Final Complete Project

Executive Summary
All most majority of the manufacturing industries in India will be acquiring loss during the financial period due to depreciation of machinery. Depreciation represents loss or diminution in the value of an asset consequent upon wear and tear, obsolesce or fall in the market value. Depreciation is a permanent, continuing and gradual shrinkage in the value of fixed assets. The company has to pay replacement cost due to wear and tear of the machinery. Welding is a joining process that produces a local coalescence of materials by heating, by applying pressure, or both. In essence, the welding process fuses the surfaces of two distinct elements to form a single unit. It encompasses a broad range of joining techniques that include fusion welding, solid state welding, weld bonding, diffusion welding, brazing, and soldering. Ador Fontech being the pioneer company in this reclamation and surfacing solution field render their service to their customers with better sales ands service to avoid wear and tear of machinery and helps the company to save their unnecessary expense in repairs and overall maintenance for the machinery. The study has covered up the industry profile, company profile, Mc Kinsey 7s evaluation, swot analysis, product profile, design of the study, scope of the study, methodology of research, sampling design and summary of findings. Statement of problem: To identify the training and development programme being provided to the employees in the welding industry with reference to Ador Fontech ltd Bangalore. 1 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Objective of the study: To determine the employees expectation on training. To analyze the past training programme have influenced the employees. Scope of the study: The study has helped to determine the level of effectiveness of training and development among the employees in Ador Fontech. The study has also helped to find out the training and development programme that has helped the employees to boost up their morale. Limitation of the study: The employees were not able to respond during the survey time as they were busy with their job. Due to time limit of the office work adequate information were not able to gather from the employees. Summary of findings: The study that have been conducted by the researcher have helped him to analyse the response received from each employees about their opinion on the training provided by the company. Recommendation and Conclusion: The study has helped the researcher to reach at a stage were the problems have been identified and researcher has been extracted absolute alternate solution to avoid the ambiguity among the employees provided to them by company.
2 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
INDUSTRY PROFILE
The Welding Industry The welding industry oversees one of the most widely used technologies in materials processing. ______________________________________________________________________ _________________ The Scope and Impact of Welding Welding dates back to the earliest days of metalworking, and continues to be widely applied today due to its cost effectiveness, reliability, and safety. When compared with other joining methods, such as riveting and bolting, welded structures tend to be stronger, lighter-weight, and Cheaper to produce. More than 100 processes and process variants comprise the family of welding technologies, and include methods for welding metals, polymers, and ceramics, as well as emerging composite and engineered materials. These various technologies allow a great deal of flexibility in the design of components to be welded. They also encourage designing for optimal cost-effectiveness in productivity and product performance. Welding and joining technologies pervade commercial and defense manufacturing, and are a significant source of value-added in the manufacturing process. Occurring late in the manufacturing stream, the joining process is typically the final step in assembly and plays the major role in ensuring structural performance. Additionally, the emergence of near-net-shape processes to produce subcomponents has raised the importance of assembly processes as the next area for increased production efficiency. The role of welding and joining in the repair and life extension of manufactured products is even more critical since these processes are frequently used to repair structures and components that were not originally welded. 3 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
A Definition of Welding Welding is a joining process that produces a local coalescence of materials by heating, by applying pressure, or both. In essence, the welding process fuses the surfaces of two distinct elements to form a single unit. It encompasses a broad range of joining techniques that include fusion welding, solid state welding, weld bonding, diffusion welding, brazing, and soldering.
OERLIKON-FON TECHNOLOGY
Evolution of welding technology Ever since man had discovered metal, he has put to countless uses in his every day life. He has learnt to extract it from it ores, purify it, alloy it with other metals and shape it for his needs. In the process he acquired very many techniques to give it strength and durability. He learnt to combine separate metals and create alloys. When metals worn out or cracked he learns to repair and reclaim them. The first primitive step in this process is were forge ring and soldering. Over the year and especially during the last two centuries welding technology has evolved into a sophisticated science not only to join metal parts together but reinforce them with strength that can withstand tremendous operational stresses. Today welding technology can be used to join almost any metal of any size, shape, thickness, composition etc. in fabrication this technology can help weld even crucial part in nuclear reactors, space crafts, electronic gadgets and other critical industries to a very high degree of reliability. the processes developed include Oxy Acetylene gas system, metal arc welding and more sophisticated process like Gas Tungsten arc and 4 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Electron Beam Welding etc. these development in welding technology have been adopted to the Oerlikon-Fon maintenance system to suite all skills kinds of needs, especially in the repair and reclamation of critical industrial metal parts, components and tools.
The Need for Conservation The wide spread use of the metals in everyday life from household gadgets to industry and space crafts has led to an increase in all type of metals like steel, aluminum, and its alloys cobalt, chromium, nickel,etc.cost of these metals have risen steadily and resources are depleting fast. Wear and tear in machinery results in crores of rupees worth metal parts ending up in scrap yards. New parts are expensive and not easily available at site. Recycling i.e. .., making use of damaged and or worn out parts by welding has become a necessity and useful tool in conservation of resources. With the advanced technique of welding a wide range of metals and alloys can be saved and recycled. Importance of Reliability in Weld Treatment As important as the need for conservation is the need for reliability in reclaiming the worn and metal parts. Welding necessities heat input which generated stress being reclaimed. This stress could cause cracks, distortion, wrapping or weakening of the metal thus defecting the purpose and the usefulness of the components. Hence in maintenance welding one must take precaution to avoid the detrimental effect of heat input. Oerlikon-Fon technology has developed products and process which ensure very high reliability of weld reclaimed parts through.
1) Low heat input techniques 5 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
2) Better weld metals to give strength and wear resistant characteristics. 3) Procedure and precaution which ensure reliability of the welded parts. In addition problems caused by impregnation and contamination of oil and grease, metal fatigue, inadequacy in vee-groove due to nature of positioning of the parts etc are taken care through this technology.
Procedure Precaution and Their Importance. In any welding job done with Oerlikon- Fon products and processes the procedure and precaution play a vital role. These have developed to enhance the reliability of weldreclamation. The following procedures are to be adopted: 1) Welding test: to check whether or not the job is wieldable with a particular product. 2) Use of low current 3) Short arc gap 4) Short bead 5) Skip welding techniques 6) Hot penning 7) Block technique 8) Keeping the job at hand heat All these factors play an important role in minimising the ill effect in the heat in maintenance welding.
Oerlikon-fon combines the advantage of welding technology will the specific needs and properties of the metal to be welded. As shown in the example of cast iron welding, proper procedures and care is needed to achieve success in any reclamation job. Recycling Of Waste Resources Parts that are lying in your scrap yard, your maintaence workshop and those in use apart from those in inventory, form substantial resources for your company. These can be weld reclaimed with oerlikon-fon technology at a fraction of their original cost. Your company can thus earn sizeable profits and reduce the operational cost resulting in continuous increased productivity. Needless to add, your spare parts inventory cost can be cut down by over 50% per year.
Maintenance programme. Take a look at the scrap in your yard the inventory of the spares required every year the money spent on new part, production losses while you wait for replacement and you will see the need for a planned maintenance programme a system that calls for better utilization of resources and offer substantial savings through planned maintenance. Proper techniques such as ABC and VED analysis coupled with sound organizational status and functional responsibility for the maintenance division would go a long way to increase efficiency production at minimum expense. Profile and Structure of Todays Welding Industry The welding industry incorporates the workforce that uses welding technologies to perform welding operations;
The welding supply industry that provides the equipment, products, consumables, and services needed by the workforce; and the end-users in the larger national and international industrial sector who rely on welding and joining processes to manufacture their products. Changes in the manufacturing sectors workforce are likely to cause the percentage of workers involved in welding to fluctuate. According to the Bureau of Labor Statistics, manufacturings share of total employment is expected to drop from 14 percent to 12 percent by the year 2006, with a loss of 350,000 jobs. Since manufacturing is expected to maintain its share of total output, overall manufacturing productivity must increase by a minimum of 15 percent, just to break even. From weldings perspective, this implies a greater reliance on mechanized, automated, and robotic welding. The End-Users Virtually every manufacturing industry uses a welding process at some stage of manufacturing or in the repair and maintenance of process equipment. From the soldering of PC boards to the heavy-duty welding of steel plates for shipbuilding to the repair of industrial boilers, industry relies on welding for reliable joining of materials. Among the manufacturing industries that rely on welding are the following: Automotive Heavy Equipment Aerospace Electronics, Medical Products, and Precision Instruments Electric Power Petrochemical Although end-user manufacturers would not typically consider themselves as part of the welding industry, advanced joining technologies allow manufacturers to use the latest materials and designs to enhance their products' performance, reduce manufacturing costs, and decrease life-cycle costs. Because the established distribution system sometimes places a barrier or filter between the manufacturers of welding products 8 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
and the end users, it is sometimes difficult for these manufacturers to learn what the users think of their products, and what their long-term needs (and opportunities) really are. The joining needs of each industry vary, of course, depending on the demands placed upon its products, and the pressures for more cost-effective productivity. Indian manufacturers have requirements in at least three areas: meeting the changing demands of their customers, competing with foreign manufacturers, and complying with government regulations. This means they continually concentrate on developing a new generation of improved, high-value-added products. Joining technologies that have evolved to meet new industrial needs include specific arc welding techniques for the shipbuilding, aerospace, and oil and gas industries, and advanced resistance welding that has been driven by the automotive and appliance industries. Even as manufacturers expand their development of new products, they must continually strengthen their production economies and achieve the bottom-line performance required by shareholders. The result is a movement towards mass customization, where the manufacturing base is both highly flexible and highly efficient. To achieve this flexibility and efficiency, responsibility for manufacturing components and subassemblies is being pushed to suppliers, leaving the prime manufacturers free to concentrate on marketing, sales, and final assembly. As a result, prime manufacturers and the companies in their supply chains are more closely integrated now than at any time in the history of Indian manufacturing. The ultimate example of this may be in the automotive industry, where a single facility has been proposed to incorporate the primes assembly plant and several suppliers' component-manufacturing operations. While suppliers have increasing responsibility for design, production, and just-in-time logistics, these smaller companies find it difficult to secure the financial and technical resources to respond to the challenge. The resources they have may be fully consumed in meeting daily production commitments and in struggling to meet the needs of their customers. 9 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Situation Analysis of Todays Industry As market pressures require industry to regularly introduce new product lines and enhancements, the prime-supplier team is driven by a short product-development cycle. Each new product cycle brings increased performance requirements and enhancements in product quality. At the same time, there is pressure for new products to be more affordable, both in their initial production costs and in overall life-cycle costs. Spurred by the needs of product developers, the research community has spawned new classes of design concepts and new families of structural materials. There are discrete examples of these Innovations being implemented in the current mix of new products, but they have not been widely used. In many cases, manufacturing technologies have lagged behind innovations in materials and design, limiting the ability of prime manufacturers to take full advantage of these new approaches.
Table 2-2. General Trends and Key Needs in Four Manufacturing Industries Industry General Trends Key Needs
Automotive
Supply chains more responsible for design and manufacture. Increased cooperation development management remain competitive on
Real-time
sensing
and
adaptive control
pre-competitive Resistance spot welding technology (RSW) process control, electrode Joining Joining Joining wear, of of and
Technology implementation and equipment design lightweight coated of high metallic strength steels dissimilar materials Polymer joining Laser processes/tailor adhesive welded blanks Structural technology Welding design and process management tools Microelectronics - Process development and reliability
Heavy Equipment
Industry typically rises and falls with the general outlook issues unclear Increased dependence suppliers and supply chains Growth in overseas operations economy, currently an optimistic for
Improved
fatigue
performance and design rules welded joints Process and structural modeling on Real-time process control Optimized robotic and mechanized welding systems Welding of high-strength steels Laser processing (first and second operations)
Impact of recent Asian economic
Aerospace
Shrinking
prime
manufacturer Welding of new Al, Ti, and Ni alloys on Solid state joining and brazing processes Polymer/composite joining development Design tools include residual stress and distortion Process modeling and
base Increased emphasis affordability (cost as an independent variable) Shorter product cycles manufacturing concepts Increased product life repair a major issue
Greater reliance on integrated control control In-process nondestructive
Aging aircraft/sustainment and testing
Electronics, Fastest growing industry sector Design guidelines for all Medical, Precision worldwide Extremely competitive 12 CMR INSTITUTE OF TECHNOLOGY, BANGALORE levels of packaging Coating and plating - effect
Instruments Driven by new products and on joining technology developed in-house; outside developers Process optimization Reliability technology: and test Joining technology historically Process/product modeling now beginning to outsource to assessment methods Process fundamentals microstructure/property correlation Laser processing
Other issues presented by new products include the weld ability of emerging materials that may not have been designed with welding and joining in mind, the need to improve feedback control of manufacturing processes, and the development of new approaches to processing. Advanced computational models will play a larger role as industry develops the next generation of design tools and manufacturing technologies, including techniques for the joining of materials. Traditionally, the development of joining technologies has involved extensive testing programs, detailed characterization of materials, and demonstration of components in service. With appropriate numericalanalysis tools, it will be possible to reduce the time for design and developmental work, improving industrys productivity and shortening the time to market.
Markets and Customers The most important factor influencing the industrys future direction is the potential for increased globalization of businesses and markets for materials fabrication. Industry will 13 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
feel the effects of this increased foreign competition as its companies begin to use suppliers and gain customers from around the world. Traditional lines between customers and suppliers and domestic and foreign markets will be increasingly blurred as joining operations and business alliances from both camps are melded. Information technology will be helpful in accelerating development of the "virtual manufacturing plant" of the future that uses the best of both worlds. The welding community recognizes also that welding technologies and skills will have to compete more keenly with alternative processes such as near-net-shaping, deposition processes, adhesive technologies, high-speed machining, direct fabrication (sometimes termed rapid manufacturing), and combinations of certain technologies. Designers and manufacturing engineers need to know the full potential of the available welding/joining processes so they can make the best selection of potential manufacturing methods. More science, engineering, and training must be incorporated into the welding process if it is to compete with other technologies and fulfill its potential in this country. Records of excellence have already been achieved by the automotive and aerospace industries in their application of welding techniques, and welding is expected to become the established joining method in many other manufacturing sectors. Welding is the established method of manufacturing for shipbuilding, power generation, structural fabrication, petroleum production and refining, construction and farm equipment, and other structural applications. In many of these industries, however, the productivity of welding needs to be improved. In shipbuilding, for example, this country lags behind most others. Who will be the future customers of the welding industry? Developments in transportation industries and the state of the aging transportation infrastructure will be increasingly important in shaping future welding markets. This network of equipment, highways, and bridges must be replaced or extensively rehabilitated in the coming decades, although it is unknown if the state governments are willing to invest in these improvements. If governments do commit funds to upgrade the infrastructure, it will drive the demand for welding in the future. The construction industry 14 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
will be heavily involved in these improvements also. Technologies are available to repair or arrest cracks and addresses the problems inherent in aging joints. However, a few additional technologies may need to be developed for this purpose. The same problems will be present in the infrastructure of other developed nations, while many developing countries will require large first-time investments in their infrastructures. These deficiencies are seen to be a major opportunity for the welding industry. Another market is already emerging to serve the needs of the aging baby boomers. Industry will develop products to support this generation's medical requirements, creating new joining opportunities in technologies such as biocompatible implants. Industry must be alert to the countrys demographics and other social conditions and be able to respond quickly to the needs of the population. Changing requirements of the government's defense systems will also have an influence on the future of the welding industry. While a reduction in defense procurements may reduce the demand for welds in areas such as aircraft and military vehicles, the good performance and affordability of welding are causing the defense sector to explore the greater use of welding and joining techniques. In addition, as the government spends less on research in universities, fewer government-funded innovations will reach the commercial sector. It will be incumbent upon the welding industry to form partnerships to fund research and develop new technologies. It seems likely that customer-specific fabricating will become increasingly prevalent, and together with just-in time production strategies will drive a shift toward small-lot manufacturing or mass customization. There may well be an opportunity for integration of welding processes into some of the direct fabrication techniques that are under development. Industrial distribution is already evolving toward the distribution of parts in real-time. This is a revolutionary change that will affect the selection of joining processes for many applications. This requires the adoption of sensor and control technology based on sophisticated programming, to enable manufacturers to effectively monitor the integrity of products produced in this new environment. However, manufacturers will need to increasingly monitor the integrity of fabricated products as this type of manufacturing becomes commonplace. 15 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Education and the Image of the Workforce People issues are paramount to the future of the welding industry. The unfortunate public image of manufacturing as an endeavor in decline is actually pushing many talented and energetic people into other fields. In academia, students and faculty are discouraged from pursuing studies in the primary production industries and expertise in these fields is rapidly being depleted. Industry recognizes the critical need to attract top-quality personnel to the welding community, from welding and manufacturing engineers to business entrepreneurs and field welders. To ensure a continuous supply of talented personnel, industry plans to pro-actively nurture the growth of educational opportunities for people choosing welding, metallurgy, and related fields as careers. Until recently, welding itself was a skill that craft people could learn without a real understanding of the science behind it. The scientific and engineering principles behind welding must replace the art of welding for it to achieve its potential as a preferred state-of-the-art manufacturing process. Another part of the solution may be more effective apprentice programs for welders and technicians. Welding as a vocation will take on a higher level of prestige as apprenticeship and certification programs become more rigorous. The industry will also grant welders greater recognition and status for their work. In addition, the industry must upgrade the existing workforce through better basic training and effective apprentice programs. Todays welders will be with the industry for a long time, and they need to continually improve their skills and their flexibility.
Business Practices and Economics Another important determinant of the welding industrys future is the drive to improve productivity. For fabricated products to compete in the future, they must be made faster, 16 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
cheaper, and better than those of competitors. While decreased labor costs are the traditional means to enhanced productivity, the industry already recognizes it needs a larger workforce to stay competitive. Corporate consolidations have weakened the industry through loss of welding expertise. Such practices as distributed manufacturing serve to isolate welding engineers from the manufacturing processes. In addition, the trend toward private or contracted welding research could discourage sharing of results. Strategies to improve the economics of welding include changes in the investment decisions made on behalf of welding. For example, if there is sufficient investment in such areas as education and capital equipment early in the process, stockholders will realize a large return on their investment and be inclined to participate. An effective cooperative research program among government, industry, and academia, with sharing of costs and resources, would be another example of a wise investment decision that could increase future productivity. New governmental tax policies could also have an influence on investment decisions by private companies. If welding is to be accepted as a significant factor in the fabrication of metal parts, accurate models of life-cycle costs should be developed for welded joints and alternatives. By exploiting state-of-the-art information technologies, manufacturers will be able to incorporate virtual/integrated techniques into their manufacturing processes and take advantage of their cost-reducing features. Modeling will certainly be important to compress the time needed between development of the design and start-up of production. The use of simulation technology to develop the virtual manufacturing plant of the future has been mentioned previously and is discussed in greater detail in the following subsection, Developments in Information Technology, and in Section 6 under Manufacturing Integration. Improvements in the energy efficiency and environmental compliance of the welding industry will also be positive additions to the overall productivity of the welding industry. As business practices, increased product quality and serviceability are considered so important, they have been included in a separate category for key drivers (see below). Developments in Information Technology 17 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Welding processes based on rigorous engineering analysis, numerical modeling, and computer-based automated manufacturing will be widely used, and will depend heavily on information technology. Similarly, information technology will be important as welding markets become more international, helping to incorporate cost-saving business practices and increase productivity both here and abroad. By modeling the life-cycle costs of welded products, designers can determine early if new products should be produced using welds. Computers will be used to solve other complex problems associated with the application of welding. The growth of information technologies such as the Internet is seen as an important driver that will influence the future of welding in other unexpected ways. Decision tools that support the cost-effective use of welding need to be put in the hands of product-development teams and of manufacturing engineers. The welding industry should not have to reinvent the wheel. There should be wide availability of established procedures. Through the use of information technology, new findings can be disseminated quickly and accurately to others in the industry. There will be no need for various segments of the industry to search extensively for information or repeat studies already carried out. Additionally, a history of past solutions should be available in a database for easy access. The welding industry should take the lead in setting up and maintaining these knowledge-based systems so that industrys progress can be shared by all interested parties. Manufacturers who experience joint failures, for instance, can use the lessons learned from these failures to improve joining strategies and system designs, and transmit this information to other companies. Development of Materials One fundamental need in the welding arena is a greater understanding of metallurgy as it applies to welded materials. Welding and materials engineers will develop new 18 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
materials and adapt existing materials, which are specifically designed to be welded into world-class, fabricated products. Also, as new materials are developed, the welding industry must develop new techniques to ensure their weld ability. New concepts in this area include the development of materials that will reduce energy requirements. Less energy will be used for both pre-heating and post-heating purposes. Smart materials will have a microchip embedded within the material, to monitor the physical characteristics of materials as they undergo the fabrication process and allow engineers to know exactly how they will perform in service. Studies will also be needed to develop new filler metals and to improve the purity of certain products associated with welding (e.g., gases, filler wires). These issues are covered in more detail in Section 6, in a discussion of materials as a key competitive challenge to the future of the industry. Safety and Health The welding environment of the past was frequently viewed as dark, dirty, and dangerous. That perception is already changing, and will continue to change as education and training increase the awareness of workers concerning newly developed welding technologies. The factory floor of 2020 will be a very different place compared to previous manufacturing facilities. Workforce demands, government regulations, changing business practices, and increasing environmental awareness will drive the manufacturing environment to be quieter, cleaner, healthier, safer, and friendlier for workers. Customers, too, will have far fewer worries about the products they purchase. In the coming decades, goods will be produced to be fail-safe and therefore safer to use.
New Technological Strategies Indian industry needs to lead technological developments that will in turn allow rapid and flexible fabrication of new products to satisfy customers' demands. To achieve this, the following strategies will be pursued: 19 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
1. Make current processes more reliable and more robust 2. Allow for greater use of process automation. 3. Develop welding technology concurrently with development of new materials 4. Develop processes and methods that facilitate joining of metals, glass, ceramics, plastics, and other materials as required, to optimize performance of the product. 5. Implement methods of integrating welding requirements and welding knowledge into total manufacturing Planning and management information systems (MIS).
Key Competitive Challenges

Materials As materials are developed with increased strength, corrosion resistance, and other performance factors, welding them can become more and more difficult. Special filler metals, pre- and post-weld heat treatment, and other techniques make welding feasible in many cases, but at substantially increased cost. The challenge is to make these materials as easy to join as simple carbon steels. By 2020, industry wants 95 percent of the materials commonly used today by manufacturers to have a corresponding alloy that can be welded. Advanced computational methods will be used to engineer materials that can be welded reliably and consistently. Research will be needed on filler metals, along with pure metallurgical research, in order to understand the behavior of materials at the atomic level. For example, solutions must be found to overcome the mechanical degradation of aluminum alloys by the welding process. With a new level of understanding of metallurgy, the entire welding industry will benefit and progress. Part of gaining this additional knowledge will be close monitoring of the various products that feed into welding operations. These include the base metal, any filler metals, and gases. Another challenge will be to ensure welds of dissimilar materials will be cosmetically acceptable to customers, as well as high in quality. The appearance of welds will be an ongoing consideration for some manufacturers. 20 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
The Workforce The attractiveness of welding as a vocation and engineering profession must be improved. Industry believes that success or failure in meeting this challenge will be important in determining how. Industry competes in world markets. A workforce that is appropriately educated at all levels will drive a technological revolution in welding for this country. The prestige and promise of welding as a career will grow as welders are certified to guarantee their capabilities, and engineers gain greater appreciation of the potential use of welding. Multi-disciplinary teams will provide a supply of necessary talents, from designer, to engineer, to operator, to welder. Workforce integration will see customers, manufacturers, educators, and possibly the government, collaborating and developing ideas for new products and new ways of using welding techniques. The communication among these various experts will be key in removing barriers to a smooth manufacturing operation. For example, with customers more knowledgeable and aware of the welding process, there will be greater participation by customers in new product development and in exploiting the potential of welding. Engineers who are working side-by-side with welding technologists will better understand the importance of their role in manufacturing. New welding-related knowledge must be widely disseminated among all interested parties, and a better educated workforce and the team approach in manufacturing will help meet this challenge. The number of qualified workers is not increasing at the moment, and a key challenge is to reverse this trend and provide adequate human resources to meet the needs of tomorrows welding industry. A stable and growing workforce will be needed in the new century.
Quality Improvements in the quality and reliability of joints will help overcome the image problem of the welded joint as the weakest link in any structure. For the industry to 21 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
move ahead, it must remove the perception of manufacturers, customers and others that welding is a barrier to a smooth manufacturing process. Another challenge is that academia typically does not accept primary metals and the primary production industries as worthwhile academic pursuits. Faculty and students are not entering the field, and academic expertise in these disciplines will eventually be non-existent. Again, a better understanding of the quality and usefulness of welded metal products will help overcome this negative perception. Processing research, artificial intelligence and robotics, advanced materials, and other developments outside the traditional scope of welding can all be applied to making dramatic improvements in welds. The industry also sees a challenge in its inability to quantitatively predict distortion of materials due to welding. Research is needed to clarify this issue. As the quality and reliability of welded products improve, their safety will also increase. There must be no opportunity for welded products to have a potentially negative impact on customers. Trends in the Welding Industry The manufacture of metal seals, pressure devices, sensors, and many other metal components require precision welding. The sealing, shaping, or joining technique must be extremely reliable because it is necessary to maintain the integrity of the product. The weld process must also be accomplished without interfering with the cosmetics or function of the product. There are many variables to consider in the welding process. The variety of materials is growing daily and thus the burden on welding personnel to stay current with technology becomes more essential. Moreover, it seems that the predominant expertise in welding is acquired at the workplace by trial and error rather than by training in educational institutions.
COMPANY PROFILE
ADOR FONTECH AN OVERVIEW: Nearly fifty years ago, Ador welding Ltd took roots as an electrode manufacturing company at a time when welding was little known to the industry. It was indeed up hill task to identify various areas of welding application and thereafter meet the parameters of specific jibs with specific welding products. Ador welding Ltd pioneer in spirit spurred the organization from one stage of expertise to another. As more and more welding application are were catered to the urge to enter specialized area of welding as in the case of core industry, elevated the company to the high end range of welding products/ the company foresaw the need to offer total solution in welding well in enhance to ensure total compatibility of consumables, power sources and accessories. Today in Indias welding history Ador Welding Ltd hold a unique position as a pioneer and leader have grown in both strength and technology to be able to cater to complex requirements in welding projects not only in India but the world over. The leader in the welding industry for more than a decades- Ador welding is the flagship company of the Ador Group. It has been rated in 1995 as one of the top 200 Indian companies and one of the 20 wealth creator in the corporate sectors.
ADOR FONTECH LIMITED was born out of the parent company Ador Welding in 1979 and the operation started in 1980. It is a front runner organization that operates on the philosophy with its clients in recommending and implementing best in class reclamation and surfacing solution. It is also the first ISO certified company in the country for both the marketing as well as the plant separately.
The company is dedicated to supply of products service and solution that meet and exceed the needs of end-users. The customer-base include mining industries, steal and 23 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
metallurgical complexes power plants, railways, roadways, transport work shops, shipping industries, sugar mills, cement pants, oil drilling and refining sector defense work shops and a whole range of engineering industries. ADOR FONTECH is a company limited by share. It is also listed company with a paid up capital of Rs 3.5 crores. The equity shares of the company are presently listed in the Bangalore, Mumbai and Ahemebabad stock exchange. With extensive connectivity of the Bombay stock exchange investors have access to dealings in the equity shares of the company all over the company. The company has an uncompromising commitment to the continuous improvement of its products, service and delivery mechanisms. Every employee and 200 authorized dealers are dedicated towards the mission of Total Customer Satisfaction and providing the end users with the best in class products and service.
THE GLOBAL PARTNERS OF ADOR FONTECH LTD

Partners
PARTNERS
Advani Oerlikon, India
PRODUCTS
Low heat input welding alloys, Flux cored arc welding wires and range of welding equipment. Copper & Copper alloyed wires & rods for MIG/TIG welding Flux in the flame The world's most wear-resistant fused-alloy steel based wear plates. Welding and cutting equipment Welding spot separation Personal protection equipment
BERCO
Berco, Germany Gasflux, USA Alloy Steel, Australia CEA, Italy CEPRO, Holland PROTECTOR, Australia
EUROMATE, Holland Welding fume extraction equipment and systems Deloro Stellite, Germany & U.K SULZER METCO, USA Cobalt & Nickel based alloys. Plasma transferred arc welding equipment Thermal spray technology products & solutions
DEGUSSA, Germany Brazing alloys & soft solders
SEVEN S MC KINSEY MODEL
An introduction to the 7s model The 7s model is better known as Mckinsey7s. This is because the two persons who developed this mode, Tom Peters and Robert Waterman, have been consultants at Mc Kinsey and company at that time. They published their 7s model in their article Structure is not organisation (1980) and their books The art of Japanese management (1981) and In search of excellence (1982). The model starts on the premise that an organisation is not just structure but also consist of seven elements.
The seven elements are distinguished as hard Ss and soft Ss. The hard Ss elements the structure, strategy and system are feasible and easily to identify. They can be found in strategy statement, corporate plans, organisational chart and other documentation.
The four soft Ss shared values, skills, staff and style however are so hardly feasible. They are difficult to describe since capabilities values and elements of the corporate culture are continuously developing and changing. They are highly determined by the people at work in the organisation. Therefore it is much more difficult to plan or to influence the characteristics of soft elements. Although the soft factors are below the surface, they can have a great impact on hard structure, strategies, and system of the organisation. Evaluation of welding industry on the basis of 7Ss model A front- runner organisation that operates the philosophy of partnering with its client in recommending and implementing best in class reclamation and surfacing solution. The world has limited reserves of mineral resource. However the depletion rate resulting from industrialization is very high. Reclamation and recycling of vital machinery components therefore assumes high propriety. In addition, in addition such an activity results in saving in downtime and inventory costs. The company is dedicated in supply of products, service and solution that that meets and exceeds the needs of end users. the consumer base include mining industries, steel and other metallurgical complexes, power plant, railways, road transport work 28 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
shops, shipping industries, sugar mills, cement plants, fertilizers and chemical plants, oil drilling and refining sector, defence work shop and whole range of engineering industry.
ADOR FONTECH is second position in the reclamation and welding industry and stands first in the product range in the industry. STRATEGY MARKETING STARTEGY The new millennium beckons us into the 'Internet Era' and the 'World Wide Web Age'. This connectivity brings with it immense challenges as well as opportunities. Ador Fontech's future strategy has to take into account these rapid technological breakthroughs. These are also opportunities of strategic alliances and mutually beneficial partnerships both globally and within our country. Collectively the Company has a quiet confidence about the future and has a strong belief that customer focus, quality and productivity will continuously improve in years to come.
Ador Fontechs Limited is a leading organisation dedicated to reclamation, welding and thermal coating solutions. The companys strategy is to provide total customer satisfaction by focusing on our key strengths - motivated employees, technological superiority and multifold services with an enviable return to our shareholders. Structure This defines the basic organization of the company, its departments, reporting lines, areas of expertise and responsibility. The structure represents the hierarchy of the organization and the reporting system. The organization structure is the pattern of relationship among various components or parts of the organization. Structure is thus 29 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
the basic frame work within which an organization carries outs its orders, decision and general functioning. It defines the unbroken line or chain of command and the span of control. The organization structure of ADOR FONTECH LTD is as follows.
Board of directors
Chairman
Managing director Finance incharge Divisional In- charge charge charge North East chcharge West South FON SS & HRD incharge.
Company secretary
Central product groups incharge FMA aaaa AA
FKT
FIA
FAC
FST
Area in- charges
Regional product group in -charge Area product group in -charge
Territory in -charge
Zonal incharge
Reclamation welding technicians
Systems The company generally uses oracle and tally. Tally: This is a software were it is mainly been used for the accounting purpose as well as the price allocation of the product also. Tally also helps to analyze newly imposed VAT (Value Added Tax) format and details, which are the basic necessity in todays business activity. Tally also helps to analyze he present tax been imposed on each commodity and the helps to procure a better price rate for the customers. Tally is also been done for the analysis of the maintaining the accounts of the company and for preparing the balance sheet of the company were its been prepared at every quarter year. Tally is used to prepare the ledger book, cash book, income and expenditure account, profit&loss account that are the key activities of the firm. Oracle: Oracle is a software which is been mainly used for the organization for the extraction of the companys activity in a smooth flow. Here oracle is mainly used as supporting software were it supports all the files in the organization. Here all the information can be stored and the firm will be able to store adequate information. Here the use of DBMS (Data Base Management System) is been used were the files of different files are been able to store in a well arranged pattern to avoid ambiguity and be able to identify the exact position of the file. The MIS (Management Information System) is been used to analyze the performance made by different departments to identify the profitability of the firm and also to used for decision making purpose also.
Systems involved in Joining and Welding Processes: Soldering and Brazing: An economical means of applying filler metal to join components both in low and high volume.
Resistance Welding: This process applies large current flow to heat the components at the point of highest resistance - at the weld joint. Electron Beam Welding: This is a fusion process performed in a vacuum chamber where a high velocity beam of electrons is focused on the surface to be welded.
Laser Welding: This process uses focused coherent light (a laser) to melt the base material and is used for precision welding or production of quality parts. Gas Tungsten Arc Welding: Gas Tungsten Arc Welding (GTAW), also known as Tig (Tungsten Inert Gas) Welding, is the most commonly used precision arc welding process. A welding arc is established between a Tungsten electrode and the part to be welded. The metal of the part is melted by the intense heat of the arc and fuses together.
Plasma Arc Welding: Plasma arc welding, basically an advancement of the GTAW process, uses a copper nozzle to surround the Tungsten electrode. A pilot arc is first established between the electrode and copper nozzle and then transferred to the part to be welded.
Tig and Plasma weld processes are the most commonly used methods for precision joining. Weld quality and repeatability has improved in sync with advances in power supply, process controls, and welding techniques. These advances allow the use of the process in even more precision applications.
Power Supplies: The welding power supply itself has been refined. The method of delivering brute force power to a welding arc has become outdated as customers demand superior products. Higher performance machines with greater efficiency, accuracy, and response time have replaced these earlier "beasts."
Welding Control Systems: In order to meet more rigorous quality demands, the welding industry has moved to a much stricter control of standards and has developed weld programmers-devices that store and execute weld programs. 33
CMR INSTITUTE OF TECHNOLOGY, BANGALORE
The welding process section of the work is automated by these programmers/controllers and helps to reduce scrap parts by executing repeatable, pre-arranged weld programs within precise welding parameters. The welding capability is thus built into the welding system through the weld controller rather than taught to the manual welder. As a result, there is less opportunity for error or fatigue. These controllers are used by manufacturing organizations for medium to large contract runs. Lower costs are attained mainly by confining the necessary skill level of an operator to loading and unloading parts. While repetitive welding is now accepted as an operation to be automated, there will always be a need for the skilled welder and manufacturing organizations have found ways to improve output here, too. Orbital Welding Systems: Orbital welding systems were designed to be used in applications where a tube or pipe to be welded cannot easily be rotated or where the space restrictions for access limits the size of the welding device. In the orbital welding process, tubes/pipes are clamped in place and an orbital weld head rotates an electrode around the part to make the required weld. Orbital welding systems are used for welding tubing in industries such as aerospace, boiler tubing, food and dairy, nuclear, pharmaceutical, and semiconductor. Tungsten Welding Electrode Tips: The Tungsten electrode, the source of the welding arc, is the element most commonly ignored by manufacturing organizations. Whether in manual or automatic welding, this is the area where manufacturing organizations can improve the consistency of their welding output with minor effort. The safety issues of Tungsten electrode material are also being looked at more closely now. Many users of the Tig or plasma welding process do not realize that the welding electrodes they use contain Thorium, a radioactive element added to the Tungsten material to improve arc starting and welding characteristics. While the radioactivity is of 34 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
a low level it brings an issue of danger - especially with the radioactive dust generated when grinding the electrodes to a point
for welding. New Tungsten materials are now available, such as Lanthanated electrodes which offer superior arc welding characteristics and are safer due to their lack of radioactivity. While these materials are now commercially available, they have been largely ignored until recently. Pre-Ground Electrodes and Tungsten Electrode Grinders: Given the Thoriated electrode radioactivity issues and the ever-increasing weld quality requirements of the final weld, more and more companies are looking for ways to ensure that their weld quality is up to par. Staff Defines the company peoples resources and how they are developed trained and motivated. ADFL boasts of highly qualified well trained and immense experienced staff. Theses staff is not just mere employees but can truly be called the very asset of the organization. They form the very back bone of ADFL without which any amount of success matter to the company. They are highly dedicated and fiercely loyal towards the company. The staff plays a very important role in prompting a healthy work environment in terms with superiors as well as peers. A key strength of the company is motivated employees with high morale and innovativeness. The work culture provides the employees with challenging goals and joy fonetwork also consist of a service-oriented authorized dealer network and suppliers both in India and overseas with whom win-win partnership exist. Continuous improvement in long term relations is considered as an investment towards the common goal of total customers satisfaction. Frequent interactions are aimed at understanding internal and external customers need and measurement of customer satisfaction levels. 35 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Skills: This is the capabilities and competencies that exist within the company. What it does best. This refers to the dominant attributes or capabilities that exist in the organization. It is already understood that ADLF has highly qualified and trained staff. Every employee is given the chance to use their talents to the maximum. The company believes in exploiting the variety of skills and talents an employee may posses to do a certain job. Thus there is always a very quality tag attached to every job done. Another aspect of that is since the company has a wide marketing network all over the country, communication skill and technical skill is deeply etched in the frontline engineers and the technical support. Style: In simple terms this explains how the leadership and the higher management behaves. Thus style would thus symbolize how the leaders choose to react in situations, how he chooses to behave with the employees in ADFL, believes in employing a democratic style in the general functioning of the company. It adopts a participative style where in all employees get their chance to express their views in major and critical decision of the company. Every employee is given the chance play a major role in all decision taken and is finally it is drawn to a conclusion with prior consent of all. Since it is collective effort on everybodys side it does not pave way for conflicts and disagreements. Thus the democratic style adopted by the ADLF allows every employee to feel they truly belong in the company and facilitates good relation between managers and subordinates.
Shared value: ADLFS Shared Values 36 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Delighting customers is first and foremost priority of ADLF Empowered employees who enjoy their work. Living up to the shared values. Innovative ideation throughout the company and continuous improvement in everything we do. Growth is the way of life. Honoring commitments whether made orally or in writing. Technology as it continues its advance will be a vital enabler in the Company's plans and operations. The vision of ADLF is to be considered as a part first choice by our customer. Mission of Ador Fontech The mission is to be partner with the customers implementing value added joining reclamation welding and surfacing solution. Quality policy The company shall strive to delight our customer by understanding and exceeding their needs. This should be achieved through continual improvement of process & the strength of our people. Quality objectives Manufacture of products as per quality standards - To reduce no of customer complains Continuous improvement in product quality - To increase the customer satisfaction Reduce cost Continues improvement in the order execution process. Ensure all gaps in competence are addressed through training
Milestones
Exclusive distributorship for Protector, Australia series of personal 2000 protective equipment. Exclusive distributorship for Cepro, Netherlands range of world class 'welding spot separation' products. Exclusive distributorship for CEA, Italy range of welding & cutting equipment. Exclusive distributorship for Gas flux range of products and services. Approval of special welding alloys from defence organisations for armour steel welding. Exclusive distributorship for Euro mate, Holland range of welding fume extraction equipment and systems. Distributorship for copper and copper alloys from Bedra Germany and for tungsten carbide products from Woka Germany. ISO 9002 Certification. Launch of ARCOFON range of the world's most wear-resistant fuse-alloy steel based wear plates and SAF range of portable welding and cutting outfits. Public issue successfully completed to raise the equity capital to Rs. 35 million. Distributorship for a wide range of Satellite products from Deloro Stellite, Germany. Equity capital increased to Rs. 22.5 million. Acquisition of FIST India Private Limited and merger of the same with ADFL. Acquisition of Kostech India Private Limited and merger of the same with ADFL. Number of shareholders increased from 112 to 1874 and equity capital increased from Rs. 4.8 million to Rs. 16.9 million. FONTECH training centre launched in Chennai. Exclusive distributorship for special brazing alloys from Degussa AG, Germany. Fontech training centre launched in Mumbai. Launch of Fonmatic open arc reclamation welding products. Finalisation of exclusive distributorship for India from Metco, USA, for Thermal spray equipment and materials New reclamation welding alloy developed for the Indian Railways in the 38 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
1999
1998
1997
1996
1995 1994
1992
1991 1988 1987 1985 1983
1980
H3 class. Commencement of operations.
DEPARTMENTAL ANALYSIS IN BRIEF

Ador Fontech Ltd does not have a very rigid system of departmentalization. In many cases it is found inter-related and overlapped with the functions. But on a board it can be separated. Human Resource Department: headed by the GM Sales Service and HRD, he is the upper most authority in the ADFL head office for all the functional purpose. Though the MD exists in the same office the GM handles the overall day to day activities in the office. In addition to the general HR function he oversees certain other procedure like the execution process, pre-quote sanction approvals handles issue of tax liabilities, job works costing approval with the MD. The general HR functions are carried out with gist. A brief scan is been given as below. Recruitment Process: this is highly decentralized wherein the area heads, zonal heads, territory heads etc identify the required man power and the skill that are lacking at their location. Selection Process: they then go about inviting applications and selecting suitable candidates on the basis of their performance in certain tests and interviews the candidate may be subjected to. Any interesting aspect in this company is that the gradation and selection is done not only foe suitable future employees but also for the suppliers and dealers. After a through process of vendor rating, the vendors or dealers are been selected. A formal procedure for dealers appointment and dealer termination
exists in the company. Once the dealers are selected dealers are to deposit fixed based on products groups and the legal agreement which is valid for two years. Induction, training and orientation process: once the employee is been selected an induction training of 25 is given which is technical and commercial based training. Each fresh employee would be put on probation basis for at least a year without leave facilities and paid sick leaves. Incentives, promotion, hikes and performance appraisal: medical insurance to the extend of one month basis salary is an incentive. In addition to this in case of hospitalization, the management uses discretion to award it in which everyway they feel suitable. For senior executive housing facilities car with driver is been provided. at zonal in charge two wheelers are been given with lap tops to the engineers. In addition to this general functions like payment of salary, provident fund, TDS etc are been handled by the GM. Performance appraisal is done in monthly review quarterly review and annual review. Generally for sales personnel performance appraisal is not based on their target achievements, immediate superiors word of mouth. Finance Department: the finance department has two heads; finance manager (who is also the company secretary) and the DGM accounts. While the secretary reports directly to the MD for all the functional purpose in the head office, she reports to the GM. As company secretary as well as the finance manager her work revolves around from conducting annual general meetings and preparing the minutes. She also handles the share transfer activities share holders complain and all matters pertaining to the shares and dividends. DGM accounts are in charge of the entire books keeping process and preparing accounts for the entire organization. Through tally he co-ordinates with other divisional offices for preparing consolidated account for the company. 40 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Marketing Departments: the exclusive functioning of marketing activities is limited mostly to the divisional areas, zonal and territory office. Those who are connected directly with this are central products group in charge (COPECS) who are mostly found traveling around the oversee the proper functioning of this activities. The frontline engineers are trained in certain product groups which they will handle exclusively. The product specialists support the selling along with them is the technical experts who are responsible for all queries relating technically repairs and maintenance process. When there is a target of developing new customers the frontline engineers demonstrated at lower level. If it is a high-tech product or a large customer base or bigger value the superiors also take part. Production Department: the manufacturing process is carried out solely in the plant located in peenya. In the Bangalore plant only the manufacturing of ADORFON and FONMATIC products are carried out. The raw materials are supplied by the present company Ador welding Ltd.
DOCUMENTATION TRAINING AND EDUCATIONAL SERVICE (DOTES)

Training Here the process of training is carried out. Every fresher is put on a rigorous 3 week training programme wherein the entire product, technical and commercial knowledge is imparted. The commercial training gives them an understanding of the tax structure, dealer policy, end user, discount structure, incentive policy, and etc.In addition to this they are also horned in their selling skills for promoting products. 41 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
In addition to this refreshment programme is held once in every 6 months for new product knowledge. These programmes are conducted division wise. For existing employees gap analysis is done. Ratings for different attribution are given for a certain level / position. These standard rating are matched with a persons rating and then training is given in that particular attribute to close or minimize the gap. They also provide external training programme to outsiders for example their customers technical staff to give them the know how on handling the machinery and what electrode is to be used for which metal. They have designed courses for theoretical and practical knowledge for end users. In addition to these 2 to 3 days workshops are conducted regularly for general maintenance knowledge. Documentation On a chargeable basis the engineers are sent to understand the components used, the procedure for welding, what electrode is to be used, what is the correct and precise welding process the repair welding techniques etc after studying the components parameters are noted down and all these details are put in the form of case study. These case study formats are stored in computerized data banks. These become reference points which are available to customers. Letters of appreciation send by customers are documented. Thus this Customer Relation Management (CRM) and Documentation Training Education Service (DOTES) are a sort of Management Information System (MIS). This MIS facilities timely access of information and aids people at all levels to clear doubts and take decision.
SWOT ANALYSIS
STRENGTH Advani Oerlikon (ADOR GROUP) has been in the business for the past 40-50 years. The leader in the welding industry for more than four decades, ADOR FONTECH LTD parent company Ador welding is the flagship company of Ador group. Ador welding holds a unique position as a pioneer and leader having both in strength and technology.
It has been rated as one of the top 200 Indian companies and one of the 20 wealth creator in corporate sectors. The equity shares of ADOR FONTECH are listed in the New Delhi, Bombay and Ahemadabad stock exchange. It would also help in creating goodwill but would also give the customer a sense of security that the company is standardized and is SEBI approved. Ador, the market leader in terms of market share accounts for about 24% of the entire market. WEAKNESS The most weakness of ADOR FONTECH is an issue that the company needs to tackle effectively at the earliest. With all the products of ADLF being priced really high, it stands number one in price. This is a major weakness even though the company has been doing extremely well. This is mainly due to the fact that their customers base includes big industry rather than small time buyers. They are loosing on lower end sectors and ignoring this sector may prove costly for the company in the long run. ADLF is also trailing behind L&T in terms of the numbers of engineers at their work base. While L&T has an approximate number of 450 engineers, ADLF has around 200 engineers only. This is another major draw back since they are lacking in the required skilled staff. OPPORTUNITY A major concern with the customers is to increase their productivity, reduce down time and improve welder health and safety requirements. World wide the demand for metal, alloys and mineral resources is on the increase. The scenario offers enamors opportunity for reclamation and recycling of vital machinery components.ADLF is already a front-runner company in supplying products and service for such needs. 43 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Demand for higher productivity welding and cutting systems, welding fume extraction system specialized surfacing and hard-facing alloys and deposition equipment are on the rise. Higher productivity welding processes such as semi automatic and automatic welding systems are increasingly in demand. THREATS There is dumping of cheap imports from the south East Asian countries especially Korea. While Ador accounts for 24% of the market share archrival ESAB accounts for 18-20% of it. If unguarded there is every opportunity for the rival company to loose the gap. Other big firms like L&T, D&H, diffusion etc pose huge threat. Other risks are associated with political instability with its impact on economic growth and investment plans of the industry.
PRODUCT PROFILE
OERLIKON FON is a market driven brand name. A wide range of low heat input welding alloys have a performance- proven track record and are being used extensively in India and at several overseas locations. FMA group consist of the following product range. 44 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
FONMATIC flux cored welding wires and wire feeders. FONARC range of welding and cutting equipments. ARCOFON the worlds most wear resistant fused used alloy steel based wear plants.
FCT group consist of the following product range: DELORON STELLITE consumables, FONCOATECH thermal spray products,
pyroputties and FONMETALL range of cold repair products and service. The agency group has the following alliances: SULZER METCO the world leader in thermal coating products and related technologies. The company represents them extensively in India. The company also represents DEGUSSA Germany exclusively for a wide range of brazing alloys.
ADOR FONTECH products and service are backed by DOTES (documentation, training and education service). This service group documents and disseminates case studies technical articles, product literature etc. at Ador Institute of Welding Technology (AIWTs- based at Mumbai, Madras, and Pune). DOTES conducts focused training programme on reclamation and surfacing technologies. They also conduct training programme and seminars at vital industrial and customer location all over India. The company has uncompromising committee to the continuous improvement of its product, service and delivery mechanisms. Every employee and over 200 authorized 45 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
dealers are dedicated towards the mission of total customer satisfaction and providing the end users with best in class products and service. ADOR FONTECH PRODUCT GROUPS THE OERLIKON FON RANGE Performance proven Low Heat Input Welding Alloys marketed under OERLIKON FON brand name are front runners in maintance and reclamation of vital machinery components. These quality products meet stringent customers specification and perform under sever work environments. OERLIKON FON products have been serving maintenance and reclamation needs of a wide range of end users. Technological back ups help in reduction of down time, spare parts inventory and spare parts related cost. FIRST DIVISION Located at Ahmednagar this plant manufactures gas welding and cutting products and thermal spray torches. Also included in its programme are the A series bare rods and wires to supplement the OERLIKON FON range.
THE FMA GROUP FONMATIC products. As an extension of the traditional business of low heat input welding alloys and to meet the continuous welding product need of the end users, the FONMATIC range was launched the main focus here is on hard facing and other specialized continuous welding applications. The product range includes joining wires, hard facing alloys, stainless steel alloys and other custom built wires and equipment.
FONARC equipment has been specially designed and developed to meet the requirement of welding power sources needed for reclamation and repairs of vital machinery components. This range has been supplemented by PRESTOPAC and PRESTOZIP SERIES of portable welding and cutting sets. ARCOFON series of wear plates are manufactured by a computer controlled weld-castprocess which enables a constant and even fusion of hyper-eutectic chrome alloy on to a mild steel backing plate. These wear plates have found numerous application in the original equipment, mining industries, powreplants, steel and metallurgical complexes and several other vital industries. THE FCT GROUP DELOR STELLITE surfacing products are setting the worlds standard in surfacing technology. These are cobalt, nickel or inter metallic cobalt or nickel based wear resistance alloys and surfacing coatings. They offer combinations of wear resistance, corrosion and oxidation resistance, high temperature hardness, resistance to galling and low cost efficient friction. FONCOATECH: wear, abrasion, erosion and corrosion of machinery components result in heavy down time losses. FONCOATECH brand thermal spray powder alloys, spray torches and guns are marked based on the development of the end suerswise specific job application.
GASFLUX is highly specialized process of applying flux for brazing by means of a flame. This process is used in a wide variety of bronze and silver brazing applications. Ador Fontech represents gas flux co exclusively in India. FONMETALL range consisting of cold repairs putties, systems and solution is now being extensively used for in-situ repair application a board spectrum of industries. 47 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Ador Fontech also offers high temperature process and maintenance products form AREMCO, USA for the repair and corrosion protection of metals and refractory materials.
OVERSEAS AGENCIES SULZER METCO: the world leader in thermal spray technology products and solution are exclusively represented in India by Ador Fontech. Any base material can achieve improved characteristics through a sprayed coating. From hand held to highly automated operations, low a sprayed coating. From hand held to highly automated operations, low volume to mass production, thermal spraying offers enomurous flexibility. DEGUSSA: the company has an exclusive distributorship for the DEGUSSA range of world- renowned brazing alloys and special soft solders. KOSTECH DIVISION State of the art welding and metal spray process are used to repair, reclaimed rebuild vital machinery parts for thermal power stations, cement plants, mining and several other core industries. Located at Nagpur, this facility is capable of taking up customerspecific and heavy duty reclamation job.
DESIGN OF STUDY
The study was been conducted in the Training and Development for ADOR FONTECH LTD, Bangalore unit. Significance of the study Training and development is an attempt to improve the current or future of the employees performance by increasing the ability to perform through learning, usually by changing the employees attitude or increasing his or her skills and know ledge. Employees should be trained as to their aspects. After the selection process of the employees for a particular job, if he wants to perform in his assignment work in the specified way, he should be aware of every related thing like knowledge, technical aspects; behavioral, disciplinary matters etc and also knowledge should be acquired about new technical as well as non technical issues on passing of time. The basic purpose of this study is to identify how the employees feel about the training programme and the requirements that are needed for the rest training programmes which the company can implement for the employees. Statement of the Problem To study the how the employees perceived the effectiveness of training and development in Ador Fontech Ltd, Bangalore. The project was mainly identifying the training programme that is given to the employees were been beneficial for them to improve their skills and knowledge in the work they were been assigned.
Objective of the study To find out whats the employees response about the necessity of training, and method. To determine the employees expectation on training. To find out how frequent the employees want to get training To analyze the company has succeeded in implementing the training programme according to their requirements of the employees. Scope of the study The study was been basically conducted in Ador fontechs Bangalore region from the marketing division and the company plant that was been situated in peenya industrial area. The study determines the level of effectiveness of training and development among the employees in ADOR FONTECH, Bangalore region where the sample size was been taken from technical as well as the non technical employees. Significance of the study The study helps in implementing actions so as to improve the present training and development system. The study also helped to analyze the training requirements recommended from the employees. Limitation of the study. The employees were not able to respond during the survey time as they were busy with their jobs. As the target was restricted to the employees of ADOR FONTECH Bangalore unit only the target sample was very small. 50 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
RESEARCH METHODOLOGY
After having identified as the problem as the effectiveness of training and development among the employees of ADOR FONTECH, it was decided that to conduct a descriptive research to find out the same. Adequate suitable secondary data was collected for the study and it was decided to take a survey to conduct for the study. As a tool for primary data collection a structured questionnaire was prepared keeping in mind for the objective of the research. Samples of 50 workers were been from the divisional office, plant was chosen as sample to be interviewed. The details of the employees were been interviewed were be taken with the help of the training manager from the plant. The employees were approached during the work hours and interviewed as per the questionnaire. As per the completion of the survey the collected data was tabulated, analyzed interpreted and the percentage was been calculated and the main tables were been drawn. Then the respective diagrams were been given to illustrate the data. And then finally interference was made for each question. Based on this interference recommendation were made and the research was concluded.
TYPE OF RESEARCH UNDERTAKEN A descriptive research was under taken to study the problem. It aim is to explore the effectiveness of training and development in the sample population of Ador Fontechs. Sources of data. 1) Primary data. 2) Secondary data. Primary Data The primary data has been collected from a group of employees working in the divisional office, as well as in the companys plant in peenya. The data has been collected through the structured questionnaire. Depending on the information given by them a report was been prepared. Secondary data The data has been collected from the companys manual, handbooks, the annual report, the employees register. These data have provided a reference in completing the study. Sampling design 1) Details of the population The study was been conducted only for technical, non-technical staffs in ADOR FONTECH LTD Bangalore consist of around 210 employees. 2) Population frame All the employees under the training scheme are the effective population frame. 3) Sampling units It represents the total population of technical / non-technical employees that consist of 210 employees of ADOR FONTECH Bangalore. Out of which the sample was been taken. 52 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
4) Sampling method Convenient sampling, non probability sample was been taken for the sample size. The sampling size100 employees was been taken.
DATA COLLECTION TOOLS: Questionnaire method was the primary tool for data collection. Interview with different employees within the organization.
Methods for analysis for data. The primary data was collected by the structured questionnaire where the employees have given opinion about training programme in the organisation and have interviewed them personally. Based on the questions in the questionnaire the analysis were done for about questions and they were been analyzed by percentage base, diagram. The information were been collected during the working hours of the firm were there was a great concern were the respondents were not willing to answer the questionnaire.
1) The training is been provided according to the skills required by the employees. Scale Very true Partly true False Total Percentage 80 20 0 100
partly true 20%
very true 80%
Interpretation: In this statement the researcher has come up with a suggestion that majority of the employees (80%) recommend that training is to be provided based on the skill requirement of the employee, while there is a minority group refereeing to partly true (20%). Here the training programme is been provided according the skill requirement of the employees. The training programme helps the employees to develop their skills in the particular job being assigned to them. 2) The existing system for the identification of training is efficient. 54 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Scale Very True Partly true False Total
Percentage 90 10 0 100
partly true 10%
very true 90%
Interpretation: In this statement it has been clearly stated that majority of the employees (90%) supports that the identification of training programme is efficient, while (10%) suggest that it is partly true. The organization provides adequate identification of training based on product development as well as employees inter-personal skills.
3) The training center is well equipped for organizing training programme. 55 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Scale Very true Partly true False Total
Percentage 100 0 0 100
very true 100%
Interpretation: Here the majority of the employees 100% agree that the training center is well equipped and organized. This is the particular statement the researcher has been able to achieve 100% response from the employees. The training center is been able to accommodate a batch of 40 people at a time. They give training on each and every products and the specification of the product. The company has its own training institutes in other parts of the country 56 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
4) The duration for the training programme is sufficient . Scale Very true Partly true False Total Percentage 70 25 5 100
false 5% partly true 25%
very true 70%
Interpretation: Here majority of the employees (70%) support that the duration for the training program is true, while only (25%) of the employees support that it is partly true, and (5%) says it is false
The training programme is sufficient enough for the employees. The induction training is been provided for 30 days by the organization. The organization keeps them under probation for 6-1 year were they analyzes the employee is capable to do the work at their best and be able to place them in the organization. The employees will do their best to achieve his task to get more impressed by his superiors. 5) The training programme is announced in well advanced Scale Very true Partly true False Total Percentage 80 20 0 100
partly true 20%
very true 80%
Interpretation: Here around (80%) of the employees supports that the training is announced in well in advance, while (20%) says it is partly true, and no one has any opinion saying it is false. Interface: The training programme is announced in well advanced to the employees. This is clear cut of understanding between management and the employees. The management gives the entire details about the training programme and the duration of the training programme to the employees. 58 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
While the rest comment that management does not fulfill their responsibility in announcing the training programme. The employees do inform the management about the need for training to be conducted. 6) The training programme helps to upgrade the marketing as well as the technical skills. Scale Very true Partly true False Total Percentage 100 0 0 100
very true
Interpretation: Here as all the employees around (100%) supports that the training programme is been utilized for both in their marketing as well as technical skills. The training programme helps to cognizes the employees in their respective field they are been assigned.
7) The training helps to built up interpersonal relationship with the superiors and subordinates. Scale Very true Partly true False Total partly true 10% Percentage 90 10 0 100
very true 90% Interpretation. Here majority of the employees (90%) very truly agree that training helps to built up the interpersonal relation ship between superiors and the subordinates, while others (10%) partly agrees to it. This has clearly stated that after the training programme the subordinates and superiors will be much interactive with each other. This is the best were they can built up a cordial relationship with each other. The knowledge about the work and the way of tackling the job in difficult situations make their subordinates more efficient and effective is the achievement for the trainer.
8) The training programmes you have attended have made any attitudinal change in me. . Scale Very true Partly true False Total Percentage 40 50 10 100
false 10% very true 40%
partly true 50%
Interpretation: Here majority of the employees (50%) says that it is partly true, while employees also have an opinion (40%) that it is very true, while (10%) says that this is totally wrong. 61 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Training only helps to change the attitude towards the work. It will help them to work in an effective manner as well as helps to avoid scraps for the organization. The employees will be having a vague idea about the work that is been assigned to them. Training programme helps them to solve all their ambiguity about the work 9) Does your boss discuss the objectives of the training programme in advance? Scale Very true Partly true False Total Percentage 80 20 0 100
partly true 20%
very true 80%

Interpretation: Here it is been clearly stated that (80%) that their boss do discuss about the training programme in advance, while only (20%) only it is partly true. Here the researcher have analyzed that superiors discuss the advantage of training programme to their employees. The employees will not be having the adequate knowledge about the training programme conducted by the company and what do they benefit from the training programme. 10) What type of training method is required? Scale Percentage 63 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Off The Job Training On The Job Training Training on the proto type machine A combination of the above Total
10 60 10 20 100
20%
10%
off the job training on the job training
10%
60%
training on proto type machine combination of all
Interpretation: Here majority of the employees (60%) prefer training should be given on the job training, (10%) prefer it should be given on off the job training, (10%) believe it should be given in proto type machine, (20%) believe it should be a combination of all. . On job training is been more efficient method for the employees to be more pro-active and understand through their mistakes and be able to rectify themselves. While the minority group claims that it should be given to the machines which are very dangerous in use. They have to be trained very well before they operate the machines, the off-job training for those who are new to this field and dont know any thing about the industry and the work to be performed. For these people off-job training is been basically required. 11) Training programme should consist of: Scale Percentage Knowledge about the work to be assigned 20 64 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
only Knowledge and communication skills 10 Knowledge, communication and public skill 60 Product knowledge and communication 10 skill Total 100
10%
20% assigned work only communication skill public relation marketing skills
10%
60%
Interpretation: Here majority of the employees (60%) prefer training is for knowledge, communication, product skill, (20%) prefer for the assigned work only, (10%) for communication skill, (10%) for the product skills. Training is been involving not only the knowledge that is been achieved by practical experience, this also helps in the building up the employees gap of communication barrier with his colleagues also. This will be helping to work as a team in an organization that helps the employees to work more cohesive and help to reach the targets of the organization.
12) In what area common training programme is desirable to all the employees in the. Organization? Scale Percentage Safety needs 40 Acquaintance with the rules and regulation 20 with the company Disciplinary proceedings 30 65 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Combination of all Total
10 100
saftey needs
10% 40% 30%
20%
rules and regulation disciplinary procedings combination of all
Interpretation: Here the employees (40%) agrees that the common training programme is desirable to all the employees in the organization is emphasized on safety needs, while (30%) believe the training programme are to be emphasized on disciplinary proceedings of the company, (20%) for the acquaintance of the rules and regulation of the company, while (10%) agrees it is the combination of all.
13) What do you think about the experts coming from out side organization and conducting training programmes in the factory? Scale Necessary Desirable Total Percentage 60 40 100 66 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
Desirable 40%
Necessary 60% Interpretation: Here as from the data collected (60%) of the employees agree that experts should come from out of the organization and conduct training for the employees, while (40%) supports that it is been desirable for the employees about the training that is been conducted by the experts outside the organization. The experts are been invited by the management to conduct training for the employees is necessary. The employees require training not only in the reclamation field industry also to create inter-personal skills to develop their communication skills and been able to approach the customers about the service being provided. The experts from outside also helps to create motivation among the employees and they will be more enacted to work effectively. This also helps to understand the recent trends of welding technology and the methods of adopting the technology..
SUMMARY OF FINDINGS
Training is the basic requirement needed for every employees after they are been joined into the organization and to get adjusted with the work as well as to improve skills and techniques to do the assigned job. Here it is the responsibly of the company to provide training for the employees. 67 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
As the perception view of the employees about the training is organized according to the skills required by the employees. Majority of the employees around (80%) supported that it is very true and (20%) believed that this is partly true. The employees perception views that training is required according to the skills of the employees. The employees will be able to develop their skills during the time of training. The existing system for the identification of trainings efficient. The survey was been taken from the opinion of employees were majority supports that (90%) the statement given was very true, while only (10%) states that it is wrong. As from the majority of the opinion been taken from the employees the identification of the existing system of training is necessary. The training is been given based on the identification for the products to be produced. The company is clear in the identification of the training needs.
The next question about the training centre is well equipped for organizing training programme is that was been taken as supports that it is very true. The training centre is been well equipped were the employees are satisfied about the training center were they are been thought well during their training time. The tutor is also well satisfied while they are able to teach their trainees with adequate technique adopted by the latest technology. Here the employees are been given a 30 days of induction training. This makes the trainers to be more involved in the work. As the next question mentions that the duration of training period is sufficient. Here all the employees partly agree that the training period is well sufficient enough. As the training period is for 30 days an induction programme is been given to all the employees in the organization to get familiar with the job to be done. As it is only required around 30 days of training for a normal person it may take some more time to understand the job and get a brush up training in every once in a month. While some states that the 68 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
training programme is well sufficient for them to understand the particular work to be done. Training time should be more adjusted and they have to be given adequate time. The training programme is announced in well advanced to the employee. Here all the employees supports that the management announces in well advance before the training is about to start. Here the management announces when the training is to start and the duration of the training also is been announced by the management. But here there have been some exceptions were around (20%) says that it is partly true. Here they do not except that the management announces for the training programme in advance. The management does not keep the word very time The training programme helps to improve the marketing as well as the technical skills. Yes all the employees agree to this suggestion that all the employees will be benefited for the development in their work. Here the employees will be able to acquire more knowledge about the work to be done. The effective training helps them to improve their inter-personal; and intra personal skills. Here another question mentions that the training helps to built up interpersonal relationship between superiors and subordinates. The employees get more acquainted with the work and are able to achieve more complements from their superiors and their motivation level also increases. Majority of the employees (90%) agrees that the statement is very true and they do believe that is required but (20%) these are partly true and they dont always stand true. The training programme that the employees have took part have affected in their day day life. The training programme plays a vital role in developing the work ability as well the knowledge about the work to be performed. The training programme that have been an advantage for the employees in developing their attitude toward the work and be able to avoid all the uncertainties / accidents during the production process.
The next question refers to is there any attitudinal to the employees during their training time? As the opinion received that the employees (50%) partly believes that it is correct and (40%) believes that it is fully true and (10%) believes that it is false. The training may some times bring attitude change towards the work they do. Here the employees may feel before entering to work that it is very difficult for the work to be performed and they will be having the fear in them they are not worth for it. After being trained for the work they will be confident as well as be more efficient and also reduce accidents during work. The majority of the employees except that their boss do discuss about the training programme to them in advance. The boss gives them instructions about the training procedures of the company and the duration of the training programme and what is been thought during the training secession. (20%) agrees that it is partly true the boss many times do not give them valid information about the training programme. What type of training method is required? Here as the survey was been taken majority of the employees were saying that (60%) they need on the job training and (10%) supports that they need off the job training. Here the major training programme is to be done on the basis of training programme to be given to the employees when they are on the job itself. So they will be able to rectify their mistakes as well as to get more accessed with the job they are been doing. Here all the employees will be having confidence and they will be much aware about the job and will not be able to acquire the fear in them. (20%) says that the training should be given on proto type machine and that there will not kinds of ambiguity how to handle the work and also understands the work.
Experts are to come from outside the organization to conduct training for the employees in the organization. Majority of the employees agree that experts should 70 CMR INSTITUTE OF TECHNOLOGY, BANGALORE
come to the organization to conduct training for the employees to make them aware about the existing business world and the new technology that is been adopted and make them aware about the technology and try to improve their working condition.
RECOMMENDATION After making the analysis of data received the researcher has come up with a suggestion to the company:
Training programme and refresher courses are been essential to all levels of employees. Here the skills of the employees should not be discriminating them in attending the training programme.
The management should understand the perception of employees towards training & development programme being provided to them. The company has to require feed back from the employees to find out any further programme is to be added.
Both monetary and non monetary incentives should be given to the employees to boost up their morale. As this is been desired by the employees all the categories of people should be perfect in their knowledge as well as communication. Safety needs, standing order and rules relating to disciplinary proceedings must be known to all the employees. The duration of training programme should be flexible, were the employees find themselves inefficient they can be more concentrated in their work.
In this rapid change of technology and techniques it is essential that he knowledge of the employees should be updated periodically. Training programme should be announced in advanced to the employees to make them aware about the scheduling and areas of training programme.
Training helps to create a cordial relationship between the employers and employees, be more comfortable in sharing their views and ideas about training.
As technology advances in welding industry training programme should be oriented towards the application of technology to day to day activities.
The training programme is been conducted within the organization. The employees should be given the opportunity to attend training session from other institute, organization, seminars workshops etc.
. The training programme should be designed not only increasing their knowledge and skills as well as make them more creative for the development for the organization.
CONCLUSION
In this study it was been analyzed that there was a feeling among many employees that the training Programme in the organization is inadequate. The training Programme is not only to make the employees aware about the job but also helps them to be more creative and proactive in their work where they result in the organization development. The training programme also helps the employees to develop their inter personal and intra personal skills. The training programme is to be provided to each and every employees based on identifying the needs of the requirement of training.
Bibliography
Human Resource Management by Ashwathappa Himalaya book publications. Human Resource Management by Subbha Rao Himalaya publications. Organisation Behavior by Stephen Robinson by tata Mc hill publications. Organisation Behavior by Fred luthens by tata Mc hill publication. Website www.CITIHR.com www.5box.com

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Executive Summary

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1) Low heat input techniques 5 CMR INSTITUTE OF TECHNOLOGY, BANGALORE

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Impact of recent Asian economic

Greater reliance on integrated control control In-process nondestructive

Aging aircraft/sustainment and testing

Key Competitive Challenges

THE GLOBAL PARTNERS OF ADOR FONTECH LTD

DEGUSSA, Germany Brazing alloys & soft solders

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SEVEN S MC KINSEY MODEL

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Central product groups in- charge FMA aaaa AA

Area in- charges

Regional product group in -charge Area product group in -charge

Zonal in- charge

Reclamation welding technicians

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Shared value: ADLFS Shared Values 36 CMR INSTITUTE OF TECHNOLOGY, BANGALORE

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1991 1988 1987 1985 1983

H3 class. Commencement of operations.

DEPARTMENTAL ANALYSIS IN BRIEF

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DOCUMENTATION TRAINING AND EDUCATIONAL SERVICE (DOTES)

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partly true 20%

very true 80%

Scale Very True Partly true False Total

partly true 10%

very true 90%

Scale Very true Partly true False Total

Percentage 100 0 0 100

very true 100%

false 5% partly true 25%

very true 70%

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partly true 20%

very true 80%

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false 10% very true 40%

partly true 50%

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partly true 20%

very true 80%

off the job training on the job training

training on proto type machine combination of all

Combination of all Total

rules and regulation disciplinary procedings combination of all