross salary.
 In case of workers LTA are fixed based on grades (between 1-8),it is paid during
Diwali.medical allowances it is 1/3 of gross salary.

Overtime

 For staff : 50 Rs per hour

 For workers: they are paid double. I.e. if their wage is 100 than they are paid
200.(Basic+FDA+VDA+HRA)

Bonuses:
12.5% bonus on their basic salary.
Bonus isdeducted from CTC & it is paid once in a year i.e. during Ganesh Chaturthi.
Gratuity
It is paid to those workers who had completed 5 or more years of service in the same
company.
Formula – basic salary (last drawn) * 15*no of years\26.

Loans and advances

10000-Loan for houseand Medical
15000-for self-management (no interest for both) .

Fringe Benefits

 House Rent
 Company car for managers
 Uniforms (one pair per worker)
 Safety equipment
 Tea
 Lunch room
 Transport for night shift.

Shift Allowances

 0ne 2nd shift=Rs 12

 One 3rd shift=Rs 14
Recreationalactivities:
Picnic once a year

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DussehraPooja(Performed by any employee): company gives sweets to workers and staff

Job Motivation
Non- monetary
 Appreciation Certificate
 Promotion (For workers)
 Job rotation (for workers)
Monetary
 Cash price (for staff and workers of production dept)
 Increment (for staff)
Conflicts
When there are conflicts between workers than the company goes for root cause analysis
that is they try to find the core problem of the conflict. Some are solved with word of
mouth but in some cases strict action has to be taken.
Trade Unions
Trade union is consisting of 92 workers. They should work as per the memorandum of
association. Approximately 8-9 workers represent committee. Workers put their Charter
of demands. Accordingly collective bargaining takes place between management and the
Workers. HR of company works as Bridge between both of them. And their demands are
settled. This settlement is of 3 years.
Disciplinary action
A workman found guilty of any misconduct may be awarded following punishments:

 Warning of censure
 Imposition of fine subject to accordance with the provision of payment of wages
act.
 With holding one or more increment

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 Production Department
The role of production department in nebula is very important. The goods for the
customers are manufactured according to the desired standards in this department. This
department is responsible to plan and organize the allocation of jobs to various machines
in a way that their maximum capacity is utilized and that the delivery is given to the
customer on time. The head of the production department is the production manager.
In nebula production department works on bases of:
 5-S
 Sorting out: stratification management for sorting out by keeping what is needed
and not needed.
 Systematic arrangement: the simple rule “everything in a place & a place for
everything”
 Spic & span: cleaning with the purpose to inspect and achieve zero
dust/dirt/grime/garbage.
 Standardization: visible management for maintaining standards.
 Self-discipline: committed with passion to create a total quality ambience

 4 ‘M’
 Method
 Money
 Man
 Machine

 SQDCM
 S – Safety
 Q- Quality
 D- Delivery
 C- Cost
 M- Method

Personnel involved in production department

Production manager
 Issue of ticket numbers and print orders
 Verification of schedules & allocation of jobs on machine
 Proper utilization of space and material
 Requisition to stores for material as per production plan.
 Monitor all department activities through log book & initiative corrective plan.
Executive PPC (Production Planning and Control):
 To tell the in charge exactly what outcome he want and when. Tell them, show
them and check whether they understood his requirement or not.
 Shift list planning for full weak

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  Dispatching
 Monitoring and verification of job cards
 Monitoring production details
 Analyzing less production & action to improve the same.
 Man power planning


Production supervisor
 Man power handling based on availability
 Study of plan
 Arrangement of raw material to the machines
 Job approval for all process
 Execution of activities as per plan
 Reporting production details to higher authorities

 Operators:
 Machine maintenance.
 Operate respective machine to complete a job.
 Check quality frequently.
 Addressing machine related problem.

 Process in charge:
 Get the job done from operators.

 Helpers:
 Loading and unloading of sheets.

 Documentation:
 Job card
 Prepare plan v/s actual
 Consulted reports
 Line clearance report
 Printing plan

NEBULA is having Job shop process flow structure as there is a production of cartons of
different brands such as COLGATE, AMUL, JOCKEY.OM agarbathi,

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Facility layout

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 Raw materials needed for manufacturing Colgate max fresh (150gms) blue

 Paperboard- Grey back (GB)

 INK- Max fresh blue, PMS 286, sea blue, white, holo red, 355 green.
 Lamination foil-690mm Met Pet
 Blanket plate cleaner-TechnovaInsta clean
 Fount solution- Akron gold
 Glue- Glue 854
 GSM-320
 Uv coating - Base coat sheet, varnish 577
 Punching- Wooden die
 Gluing - CP glue

Process flowchart for the job of Colgate max fresh(150gms) blue

PLATE MAKING
(CTP)

LAMINATION
(BOPP)

COATING

PRINTING

PUNCHING

STRIPPING

SORTING

GLUING

PACKING

DISPATCH

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Production Number Number Number Number Number Number IPH
process of of of of in of of (Impression
machines operator helpers charge feeders Delivery Per Hour)
boys

Plate making 1 1 1 - - Depends on

job
Printing 3 3 6 1 3 3 36000
Lamination 2 2 - - 2 2 5000
Foiling 2 2 1 - - - 2600
Coating 4 4 3 1 1 1 14700
Punching 4 4 3 1 - - 22500
Gluing 3 - - 1 3 6 114300

Plate making
 In this department artworks are processed through different software’s like
Photoshop, CorelDraw, and PageMaker etc. As per customer specification. This
design is made on the plates with the help of CTP machines and then they are for
printing after customer’s approval.
Lamination
 In lamination boards gets cut and glued according to the size given in the SOP.
For Colgate max fresh lamination type is BOPP. In this silver lamination foil is
rolled on a cylinder & it get pasted on sheets and then the exact cutting is done at
the last unit of the machine. The temperature they maintain for this job is 80-70
%. After this it is sent for water base
Coating (water base)
 In this process board is varnished where a glossy effect is given to give
smoothness to board to make it attractive and appealing to the customers eyes. For
this job waterbase is done where water is mixed with solution and it goes through
the roller and gets the glossy effect on the board. Water base is done because the
printing stays for long period.
 Load-water base-dry-delivery
Printing
 In printing helper load the file of 3000 sheets on the machine than it is feeded in
the machine by an operator and sent for printing unit, before that the ink is poured
into the machine manually and also the plates are fixed in the machine as per the
job. Once the job goes to printing unit the ink gets pasted on the plate and then the
plate gets pasted on the blanket than the blanket with the help of cylinder get the
impression which is there on the plate and finally gets printed on sheets.

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Punching
 After the sheets are printed they are brought in for punching stage. The punching
dies are ordered as per the design of the job from other companies. Rubberizing
the die is done by the operator manually and creasing is done as per the GSM of
the paperboard and accordingly the pressure is maintained for punching the sheets
as per the UPS (number of cartons) the pressure increase as the UPS get
increased.
Stripping
 This stage is after punching where the workers manually strip the wastage part of
punched sheet than they are sent for sorting and then for gluing.
Sorting
 At this stage the workers segregate the stripped cartons as per the shade card and
even they sort if they have printing defects, punching defects and UV problem.
Gluing
In this stage one person feeds the carton into the machine manually on the first stage
first and last part of carton gets folded on the second stage second part gets folded and
then on the third stage carton gets third(last) fold and glued and sent for pressing and
then delivered to the delivery boy.

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 Purchase department
Purchase reviews the monthly raw material stock report and stock level which are
maintained manually. Than they place an order for required raw material after obtaining
quotation from more than one supplier .After this they issue PO based on the rates which
are finalized. PO highlights the product description like quantity, date of delivery,
payment terms etc. On receipt of material GRN is done by stores. In case of rejection the
stores inform the purchase and in turn purchase informs the supplier of rejection and
request for replacement of rejected goods if required.
Function of manager

 Negotiation/cost analysis
 Supplier rating and evaluation
 Releasing PO with necessary specification and documents
 Getting quotation from different suppliers
 Maintaining approved supplier list and price list
 Consult with accounts for allocation of funds, check GRN for billing
 Consult each department for their requirement.
Documents

 Stores requisition,
 Purchase requisition from different department
 Purchase orders
 Delivery challan
 Quotation files
 Excise invoice for Dispatch (FG)
New supplier evaluation and selection

 Purchase department locates new supplier from internet for their requirement later
they ask them for samples and specification for review.
 After the samples are approved the purchase department proceeds further.The
supplier is informed about the trial samples whenever there is requirement for
new product.
 The trial suppliers are evaluated for their quantity, quality and delivery time.If the
trial samples fulfill the need than they are approved and listed to the approved
vendor list
Materials needed for manufacturing cartons:
 Paperboard (80% are A – class item)
 Ink
 Varnish
 Plates
 Shippers
 Glue

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  BOPP film
 Lamination film
 Stretch films

Main suppliers are

 JANI SALES PVT.LTD, VACMET

 DIC INDIA LTD, PYRAMID INDUSTRIES
 SIEGWERK INDIA LTD

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 Dispatch Department
Functions

 Maintain CANVAT register

 Stock register (daily)
 Filing reports every month
 Taking acknowledgement from customers
 To ensure that the product sent are delivered in good order to customer.
 Make sure that the product goes to right location.
 Making invoices with correct data which is provided I n the purchase order and
which is agreed upon the by the seller and buyer.
 Daily coordination with the production department for receipt of goods.
 To make proper identification label during the time of dispatches
 Keeping tracks of PO’s
 Intimating mail to customer with detail either for their reference, post-dispatch or
pre dispatches for obtaining e-sugm or way bill form.
 Certificate of GRN (duplicate of transport)
 Issue FMT (Finished Merchandise transfer) slip with OK
 Take finished goods from production department to warehouse.
FMT (Finished Merchandise transfer) includes

 Shifts, machine, SKU (Stock Keeping Unit), quantity details, ticket no and
remarks.
Documents

 Cen vat register

 FG stock register
 Tax invoice
 Receipts
 Order files
 Material gate pass
 CT 1, CT 3
 ERE 1, ERE 3
 ER 1, ER 6, ER 5
 RG1 Register
Invoice includes

 Consignees name and address, Invoice no, PO no, Tin no, Text identification no
 Date and time of removal of good
 CST Basic excise duty( vary from item to item)
 Education tax, Sec education tax
 Vat: within goa: 5%, Outside goa:2%

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 Stores department
Store department receive material (raw/consumable/packing) based on the Purchase order
and raw material are accepted once the quality and quantity of material is checked and
then GRN(Goods Receipt Note) is raised
Acceptance of material is based upon:

 QA analysis of report of the supplier

 If quantity received differs from the ordered quantity then the short receipt is
taken and payment is made accordingly for short supply
 After testing the material on a laboratory as per the specification
After this the material is labeled for identification purpose, mentioning details of
(supplier MFD, EXP) etc. for ink and varnish.
Boards are tagged with details like item description, board size, GSM, LOT Number. Tag
also has details like ticket no of the job which the board has been issued.
Functions

 Receipts of raw material packing, consumable items etc.

 Issuing material to production department based on requisition.
 Acknowledgement of material after the material gets unloaded.
 New material to be tagged and stored separately with clear identification.
 Making invoices
Documents

 Stock chart
 Receipts
 Printing plans

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 Job Development (Pre-Press department)
In this department files are received from client via mail, CD OR FTP, these files are
saved as per clients’ name. This client file includes the product name and code
number.This designs are made as per customer specification.
Original files are saved in client folder and the file which they use for output has to save
in production folder.

Software Used for

ESKO Used to generate single up Keyline and
multi ups Keyline
Coral Draw Files of customers are received
through this and their Dpi must be
above 300.
Illustrator To convert coral draw file into ai
format, to check the crease and cutting
line.
Photoshop For saving the file in PDS format
Developer Washing and heating

Other software used is artoscad, despack plugins, Plato, automation engine pilot, bitmap
viewer.
Equipment’s (machine)
 Viotar FA & computer to plate (CTP)
 Raptor 85 polymer (plate developer)
 Kongsberg XE – 10 (Sample Maker/plotter)
Procedures
 Artworks are received through mails or CD from customer.
 There artworks are downloaded to prepares computer with respective customer
folder.
 Artworks are checked with customer approval sample or reference sample. There
samples will be checked for dimensions, text, color separation special finish etc.
 These edited artworks are sent to customer for approval through print out or
through soft copy.
 As per customer feedback artwork will be preceded if any editing or correction is
needed and get it approval from them.
 After approval multi-up layout or proofing layout prepared as per the layout
worked during costing.
 This artwork will be saved as final job for production and the original file will be
kept in customer original file.
 Approved printout of artwork is given to quality for reference along with job
details.

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How plates are processed
 Multi-ups layout are developed on Esko plate software.
 On CTP computers jobs are planned according to the printing machine
requirement.
 Individual plate is fed at time to CTP processor/exposer and plates are removed
after a specific time.
 After exposing the plate is fed into the developer and removed after specific time.
Function of CTP Department
 Conversion of soft copies to plate
 Multi ups
 Proofing layout
 Correction of design
 Sampling

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 QUALITY ASSURANCE DEPARTMENT

The main task of quality assurance department is to check the quality at various levels of
the product manufactured in the company. i.e. when the material comes in to the
company till the finished goods leaves out. Nebula has its own standards and
specifications set for quality check of its products and processes. The different processes
followed to assure the quality of the raw materials used in the production of nebula
products.

In quality there are 3 divisions

I. Incoming quality check
II. In process quality check
III. F.G (Finished goods)

I. In first division there are material on its arrival undergoes an incoming quality
check. This quality check is done as per the specification and standards set for
certain raw materials and as per the requirement. When the material goes to stores
again they are verified according to PO (Purchase order)

Checks of Materials are:

Paper Board
 Moisture using moisture meter
 GSM is checked using electronic weighing machine. Maximum GSM is 250 and
minimum 450 depends on job varieties.
 Caliper test using caliper tester for thickness of paperboard
 Lot number, Size, Surface color
Varnish
 MFD date, Exp. Date, Supplier, Batch no
Lamination film
 Size, Surface quality, Film on the top side
Ink
 Exp. Date, Mfd date, Weight, Batch no

II. In second division INPROCESS quality check is made.

Printing: in this department quality inspector check:
1. Gain direction: whether the sheets are in center or not.
2. Text matter: they check the text as per the approved A/W if even a small mistake
is found they stop the job and send the plates to CTP for checking & change the
plate.
3. Scuffing: in this using Rub Resistance tester it is checked whether there is any
problem in ink.in RR Tester two pieces of cartons are kept on top of each other
rotate for few minutes.ie. 80 rubs and then approved.
4. MEK (Methyl Ethyl Ketone) test: in this test hearing birds are dipped into the
MEK solution and it is rubbed on the printed sheet for 10 times & this is done
very soon after printing if printing color shades than it is rejected.

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 5. , Shade check: shade check is done as per the shade card which is approved by the
customer. Shade card have three shades light, medium, dark and the printing must
be within those shades. Shade approval is done with OK sheets.
They also check smudging, set off, plate damage, doubling, and rough print.
Surface coating water base/UV: In this they check:
1. Scuff test: it is done using RR Tester. It is rotated for 400 times.
2. Blocking test: in this test they rub the printed sheets if it goes smooth than the
printing is approved if it stuck than it is rejected.
3. MEK (Methyl Ethyl Ketone) test: Using MEK solution.
4. Gloss check: gloss check is done using gloss meter of UV sheets and the gloss
range must be within 70-90
5. Drying: they check the sheets whether are dried or need to be dried.
Met pet & Lamination: In this they check:
1. Drying: they check the sheets whether are dried or need to be dried.
2. Position of the film: They check whether the film is in center or no.
3. Spots and marks.
4. Wrinkles
5. Patchy coat
Punching: In this they check:
1. Position / centering the design: they check whether the punching is done exactly
as per the design.
2. Punching embossing: they check whether embossing is done as per the design or
it is out.
3. Crease cracking
4. Rough cutting
Foiling: In this they check:
1. Cracking of cartons are checked, Gloss is checked, Patchy foiling are checked,
Rough edge
Gluing: In this they check:
1. Printing defects, Punching defects, Lamination defects, Gum squeeze, Cracking
on crease, Overlapping, Scratches

III. Finished Goods

In this stage they check the cartons as per acceptance quality level plan

Batch size Sample size DEFECTS ACCEPTANCE LEVEL

Critical 0.40% Major 1.50% Minor 4.00%
1201 to 3200 125 0 3 8
3201 to 10000 200 1 5 12

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10001 to 35000 315 2 8 18
35001 to 150000 500 3 12 18
1500001 to 800 5 18 18
500000
500001 to over 1250 8

Defects on which cartons are grouped

Critical 0.40% Major 1.50% Minor 4.00%

Side gluing open Dirty cartons Minor defects printing
Rub Resistance failure Wrong quantity Rough cutting
Bend carton Gum squeeze Improper stripping
Missing text matter Blocking of carton Loose bundling
Out punche carton Cross pasting Spots on prints
mix-up of carton Improper embossing
Shade variation

If nebula has manufactured 10000 to 30000 the sample the quality inspector has to check
315 cartons which is the minimum size. These 315 cartons are checked by quality
inspector if he found 2 critical, 8 major and 18 minor defects they are accepted but if they
cross this they are rejected.
Documents

 Internal specification
 Job specification
 Shade card
 Maintaining ISO record.
 calibration reward
 Printing OK sheets process flow
 Incoming quality plan
 In process quality plan
 FG (Finished Goods)
Complaints handling

 On receiving customer complaints an quality official from the company

immediately visits customer & offers immediate solution to the problem.
 This complaint is put up on Q.A notice board so that the employee comes to know
about quality defect
 Than the quality official find the root course like shift, machine, operator and they
take preventive action to avoid future problems.

Personnel involved in Quality assurance

Senior executive

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  Improving process and product quality
 Monitoring supplier rejection & taking corrective action
 Implementing, monitoring & sustaining quality system
 Training employees on product & process knowledge.
 Training employees on 5’s’ activities
Quality control officer

 Incoming, inprocess and final inspection monitoring and verification

 Monitoring and calibration of instruments
 Implementation of customer requirements down the line
 Preparing the quality plan
Quality inspector

 Verification of inprocess inspection report

 Approval of job in each and every process after setup
 Incoming test report filling
 Testing and measuring of key parameter of finished goods.

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 Finance department
The goal of any finance function is to achieve three benefits: business support service,
lowest costs and effective control of the environment. Money is the lifeblood of a
business and finance is the nerve center. Finance is required to promote or create a
business, gain assets, develop products, run market surveys, advertise.
The finance department manages all cash flow into and out of a business. Vendors and
creditors need payment correctly and on time to keep things running smoothly. You need
to stay liquid--the right amount of cash on hand--at all times and finance must maintain
payment plans that keep everything on track.
Nebula don’t have separate department called as Accounts it is handled by finance
department only.
Function of finance and accounting

 To maintain day to day transaction of accounting and ensure that there are enough
funds to meet the day to day payment.
 To manage all cash flow into and out of business.
 To maintain annual financial statement.
 To ensure the organization is paid on time according to nebula’s payment policy.
 To get the working capital from bank or any other money lender.
 Payroll – calculate gross wages etc
 Cash collection i.e. all cash received from sales and from all sources has to be
carefully identified and recorded.
Receipt procedure
Cash payment
Nebula always goes for credit payment because if it goes for cash payment:

 Income tax will question them

 Bank will not except money after certain limit
 Most of the black money is paid through the cash payment
According to nebula companies must deal with credit, cheque& electronic payment.
Credit payment

 When we do credit payment must always pay by cross cheque. It ensures that the
money is paid to the right person. it is the healthy way of dealing.
In case of small payment like labor wage, loading, unloading charges are paid by cash.
Nebula is not a listed company it is a family business is carried out by Mendes family so
the shares are quoted by the company owners or by family members.
Documents which they handle
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  Purchase voucher
 Sales voucher
 Invoices
 Legal matters
 Agreements
 Receipt voucher
 Sales
 Purchases
 Working capital
Working capital means taking money from bank or any money Lander for finance.
Petty cash book – all cash we have to pay like loading charges, unloading charges, labor
wage etc it includes all petty payments.
All the records in nebula are computerized for this they use software called Tally ERP 9.
Bases of accounting

 Cash bases
 Accrual bases
Cash bases-in cash bases accounting, revenue & expenses are recorded as they are
received or spent.
Accrual bases- in cash bases accounting, revenue & expenses are recorded as they are
incurred. Nebula uses accrual bases (mercantile system of accounting)
Reports they generate

 General ledger
 Cash receipt
 Payroll register
Reports are done on daily bases as per the requirement.
In nebula invoices are approved by directors. The invoices cannot be cancelled so the
they utmost care in completing those invoices than only they are sent for approval.

 Turnover of the company - 90 crores

 Sales of the company -80 crores

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 Maintenance department
Manager

 Prepare daily maintenance schedule

 Maintenance of each machine as per schedule
 Updating of all machines and utilities etc.
 Breakdown maintenance
 Planning of maintenance items and consumables and follow up list of spare parts
& lubricants.
 Planning of machine maintenance whenever no production plan/lunch breaks etc.
 Prepare work instruction for all machines (function of each part)
 Sending rollers for rubber rising, mechanical maintenance, motor rewinding
Working supervisor

 Maintenance of each machine as per schedule - daily

 Checking of electrical loose connection
 Sending rollers for rubber rising, mechanical maintenance, motor rewinding.
 New machine installation.
Technician

 Attending breakdowns
 Assisting supervisors for critical repair
Documents

 Break down register

 Machine log book
 Maintenance report
Objective

 To ensure that all the problems are solved in time

 To Minimize breakdown of machines
 Effective preventive maintenance
 To Keep Stock of consumable items
 To see that the complaints/problems are solved as soon as possible.

Type of maintenance
Preventive maintenance
In this all the activities are done as per the machine manual like changing of oil should,
replacement of parts, it includes all information of the machine and when the activities
has to be done(weekly, monthly or yearly).

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Breakdown maintenance
This is when the running machine get some problem and the maintenance people go and
solve the problem immediately.
If preventive maintenance is not done regularly it give rise to breakdown in machine.
Sometime the problems arise due to mishandling of machine by an operator.
Procedure
Whenever any problem comes to machine the production supervisor gives a memo to
maintenances department than they solve the problem and write down the work done or
any part is replaced, whether the problem is mechanical or electrical, timings all this is
written in the observation column and handover the machine.

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 Marketing department
In Nebula there are 3 people working in marketing department one is in Gujarat, one is in
Kolkata and one is in Goa, they are directly reporting to the directors of Nebula. Their job
is to get as many possible customers to nebula and meet their requirement.
SWOT Analysis:
The evaluation of company’s strengths, weaknesses, opportunities and threats:

 Strength
 Experienced workers: In nebula all workers are experienced and from ITI
background.
 All process under one roof: In nebula all stages from printing to dispatch is done
in one roof no outsourcing is done.

 Weaknesses
 Insufficient space: if doubled the production.
 Delivery issues: not every time but still an issue.

 Opportunities
 There lots of opportunity as its segment is FMCG (Fast moving consumer
Goods).
 Higher Employee Performance

 Threats
 Increasing competitors

Competitors of Nebula Home Products Private Limited:

 Borkar Packaging (Goa)
 TCPL (Twenty First Century Packaging Limited) (Daman and Himachal Pradesh)
 Manohar Packaging (Goa, Daman and Himachal)
 ITC Packaging (Chennai and Pune)

Target Markets, Positioning And Segmentation:

NEBULA has chosen FMCG (Fast moving consumer Goods) their segment as these
products are sold quickly and at relatively low cost.

Characteristics of FMCG
 From the consumer perspective
 Low price

 From the marketers perspective

 High volumes

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Process

 Generate enquiry from customer as per specification or requirement.

 Target the customer
 Requirement approach
 Pricing the product (quotation)
 Finalizing the product
 Sampling of products
 Sampling finalizing

Customers Of Nebula

 Colgate
 Jockey
 Amul
 Classmate
 Munch
 Himalaya
 Palmolive
 Cello
 AUM agarbathi
 Geno
Competitive forces of NEBULA:Five force analyses
1. Threat of intense segment rivalry:
High intense rivalry

2. Threat of new entrants:

As huge capital is required so there is low threat of new entrants.

3. Threat of substitute products:

Plastic bags are the substitute products of NEBULA so low threat of substitute
products.

4. Threat of buyer’s growing bargaining power:

As there many companies in this sector so customer have high negotiating power
or switch to other buyer.

5. Threat of supplier’s growing bargaining power:they have many suppliers like

gayatri ITC so they have lowsuppliers bargaining power.

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Conclusion
To conclude this report I would say I felt really involved in this company as it was not
that hard for me to get friendly with the employee as they have very friendly nature.
Nebula not only gave me practical experience but also gave me really good friends which
I will remember for my lifetime.
Finally I can say that this internship was very instructive and that I enjoyed working for
Nebula. To work on manufacturing field as on different departments gave me an
overview of all department .i am really thankful to all the managers and supervisors for
their support and explanation as it was impossible without their help.

Learning
 In HR department I learnt how to face the problems and take best of solution to
solve that problem.
 Learnt the different types of benefits provided to worker in nebula.
 Learnt the organization culture and came to know how it helps in company’s
growth.
 Learnt how the interest of employee helps company to higher its production.
 Learnt how performance appraisal to rate the employees work.
 Learnt how much important role quality department plays in the company as from
incoming of raw material to dispatch of the finished products.
 Learnt how finance department maintain balance to meet the day to day payment.
 Learnt how carefully to select supplier and negotiate with them.
 Learnt how maintenance is important when breakdown takes place.
 Learnt how to work in team and built a strong team.
 Learnt how to communicate with the clients and convince them.
 Learnt how nebula approach to their customers and satisfy them by provided
quality products.
 In production I Learnt how a small mistake by an operator can turn into huge loss
for the company.
 Learnt the 5’S’ that is Sorting out, Systematic arrangement, Spic & span
Standardization and Self-discipline which is the bases of production department in
nebula.
 Learnt the segment which nebula is targeting.

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Suggestions
 In sorting stage machine should be used instead of man force to speed up the
production.
 In charge for each stage is not required as his work can be handled by operator
itself.
 Nebula should try to minimize wastage.
 Nebula should give employees mask to protect from smell of chemicals in
production department for better working environment.
 Maintenance people must check the machine time to time to avoid breakdown.
 Employees must be more involved in decision making.
 Company should conduct survey to know the employees interest in their jobs.
 Appraisal and increment should happen in time.
 Employees coming for tea in production department should be provided special
place.

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Bibliography
 AGARWAL, OPERATIONS MANAGEMENT FOR COMPETITIVE
ADVANTAGE, 11TH EDITION, 162-307
 ASHWATHAPPA, HUMAN RESOURCE AND PERSONNEL
MANAGEMENT, 4TH EDITION, 3- 374
 WWW.GOOGLE.COM
 WWW.NEBULAHOMEPRODUCTS.COM

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