Sheet Metal Fabrication Industry

ORGANIZATIONAL STUDY ON

SRI LAKSHMINARAY ANA ENGINEERING INDUSTRIES

ORGANIZATIONAL STUDY SRI LAKSHMI NARAYANA ENGINEERING ENGINEERING INDUSTRIES Submitted in partial fulfillment for the award of the degree of

Master of Business Bu siness Administration Of Mahatma Gandhi University By GINO GEORGE (Reg.No«««..)

Under the Guidance of MR. KPC NAIR

Sree Narayana Guru Institute of Science & Technology North Paravur (2009-11) ( 2009-11)

1



CONTENTS

1. INTRODUCTION 2. INDUSTRY PROFILE 3. COMPANY PROFILE 4. OBJECTIVES AND METHODOLOGY 5. ORGANIZATIONAL

CHART

AND DEPARTMENTATION

6. MANUFACTURING PROCESS 7. SWOT ANALYSIS 8. FINDING AND SUGGESTIONS 9. CONCLUSION 10. REFERENCE 11. BIBLIOGRAPHY

2


CHAPTER


-1

INTRODUCTION

3



INTRODUCTION Fabrication , when used as an industrial term, applies to the building of machines, structures and

other equipment, by cutting, shaping and assembling components made from raw materials. Small businesses that specialize in metal are called fab shop. Fabrication comprises or o verlaps with various metalworking specialties:

y

Fabrication shops and machine shops have overlapping capabilities, but fabrication shops generally concentrate on the metal preparation aspects (such as sawing tubing to length or bending sheet metal or plate), welding, and assembly, whereas machine shops are more concerned with the machining of parts on machine tools. Firms that encompass both are also common.

y

Blacksmithing has always involved fabrication, although it was not always called by that name.

y

The products produced by welders, which are often referred to as weldments, are an

example of fabrication. y

Boilermakers originally specialized in boilers, leading to their trade's name, but the term as used today has a broader meaning.

y

Similarly, millwrights originally specialized in setting up grain mills and saw mills , but today they may be called upon for a broad range of fabrication work.

y

Ironworkers, also known as steel erectors, also engage in fabrication. Often the fabrications for structural work begin as prefabricated segments in a fab shop, then are moved to the site by truck , rail, or barge, and finally are installed by erectors.

Metal fabrication y

Metal fabrication is a value added process that involves the construction of machines and structures from various raw materials. A fab shop will bid on a job, usually based on the engineering drawings, and if awarded the contract co ntract will build the product.

y

Fabrication shops are employed by contractors, OEM's and VAR's. Typical projects include; loose parts, structural frames for buildings and heavy equipment, and hand railings and stairs for buildings. 4



Engineering y

The fabricator may employ or contract out steel detailers to prepare shop drawings, if not

provided by the customer , which the fabricating shop will use for manufacturing. Manufacturing engineers will program CNC machines as needed.

5


CHAPTER


-2

INDUSTRY PROFILE

6



INDUSTRIAL INDUSTRIAL PROFILE Metalworking is the process of working with metals to create individual parts, assemblies, or

large scale structures. The term covers a wide range of work from large ships and bridges to precise engine parts and delicate jewellery. It therefore includes a correspondingly wide range of skills, processes, and tools. Metalworking is a science, art, hobby, industry and trade. Its historical roots span cultures, civilizations, and millennia. Metalworking has evolved from the discovery of smelting various ores, producing malleable and ductile metal useful for tools and adornments. Modern metalworking processes, though diverse and specialized, can be categorized as forming, cutting or joining processes. Today's machine shop includes a number of machine tools capable of creating a precise, useful work piece.

Prehistory Metalworking predates history. No one knows with any certainty where or when metalworking began. The earliest technologies were impermanent to say the least and were unlikely to leave any evidence for long. The advance that brought metal into focus was the connection of fire and metals. Who accomplished this is as unknown as the when and where, but the Egyptians are thought to have been one of the first civilizations to work gold. Not all metal required fire to obtain o btain it or work it. Isaac Asimov speculated that gold was the "first metal. His reasoning is that gold by its chemistry is found in nature as nuggets of pure gold. In other words, gold, as rare as it is, is always found in nature as the metal that it is. There are a few other metals that sometimes occur natively, and as a result of meteors. Almost all other metals are found in ores, a mineral bearing rock , that requires heat or some other process to liberate the metal. Another feature of gold is that it is workable as it is found, meaning that no technology beyond eyes to find a nugget and a hammer and an anvil to work the metal is needed. Stone hammer and stone anvil will suffice for technology. This is the result of gold's properties of malleability and duct ility. ility. The earliest tools were stone, bone, wood, and sinew. They sufficed to work gold. 7



At some unknown point the connection between heat and the liberation of metals from rock became clear , rocks rich in copper , tin, and lead came into demand. These ores were mined wherever they were recognized. Remnants of such ancient mines have been found all over what is today the Middle East. Metalworking was being carried out by the South Asian inhabitants of Mehrgarh between 7000±3300 BCE. The end of the beginning of metalworking occurs sometime around 6000 BCE when copper smelting became common in the Middle East. History

By the historical periods of the Pharaohs in Egypt, the Vedic Kings in India, the Tribes of Israel, and the Mayan Civilization in North America, among other ancient populations, precious metals began to have value attached to them. In some cases rules for ownership, distribution, and trade were created, enforced, and agreed upon by the respective peoples. By the above periods metalworkers were very skilled at creating objects of adornment, religious artifacts, and trade instruments of precious metals (non-ferrous), as well as weaponry usually of ferrous metals and/or alloys. These skills were finely honed and well executed. The techniques were practiced by artisans , blacksmiths, atharvavedic practitioners, alchemists, and other categories of metalworkers around the globe. For example, the ancient technique of granulation is found around the world in numerous ancient cultures before the historic record shows people traveled seas or overland to far regions of the earth to share this process that still being used by metal smiths today. As time progressed metal objects became more common, and ever more complex. The need to further acquire and work metals grew in importance. Skills related to extracting metal ores from the earth began to evolve, and metal smiths became more knowledgeable. Meta lsmiths became important members of society. Fates and economies of entire civilizations were greatly affected by the availability of metals and metal smiths. The metalworker depends on the extraction of precious metals to make jewellery, build more efficient electronics, and for industrial and technological applications from construction to shipping containers to rail, and air transport. Without metals, goods and services would cease to move around the globe on the scale we know today.

8



More individuals than ever before are learning metalworking as a creative outlet in the forms of jewellery making, hobby restoration of aircraft and cars, blacksmithing, tinsmithing, tinkering, and in other art and craft pursuits. Trade schools continue to teach t each welding in all of its forms, and there is a proliferation of schools of Lapidary and Jewelers arts and sciences at this- the beginning of the 21st Century AD.

9


CHAPTER


-3

COMPA NY NY PROFILE

10


Company


Profile

Established in 1990, ³Sri Lakshmi Narayana Engineering Industries´ is functioning in our own premises at Narasimmanaikenpalayam for the past 15 years. G. DORAISWAMY is the CEO of the company. We are a sheet metal fabrication fabrication company with with good client base that includes leading players like Indian Railways, Lakshmi Machine Works, Eureka Forbes and True Air System to mention a few. The company specialize in performing high accuracy jobs and some of our products include CNC machine covers and parts, outer chasing for water purifiers, paddy thrasher in agricultural segment blowers and dryers for humidification plants and the like. Our latest foray has been into the fields of hospital equipments and kitchen equipments where we are making good strides. The company expertise in particular includes 15 years of experience in the fabrication of electric panel¶s board both for PCC, MCC and M.V.PANELS, SSB, DB The company machinery infrastructure includes all facilities for fabrications are also

available at our premises. Our ultimate impetus is on quality and values and in our quest to become global players in our field we continuously aspire to provide value-added products and services to the society. Innovation in a sustained and determined manner and integrity are our key goals goa ls..

11



CHAPTER-4

OBJECTIVES & METHODOLOGIES

12



OBJECTIVE OF THE STUDY 

To study about general aspect of SRI LAKSHMI NARAYANA ENGINEERING

COMPANY 

To explore the organization structure of the company



To understand different departments in the organ ization and their functioning.



To do a SWOT analysis with the available information

Methodology

Primary data y

Direct interview with the managers, other employees and workers.

y

By observing the departmental works.

Secondary data y

From office records

y

From internet

Limitation of the study

y

The time period of this study is very short

y

language of labours made some some communication barrier The local language

13


CHAPTER


-5

ORG A NISTION NISTION A L CH A RT RT &

DEPA RTMENT RTMENT A TION TION

14



ORGANISATIONAL

CHART

CEO

TECHNICAL MANAGER

Purchase

Marketing

Prod/Maint

uality Q ual

Accounts

Assurance

Stores

Operators/Fitters

Inspectors

Assistants

15



RESPONSIBILITY AND AUTHORITY CEO A) Reports to the Board of Directors B) Responsible for: y

Overall management of the company

y

Laying down quality policy and objectives

y

Carrying our management reviews

y

Approval of product & process, Design & quality.

y

Ensuring the compliance to the quality management system of the company

y

Review and approval of quality management system documents

y

Finance management

y

Approval for purchase of raw materials, consumables and spares

y

Review and authorizing all a ll agreement / contract (customer / suppliers)

y

Overall responsibility for new products and projects

y

Defining responsibility and authority of functions who are expected to take the independent decision

y

Providing resources as identified including training

y

Appointment of management representative

y

Review the performance of the quality quality management system in line line with ISO 9001 / 2000 STD requirement

y

Review of orders received from customers custo mers

y

Review of nonconforming products pro ducts as a member of review meeting

y

Approval of corrective actions taken against customer complaints and purchased products including productions operations

y

Coordination and spear heading the continuous improvement activities of the organization

y

Receive and record reco rd customer complaints in the register

y

Maintaining the data related to delivery schedule adherence to customers 16



y

Outsourcing Operations (Productions) as requ ired

y

Identification of training needs of functions reporting to him

y

Has the authority to stop production

TECHNICAL MANAGER A) Reports to Chief Executive Officer B) Responsible for: y

Overall activities of the day to day production operations

y

Planning and review of production against plan

y

Process design and development

y


y

Preparation of work instruction for production act ivities ivities

y

Initiation of corrective action with regard to in process / final stages of production

y

Maintaining customer satisfaction and taking suitable corrective action

y

Implementing the corrective actions for the customer complaints in coordination with CEO

y

New Product Development

y

Initiating the corrective action against the custo mer complaint complaint in coordination with CEO

y

Proposal of corrective action and verification verificat ion of effectiveness of

y

corrective actions

y

Monitoring customer satisfaction and taking suitable corrective actions

y

Ensure safe working practice

y

Drawing control in related to distribution distribution and revision and over all maintenance

y

Control of customer supplied products / documents do cuments

y

Has the authority to stop production, to correct the qua lity lity problems. pro blems.

17



PUR CHASE STORE IN CHARGE A) Reports to CEO B) Responsible for: y

Preparation of purchase order / Arranging for purchase of Raw Materials, spares and consumables

y

Supplier evaluation and maintenance maintenance of approved suppliers list follow up with suppliers

y

Maintenance of record in relation to purchase of products

y

Maintenance of minimum stock level

y

Maintenance of FIFCO system for Self S elf Life Item

y

Stock register and material identification

y

y

Preservation of materials identification Preservation of materials stores

MARKETING IN CHARGE A) Reports to CEO B) Responsible for: y

to material Inward and Inspection

y

Receipts of enquires / Orders from the customers and e nter in the register

y

Receives and record customer complaints in the register

y

Maintaining records related to customer related processes

y

Tracking of customer satisfaction and on time deliveries

18



SUPERVISOR-PRODUCTION A) Reports to technical manager B) Responsible for: y

Production , quality as per planning

y

Man, Materials, Methods, Machineries Management

y

Monitoring House Keeping

y

Ensure

y

Maintenance of records related to production & quality

y

Identification of training needs of f unctions reporting to him

y

Has the authority to stop production, to correct the quality problems

saf e working practice

MANAGEMENT REPRESENTATIVE A) Reports to CEO B) Responsible for: y

Planning, establishing and implementing quality Management system in consultation with CEO

y

Organizing internal quality audits

y

Organizing management Reviews meeting and taking follow up actions

y

Initiate preventive actions with regard to repeat ed system non conformities

y

Liaison with certifying agencies and arranging for external audits

y

Ensuring internal communication in regard to effectiveness of quality quality management manage ment system

MAN POWER  There

are 165 employees



72 Skilled technicians



17 Engineers



12 Administrative staff members

19



CLIENTS Kerlosker Poduval sons Indian Railways Lakshmi Machine Works Eureka Forbes True Air System

PRODUCTS CNC machine covers Outer chasing for water purifiers Paddy thrasher Hospital equipments Kitchen equipments

20



INSPECTION PROCESS

QUALITY CONTROL Process input

Mode of output

Process Measures

1.Quality plan/Work Instruction

1. Inspection report

1. Number of customer

2.Drawings/Specifications

2. Non conformance complaints

3.Incoming

Raw

material report

Related to quality of the

specification

3. Corrective action product

4. Measuring devices

report

2. Customer rejection

5. Inspection skill

4. Test certificate

percentage

6. In formations/feedback from the customer with regard to quality of the product. 7. Inspection status

21



INCOMING STAGE: A. On action on receipt of raw materials from suppliers/processed products from the service providers are inspected as per incoming/process/product incoming/process/product wise wise quality B. The

raw

materials/production

operations

are

accepted

based

on

the

test

certificates/inspection reports wherever required as applicable received from the suppliers/service providers. C. The quality supplied and accepted criteria is ensured against P.O/job order as applicable and the same is updated in the material inward inspection report/service provider¶s register D. The consumable are checked for the quality and specification (Visual through labels or stickers etc.) as per purchase order/purchase orders register and accepted. The result are updated in MIIR The non-conformance identified during this inspection, are handled as in continual

improvement process

IN PROCESS AND FINAL S TAGE A. In process and final inspection are carried out as per the process and final inspection quality plan. The inspection results are recorded in inspection reports. B. Final inspection/Testing are done on the finished 100% Qty of the product as per the final inspection quality plan C. Final inspection/Testing results are recorded in the Final /stage inspection inspection report. D. If result are not meeting accepted criteria/tolerance during in process /final stage ,then non-conforming product control process is implemented as per the process modulecontinual improvement process E. Inspection status is identified on the components through tag/board/respective location/paint mark identification. F. Inspection skill is measured through skill matrix and necessary action is taken as per the process module. G. Proper instrument with valid calibrated are selected for the inspection. Instrument are selected such that its least count is 10% o f the size under measurement. 22



SUPERVISOR-QUALITY CONTROL A) Reports to technical manager B) Responsible for: y

Overall quality control and assurance

y

Maintenance of records related to incoming materials, in process materials and final stage productions inspection reports including dimensional inspection

y

Calibration of inspection and testing equipment / instruments

y


y

Has the authority to stop production, to correct the quality problems

ACCOUNTS A) Reports to CEO B) Responsible for: y

Overall responsible for accounts related activities includes sales tax, excrise & banking

y

Maintaining commercial records and invoice

y

Coordinating with auditors for carrying out annual audit

RESPONSIBLITIES OF OTHER PERSONNELS Concerned sections in charges define and communicate the responsibilities of personnel working in their respective areas.

QUALITY ASSURANCE The management of SRI LAKSHMI NARAYANA ENGINEERING INDUSTRIES is fully

committed to the development and implementation of modern quality management system and continually improving its effectiveness. Towards these requirements, the company has oriented all its systems and procedures inline international quality management standards and practices L AKSHMI NARAYANA ENGINEERING INDUSTRIES is The quality manual of SRI LAKSHMI issued on 31.08.06, which incorporates company¶s quality policy and the basic procedures. 23



The company has decided to obtain ISO 9001/2000 certificate to fulfill the requirements of its

discerning customers, who are constantly upgrading their own requirements and making increasing demands on their t heir supply chain to enable better competitiveness. The quality management system is oriented to achieve, maintain and improve overall

organization performance, capability and also to identify and meet the needs and expectations of the company¶s customers, employees, suppliers and owners. The quality management system procedures in the quality manual are supplemented with further

supporting work instructions, check sheet and together they form a comprehensive documented quality management system, designed to result in better customer satisfaction, a basic requirements of the company¶s quality policy T he Chief Executive Officer/MD, Technical Manager/section in charge is committed to

the development and implementation of the quality management system and continually improves its effectiveness by A) Communicating within the organization, the importance of meeting the customer as well as statutory and regulatory requirements b) Establishing the quality policy c) Ensuring that quality objectives are established D) Conducting management reviews E) Ensuring the availability of resource The Chief Executive Officer is authorized to approve the quality management system

procedures incorporated in this manual and su bsequent amendment to them. The Management representative is authorized to approve other work instructions, check

sheet and formats o the quality quality management system to maintain uniformity within the company. It is mandatory on the part of all employees of SRI LAKSHMI NARAYANA ENGINEERING INDUSTRIES, to faithfully implement the quality management system and work towards continuous improvement based on regular analysis of current performance data and keeping in view t he increasing expectations of the customers. custo mers.

24



CHAPTER-6

MANUFACTURING PROCESS 25



MECHINARY LIST SL NO

M/C NAME

MAKE

CAPACITY

QTY

1 2 3

SHEARING BENDING CNC BENDING CNC PUNCH

TEE TEE JFY

4MM*2500MM 3MM*2500MM 4MM*3100MM

1 1 1

JFY

6MM*2500*1250MM

1

SME

WITH 32 STATION 30 TONS

1

AMC

6MM

1

L&T

300A 300A 250A 15KVA4+4MM

2 1 5 1

4

5 6 7

POWER PRESS NIBBING WELDING

MIG SUPREME TIG BHARAT ARC MALIK SPOT

26



CUTTING

27



PUNCHING (SHEARING)

28



BENDING

29



NIBBING

30



WELDING

31



CUTTING -Ordinary cutting machine

32



FINISHING -For Finishing sander machine is used

33



POWER PRESS PUNCHING MACHINE

34


\


PROCESS STEPS

BENDING

PUNCHING

BENDING

WELDING

FINISHING

DESPATCHING

35



PROCESS

MAP

BASIC PROCESSES FOR PRODUCT REALISATION

RECEIVING CUSTOMER ENQIURIES AND EXAMINING FEASIBILITY OF MANUFACTURE BEFORE COMMITTING TO CUSTOMER

PLANNING FOR DESIGN/DEVELOPMENT, PRODUCTION AND TOOLING

PROCUREMENT AND STOCK

INSPECTION OF

OF RAW MATERIALS

INCOMMING MATERIALS

DEVELOPMENT OF INITIAL

DESIGN AND DEVELOPMENT

SAMPLES

OF PROCESS/Q UALITY PLAN

CUSTOMER APPROVAL OF SAMPLES

IN-PROCESS AND FINAL

PROCESS CONTROL AND REGULAR

INSPECTION

PRODUCTION DELIVERY TO CUSTOMER

AFTER SALES SERVICE

CUSTOMER FEED BACK/COMPLANTS/INVEMEGATION AND CAPA 36


PROCESS


FOR QUALITY MANAGEMENT SYSTEM

DEVELOP Q UALITY POLICY AND OVERALL OBJECTIVES AND COMMUNICATE

DEVELOP Q UALITY MANAGEMENT PROCEDURES/WORK INSTRUCTIONS, CHECKS SHEETS AND IDENTIFY Q UALITY RECORDS

PROVIDE NECESSARY RESOURCES INCLUDING TRAINING

IMPLEMENTING Q UALIYY MANAGEMENT SYSTEM

MONITOR EFFECTIVE IMPLEMENTATION

FEED BACK TO MANAGEMENT FOR ASSESSING SYSTEM EFFECTIVENESS

AND FUTHER IMPROVEMENT

37


PROCESS


FOR MEASURMENT

PROCESS CONTROL MEASURMENT

PRODUCT CONTROL MEASURMENTS

CONTROL OF MEASURING SYSTEM

CUSTOMER SATIFICATION MEASURMENT

Q UALITY MANAGEMENT SYSTEM MEASURMENT THROUGH INTERNAL AUDIT

ANALYSIS OF RESULTS OF MEASURMENT AND CONTINUOUS IMPROVEMENT CONTINUAL IMPROVEMENT OF THE QU ALITY 38



CONTINUAL IMPROVEMENT OF THE QUALITY MANAGEMENT SYSTEM

CONTINUAL IMPROVEMENT OF THE Q UALITY MANAGEMENT SYSTEM

MGNT. RESPONSIBILITY N O I T C A F S I I T A S R

T N E

M R I U

Q E R R

RESOURCE MANAGEMENT

E

M O T S

MEASUREMENT,

E

ANALYSIS IMPROVEMENT

M O T S

U

U

C

C

PRODUCT REALISATION INPUT

OUTPUT

39



PUR CHASE AND STORE PRO CESS PROCESS MANAGEMENT PROCEDURE ACTIVITY The purchase in-charge maintains the list of materials list of suppliers and list of services

providers SELECTION OF SUPPLIERS (PURCHASE PROCESS) All the existing suppliers/service provider as on 31.08.06 are brought into the list of approved suppliers and the list of service providers based on the past experience with respect to quality and delivery. If there is a need for any new suppliers/service providers, purchase in-charge source the information about the potential suppliers/service providers through market information. Purchase in-charge sends the assessment questionnaire for supplier registration to them, and their details are collected. CEO review the information provided by the suppliers/service providers and decides about their approval. If approved, their names are included into the list of suppliers/service providers. A new/unapproved suppliers/service provides is included in the list of approved suppliers based on the following conditions. a) Quality feedback received from the production/Q.C for at least 3 trail supplies. b) Filled supplier registration from approved by CEO

PLANNING AND PROCRING OF MATERIALS (PUR CHASING DATA)

The Raw material and the production related consumables are purchased based on monthly

orders/schedule or during day to day d ay work orders and subsequent stoke verification. 40



If production in charge found stock Qty is less, raises the material requisition to stores and stores in turns raises indent to purchase in charge for the procurement of the materials. Purchase orders are raises against the stores indent/purchase requisition memos to the approved suppliers on a yearly/ monthly/daily basis as applicable and required. If there is any change in the contract within the financial year , amendment of purchase order is raised to the t he suppliers. Further if purchases are made through letter or orally, the same is monitored through purchase order register Emergency purchase is done from the suppliers other approved suppliers on ane time basis if approved by the CEO.

PLANNING OF SERVICES The list of service providers contains the name of the service providers and their scope of supply

is maintained by purchase/prod in charge. The production in charge/CEO orders the service to those in the list on a need basis. The

communication

about

the

services

requirements

is

communicated

through

drawing/sketches/work instructions. instructions. The material is send to the service providers through the delivery channel and sends and returned

details are recorded in the service provider pro vider register

RECIEIPT OF MATERIAL (VERIFICATION OF PUR CHASED PRODUCT) The material received from the suppliers/service providers are inspected and stored in the

material storage area. The raw material/consumables received are checked for the quality against the advised quality

and updated in the MIIR. If there is any excess/shortage the supplier is informed suitably. The

41



accepted material is stored in their respective storage location and the stock ledger for raw materials and consumables are updated updat ed for the receipt of corresponding quality. The material received from service provider like machined casting is updated in service

providers register. The machined castings are accepted based on the service provider inspection report or Q.C/inspector carries out the inspection as per the requirement and the inspection is recorded in the inspection report. If any deviations occur , is informed to the service provider suitably and CEO/Q.C in charge is responsible for making decision based on the severity of the deviations either to rework or accept conditionally. The accepted materials are stored in their respective storage location and the records are updated.

ISSUE OF MATERIAL The material in storage is under the control of stores in charge. The material required for

production is issued against the material requisition by production. The material are updated in the stock ledger the store in charge The CEO/production in charge review the stock status of the material periodically to ensure the

availability the material for production against the minimum stock level maintained at stores. Shelf life item are issued as per FIFO system by maintaining the shelf life item list in stores

EVALUATION OF SUPPLIERS/SERVI SUPPLIERS/SERVICE PROVIDERS The performance of the suppliers/service providers are monitored and rated based on the quality

of the supplies and delivery performance. The supplier/service providers rating is carried out on half yearly basic. The rating is done on

two aspects namely quality (60%) and delivery (40%) weight age and rating in recorded in suppliers / service provider rating from

42



FOR PRODUCT QUALITY

A) For purchase products

Total Q ual uality Accepted X

60

Total Q ual uality Supplied Qty. Rejected X 60 B) For Productions operations: 60-

Qty. Reworked +

Tot. Qty S upplied

Tot. Qty supplie d

For Delivery Adherence Qty. Supplied on time A) For purchase products:

X4 0

Ordered Q ual uality

B) For productions operations:

40-

raction of delayed Qty. Supplied X Sum of f rac No. of days of delay

43



PRODUCTION PROCESS

Process inputs

Mode of Output

Process Measures

1.Customer order

1.Production

1.Adherence to

2.Work order/Daily plan

Process

planning

3.Customer Drawings

2.Products

4.Quality plan/Work Instructions I nstructions 5.Trained human resource 6.Machines 7.Raw materials and consumables 8.Safty precautions 9.Feed back received from QC ,IA,MRA and customer complaints 10.Product nonconformities nonconformities 11.Product identification method

44



PROCESS MANAGEMENT PROCEDURE ACTIVITY 1. The schedule/orders from the customers are received by the CEO. After consolidating the schedule, CEO reviews the availability of the capacity along with technical manager/concerned section in charge received from the customers marketing in charge raises the work order to production in charge 2. Based on the work order received from marketing, production plan is arrived by the production in charge in the work order rear side itself. 3. Based on the weekly plan, the raw material/consumables planning is carried out by the CEO interacting with the production in charge and the material requisition is raised to stores about procurement. Stores in charge after verifying the stock raised the indent to purchase in charge for procurement 4. If any additional schedules are received from the customers CEO along with technical manager section in charges in consultation with CEO amend the monthly/Weekly planning. The raw material/consumable planning are also reviewed for additional and if necessary, requirements are informed to purchase in-charge 5. In case of no-availability of the required from the capacity CEO decide about the action to be carried out, including the action of the service providers. pro viders. 6. CEO instructs the production departments highlight ing technical and quality requirements. 7. The production is carried out under controlled condition based on the customer drawings/requirements. The work instructions/process flow charts/activity charts, quality plan product wise as applicable, are available in the work spot skill to carry out production process are identified through skill matrix once in a year and the appropriate records are maintained by the section in charges. 8. Production details are recorded in daily production logbook maintained by the concerned section in charges.

45



9. The in process inspection is carried out as per the quality plan-product wise it is section in charge¶s responsibility to ensure that operators follow the work instructions. It is ensured that inspection/testing is carried out all stages as per work instructions/quality instructions/quality plan-product plan-prod uct wise. 10. Process parameters and product characteristics are monitored as per work instruction or as per customer requirement/quality plan-product wise. 11. In case of any out sourcing productions operations is required it is done through the service providers. The performance of service providers is evaluated and monitored by rating once in 6 months by CEO/Q.A in charges 12. The products after completion of all processes are offered for pre-delivery/final inspection as per the quality plan-products wise wise are available ava ilable at work spot. 13. Based on work order/production plan whenever products are already for dispatch, they are dispatched either in loose condition or packed as per customer requirements and the relevant documents are sent along with products. Test certificates and inspection reports are verified by quality control before dispatch. 14. Section in charge in consultation with CEO, decides the corrective action to be taken, in case of any problems related to production and dispatch.

IDENTIFICATION AND TRA CEABILITY INCOMMING STAGE: a. Raw materials/consumable are stored in bags/containers/loosely at identified areas or through tag/labeling as applicable b. Raw materials like rough casting are stored in casting stores identified with name boards or as suitable.

46



IN PROCESS STAGE Product at various stages of production process is identified with its status displayed on the board¶s viz. under process, for inspection, for fitting, for painting, for dispatch as applicable.

ACTIVITY FINAL STAGE Manufactured products are identified by manufacture¶s name board detailing the product name, manufacturing date, specification, etc. As required by the customers custo mers

TRACEABLITY Manufacturing details including the name of the manufacturer date of manufacturing, working capacity and other specifications as applicable and as required by the customers are affixed on the product.

CUSTOMER PROPERTY: CUSTOMER

PRODUCTS

No customer products either supplied or involved involved in manufacturing process. If at all in future, the customer products will be maintained for its suitability to use.

CUSTOMER

DOCUMENTS

The documents supplied by the customers such as drawings, specification are maintained in

the relevant file. Section in charge maintains list of customers supplied as /internal drawing. The control of documents, issue of documents, revision of document are carried out as per

the documentation process.

47



PRESERAVATION OF PRODUCTS a. The products are preserved in such a way as to no damage is done to the product in any form. b. After the completion for each stage of process, the products are stored in the respective identified area with status. c. Shelf life and FIFO is not applicable for the products as its quality is not deteriorated due to storage. d. If required by the customer by contractually, products are provided with rust preventive oil or paint coating or as required by customer on preservation of products e. Based on production plan, whenever the products are ready for dispatch, they are packed as per contractual requirements/customer requirements to avoid transit damage. f. Products are packed as per the contractual requirements/customer requirements either in wooden cases or in carton boxes or wooden creates or as suitable to avoid any damages. When the quality is not affected during transport , products are also dispatched in loose conducting the number of products taken.

WORK ENVIRONMENT The following factors are managed to achieve co nformity of product

1. Proper Housekeeping 2. Identification of products 3. Proper illumination 4. Proper Air Circulation 5. Proper safety equipment is available. Feedback received from internal audit, Management review and customers are reviewed to improve the process performance

48



SERVICING y

Complaints received after warranty period are taken as servicing calls are entered in service register by making in charge

y

Most servicing is done at customer premises, and on special request by the customer is done at customer end

y

Q.A Executive test the motor received for service as per the quality plan and detect the problem and forward to production executive for necessary action.

y

Production executive attend the problems and make the motor functionally o.k.

y

Q.A Executive re-inspects the motor and g ives clearance to dispatch to the customers. custo mers.

y

If any service is due to operating mistakes, the concerned customers are properly trained for correct operating procedure.

y

All the details of the service activities and any spares replaced are recorded in service register and the service report is send to the customer along with test report.

EQUIPMENT MAINTAINANCE PROCESS

Process inputs

Mode of output

Process measures

1.Preventive

1.List of machinery

1.Machine down time

Maintenance Maintenance plan

2.Preventive maintenance record

2.Equipment

3.Machine History Card

3.Spares 1.Measuring

1.List of measuring instruments

instruments/gauge

2.Calibration history cards and found reports

1.No of occasions instrument having

error

exceeding acceptable error limit

49



PROCESS MANAGEMENT PROCEDURE ACTIVITY

INFRASTRUCTURE The Management of SLN identifies, provides and maintains the facilities it needs to achieve the

conformity of product, which includes, 

Buildings, Workspace and associated facilities,



Equipment, hardware and software,



Supporting services(Such as transport, Communication etc)

Equipment used for manufacturing activities is listed in list of machineries measuring instruments are listed in the list of measuring instruments

MAINTENANCE OF MACHINERY Preventive maintenance of machinery is carried out as per the preventive maintenance plan and the result/observations while checking are recorded in the preventive maintenance record Preventive parameter are reviewed at least once in 3 months during dur ing the MRM meeting. On the basis of repeated break down do wn occurred and the plan p lan is revised if necessary. Problems/break down and the corrective action act ion taken is recorded in the machine history h istory card

50


CALIBRATION


OF MEASURING/TEST INSTRUMENT

A. All the measuring instruments or any other devices used to measure are listed in the list of measuring instruments B. The acceptable error limit is fixed based on the measurement tolerances of the dimensions measured using the instrument. The calibration frequency is fixed based on the usage of the instrument. If required in the future, based on the calibration results the Q.C review the frequency suitably. C. It is ensured that the master instrument used by the calibration agency have been calibrated against national/international measurement standard by receiving a calibration report of master instrument used. D. After receipts of calibration report, the results are reviewed against the accepted error limit fixed in the list of measuring devices. The calibrated details are recorded in the calibrated history card. E. If the result of calibrated is not acceptable, inspection result taken before the calibration is assessed for the past 6 months from the date of calibrated against customer complaints/product acceptance/quality rating report from the customer. Results of assessment including documents verified are recorded in the ca librated history card. F. calibrated status is identified through a sticker , which contains instrument code No, date of calibrated and calibrated due.

51



CHAPTER-7

SWOTS ANALYSIS 52



SWOTS ANALYSIS Sri Lakshmi Narayana Engineering Industries - SWOT Analysis company profile is the essential source for top-level company data and information. Sri Lakshmi Narayana Engineering Industries - SWOT Analysis examines the company¶s key business bus iness structure and operations, history and products, and provides summary summary analysis of its its key revenue lines and strategy strategy Sri Lakshmi Narayana Engineering Industries is a steel manufacturer and recycler in the coimbator. The company manufactures hot-rolled steel (angles, rounds, flats, channels, sheet, wide-flange beams, pilings, billets, blooms, beam blanks, and plate), cold-rolled cold-rolled steel stee l, steel joists and joist girders, steel deck , cold finished steel, steel fasteners, metal building systems and light gauge steel framing.

Reasons to Purchase - Support sales activities by understanding your customers¶ businesses better - Qualify prospective partners and suppliers - Keep fully up to date on your competitors¶ business structure, strategy and prospects - Obtain the most up to date company information available

STRENGTH y

High reputation

y

Well qualified and technically skilled manpower

y

Company has very long period of experience

y

Good employee management relationship

y

Product Quality

y

Company reputation

WEAKNESS y

Workers are not able to adopt new technologies 53


y


Lack of Export.

OPPORTUNITIES y

y

Uses of machines are increasing increasing New technologies are developing

y

Increasing demand of steel day by day

y

Increasing demand of steel day by day

THREATS y

Heavy competition

y

Increasing in the price of o f raw materials

y

Adopting old techniques of o f manufacturing

54



CHAPTER-8

FINDING AND SUGGESTIONS

55



FINDINGS 1. The company have have structured structured organization 2. Absenteeism of the company comparatively co mparatively large. 3. There is a heavy competition from other companies 4. Increase in the price of the raw materials is one of the main thread 5. They have a effective team work 6. They have a full team of experts

SUGGESTIONS 



Welfare activities of the worker should have to be improved. Company should ensure participative management.



Promotion and adverting activi act ivities ties should be improved



Scope for expansion



Company focuses on modernization & up gradation

56



CHAPTER-9

CONCLUSION 57



CONCLUSION

Our machinery infrastructure includes all facilities for fabrications are also available at our premises. Our ultimate impetus is on quality and values and in our quest to become global players in our field we continuously aspire to provide value-added products and services to the society. Innovation in a sustained and determined manner and integrity are our key goals

58



CHAPTER-10

REFERENCE

59



REFERENCE

y

GOOGLE

y

WIKIPEDIA

y

COMPANY WEBSITE

y

MANUALS, BOOKLERS

60



CHAPTER-11

BIBLOGRAPHY 61



BIBLOGRAPHY - Company manuals - Direct interview with managers - Internet

62

Sheet Metal Fabrication Industry

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