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1.1 INTRODUCTION
The aim of organization study is to gain an organizational
familiarization and in- depth knowledge of the functioning of various
departments. The study was undertaken with the objective of understanding
the working of a business organization. It gives clear idea about the
functions and practices of various department heads, SWOT analysis, porters
five forces model analysis etc. The organizational study is intended to access
and to acquire the knowledge regarding the functional as well as the
management aspects of the firm.
An os study has been conducted at TERUMO PENPOL LTD;
TRIVANDRUM. This study is oriented towards understanding, how the
company functioning. In practice, by interaction with the various
departments in the organization. Blood Transfusion is an integral part of the
Health Care delivery in any country. In fact it is the most important part of
the health care system. Blood bag is a disposable bio-medical device used
for collection, storage, transportation and transfusion of human blood and
blood components. The system consists of a single or multiple bags
connecting with tubing, needle, needle cover, clamp etc. The blood bags are
made of plastic materials which are compatible with blood. Blood Bags can
successfully replace the use of glass bottles for collection, storage,
transportation and transfusion of blood and blood components since bottles
require exhaustive cleaning, rinsing and autoclaving procedures and there
are chances of breakage at any stage. Blood bags are most ostensibly serving
the medical field in crucial hour. As the number of hospitals, nursing homes
are increasing; the demand for the blood bags too is increasing
pg. 1
tremendously. Blood bags cannot be advertised. The USP for these products
is quality.
In March 2011, the company bought U.S. medical device company
CaridianBCT for around $2.6 billion. It is the largest acquisition by a
Japanese medical equipment maker and makes the company to the top of
global blood transfusion market.
1.2 OBJECTIVES OF THE STUDY
The main objectives are:
To the study about the blood bag industry.
To study about the history of the TPL, each department functions, its
vision and mission.
To study the organizational policies, procedures, practices and future
plans of the firm.
To evaluate the strength, weakness, opportunity and threats of the
company.
To analyze PORTER’S five force model of the organization which
leads to the findings, Suggestions and conclusion.
1.3 METHODOLOGY
This study familiarize with general working conditions of the
organization with respect to departments, functions, authority and
responsibility and procedures. The collection of data made through various
methods. These are:
pg. 2
Primary sources
Primary data is the data which is collected by the researcher directly
from his own observations and Interviews.
Sources of primary Data;
Observation
Interview with Managers, office staff and workers.
Secondary sources
Data from a secondary source is any data which has been collected by
another researcher, whether it is a group of people or just one person. The
data may have
originally been used for a different type of research, but we can manipulate
it to fit our research, instead of using it as it was intended to be used.
Sources of Secondary Data;
Data collected from Annual Reports of the company.
Data collected from Department manuals.
Data collected from Journals, Magazines, Brochures, and Websites.
1.4 SCOPE OF THE STUDY
The study helps to develop a practical knowledge about the working
of the organization. It helps to get familiarized with the organizational
procedures and understand company’s strategy for growth, which faces
further expansion of capacity, modernization of processes, follow to strict
quality assurance protocols and to boost efficiency in manufacturing.
1.5 LIMITATIONS OF THE STUDYpg. 3
The information obtained is not complete and accurate, as confidential
matters were not disclosed for the purpose of the study.
The study has limited scope, as it aims an overall organizational study
and not an in-depth study.
The main limitation of the study was time constraint.
Probable bias of the respondents: the secondary data provided for the
study by the authorities may be biased. Errors might have been caused
due to certain biases of the respondent.
Difficulty in meeting with all the top level officials.
2.1 BLOOD BAG INDUSTRY
Blood product belongs to biological products and is a biological
active preparation, which collects healthy blood as the raw material and then
is made through biological process or separation and purification
technologies. Blood products are irreplaceable in the application of medical
emergency and prevention & treatment to some specific diseases. Blood bag
is a disposable bio – medical device used for collection, storage
transportation and transfusion of human blood components. Indian Research
and Development organization is offering technology for the manufacture of
disposable blood bag systems. The system consists of a single or multiple
bags connecting with tubing, needle cover, clamp etc. The blood bags are
made of plastic material, which are compatible with blood. Blood bags can
successfully replace the use of glass bottles for collection, storage,
transportation and transfusion of blood and blood components since bottles
require exhaustive cleaning, rinsing and autoclaving procedures and there
are chances of breakage at any stage. Further, use of disposable bags
pg. 4
eliminates the possibility of any contamination. In recent times the blood
bag has become a conspicuous item and essential need of hospitals and
nursing homes to meet blood infusion emergencies. Blood bags are most
ostensibly serving the medical field in crucial hour. As the number of
hospital, nursing homes are increasing the demand for the blood bags too are
increasing tremendously. A blood bag system comprises of a container
holding an in-activator that inactivates micro – organism contained in blood,
a container holding an anticoagulant and a connecting tube connected liquid
– tightly to the container, wherein the activator contains as a main
component a platinum compound capable of binding to nucleic acid of the
micro – organism or an aqua complex of the platinum compound; and a tube
for introducing a neutralizing agent to neutralize the in-activator which is
connected with the container holding the in-activator.
pg. 5
Fig2.1
Trend of Plasma Volume Collected in China, 2001-2008
Source: www.researcinchina.com
The increasing trend of Plasma Volume Collected in China
from2001to 2008 is a good example to state the increasing requirement of
blood bags, as blood bag requirement is directly proportional to blood
product requirement.
Advantages of Indian Technologies;
Low capital investment.
High employment potential.
Maximum use of local raw materials and manpower resources.
Adaptable levels of sophistication.
2.2 WORLD SCENARIO
Globally, approximately 75 million blood bags are collected annually
[Source: WHO], Major blood bag manufacturers globally include
Baxter Bioscience, USA; Bayer Corporation, USA and Octapharma AG,
pg. 6
Switzerland. With the increasing global demand for blood bags and growth
rate of its market being 15 percent annually the business for the potential
investor is desirable and is expected to generate high returns from the
business. The investor would need to set up highly standardized plant as the
demand for these products largely depend on their quality. The blood bag
manufacturing industry is now in a growth stage. It is now witnessing high
customer traffic. This particular industry goes hand in hand with new
technology. It also contributes a fair portion of revenue to the economy.
2.3 INDIAN SCENARIO
Terumo Penpol is India's largest manufacturer of Blood Bags. The
company is one of the largest producers of blood bags in Asia, other than
Japan with a capacity of 10 Million Blood Bags. The company has come a
long way since its beginning in 1987.In1985 Peninsular Polymers which was
a pioneer in the field of manufacturing blood bags was set up by Mr.
C.Balagopal, an EX-IAS officer and his brother Mr.C.Padmakumar. In July
1999 the company formally collaborated with Terumo Corporation, Japan.
Terumo Corporation invested in the equity capital of the company and today
it holds 74% with the balance 26% held by the promoters. The name of the
company was changed to TERUMO PENPOL LIMITED on 01/10/99.
The company pioneered the manufacture of Blood Bags in India and
then successfully launched a range of medical electronic products required
for blood transfusion centers. Driven by its strong customer-focus and
innovative spirit, the company has been the market leader ever since it
introduced blood bags in India and then successfully launched a range of
medical electronic products required for blood transfusion centers. Today, it
is more than double the size of any other blood bag manufacturer in India.
pg. 7
Not only does Terumo Penpol offer customers a wide range of Blood Bags
and Blood Bank Equipment, but also offers tailor made products to meet
specific requirements.
3.1 COMPANY PROFILE
Terumo Penpol is India’s largest manufacturer of blood bags. The
company is one of the largest producers of blood bags in Asia, other than
Japan with a capacity of 13 million blood bags. Peninsular Polymer Ltd or
Penpol was established in 1987. On 19th July 1991 Tokyo based Terumo
Corporation has signed a contract to acquire 74% share of Peninsular
Polymers Ltd. The new venture came to be known as Terumo Penpol Ltd.
Terumo Penpol manufactures a wide range of blood collection systems and
medical equipments required for blood banks and component centers.
The company has come a long way since its beginning in 1987. The
company pioneered the manufacture of blood bags in India and then
successfully launched a range of medical electronic product required for
blood transfusion centers. Driven by its strong customer-focus and
innovative spirit, the company has been the market leader ever since it
introduced blood bags in India. Today, it is more than double the size of any
other blood bag manufacturer in India. Not only does Terumo Penpol offer
customers a wide range of blood bags and blood bank equipment, but also
offers tailor made products to meet specific requirements.
Terumo Penpol is part of the multibillion dollar Terumo Corporation,
a Japanese company having its presence in over 150 countries. Terumo has
pg. 8
distinguished itself as a high quality manufacturer of medical products with
13 factories around the world. The company generates annual sales of about
$2 billion and employs 7500 people worldwide. Terumo is pioneering
products of future like implantable left ventricular assist system, artificial
vessels, minimally invasive surgery devices, nano capsules and more.
The Blood Bag Factory (BBF) is situated at Puliyarakonam, a suburb
of Trivandrum, and employees over 600 skilled people. In 1998, the
production capacity was only 1 million bags per year. In 1996, the
production capacity was 3 million bags.
Today TPL has a manufacturing capacity of 24 million bags per year. The
bags are tested against parameter set out in ISO-3826, which provides for
products that ensure safety of blood and blood components. They also offer
resistance to breakage in centrifuge among other parameters. The blood
bags are sold in over 60 countries across the world.
The Medical Systems Group was established in 1995. Medical
Systems Group is engaged in the design and manufacture of specialized
blood bag equipment and software aimed at improving the blood
management systems and procedures in blood banks.
The manufacturing facility follows an integrated production system from
raw materials to finished products, ensuring strict adherence to Good
Manufacturing Practice (GMP). The production system ensures careful
selection of materials/components, controlled production environment,
comprehensive testing of all inputs, intermediate products and finished
goods.
pg. 9
The main feature of the manufacturing facility is the flexibility it offers:
I. Flexibility in product features.
II. Flexibility in minimum order quantity.
III. Flexibility in delivery schedules.
Terumo Penpol has 700 customers all over India and its blood bags are
sold in over 60 countries across the world and its Medical Equipment
Division has more than 1900 installations to its credit. Terumo Penpol has
its headquarters in Thiruvananthapuram and employs 766 people. The
company has an experienced team of marketing and sales professionals
covering the whole of India. The team is further supported by a well trained
service group.
Terumo Penpol manufactures a wide range of blood collection systems
and medical electronic equipment required for blood banks and component
centers. At Terumo Penpol quality is a way of life. Utmost care and
attention is given to each and every stage of production to ensure strict
adherence to GMP and CE Mark standards.
3.2 TIMELINE OF IMPORTANT EVENTS
1987: Terumo Penpol Ltd launches India’s first single blood bags.
1988: TPL launches India’s first double blood bags.
1993: TPL launches India’s first triple blood bags.
2001: TPL launches the Terumo Automatic Component Extractor
(TACE) which helps to bring down the time required to separate
blood components in blood banks by easy, fast and standardized
method.
pg. 10
2004: TPL launches two products, thawing bath CB 100 and WB
100, for the safe and uniform thawing of fresh frozen plasma. It can
maintain temperature at any set value between 4 degree Celsius and
37 degree Celsius.
2004: TPL launches the improved version of Donor station Compo
safe DC 200, which increases comfort and safety to the donor and the
phlebotomist.
2004: TPL introduced new Deep Freezer Compo safe DF-40, which
is designed for the storage of plasma and preserving the labile factors
during shelf life.
2005: TPL introduces blood bag with safety features that assure
protection from blood borne diseases.
2006: TPL introduces Compo safe Semi- Automatic Expresser SAE
500 that helps standardize the red cells/ packed cells by retaining
selected volume of plasma with RBC in double and triple blood bags.
2006: TPL launches new 80 degree centigrade Deep Freezer, which
is designed as fast freezer for the preparation of fresh frozen plasma
and cryoprecipitate.
2007: TPL won the state level award instituted by PRS( Public
Relation Society of India) for the best company promoting corporate
social responsibility activities among the industries in Kerala
2008: TPL’s new West blood Bag Plant building was inaugurated by
Mr. Kenji Sekine (President Transfusion Business, Terumo
Corporation). With this expansion project, TPL has doubled its
production capacity which is presently 13 million.
2008: TPL organized a mega blood donation camp in association
with All Kerala Blood Donors Society, Club 25, Kerala Sports
pg. 11
Council and SBT as part of the programs in connection with world
health day. Out of the 217 donors who attended the camp, blood was
collected from 107 donors by the blood banks of Medical College
Hospital, Regional Cancer Centre, and SreeChitiraThirunal Institute
for Medical Sciences.
2009: TPL has won the Outstanding Safety Performance Award in
the category of medium size industries other than chemical and
engineering (0.5 million to 1.5 million man hours worked ) instituted
by the Kerala Chapter of National Safety Council of India.
3.3 MISSION
The Mission of TERUMO PENPOL is;
‘Better Ways to Better Healthcare’
Their perception is that today’s best will be replaced by something
still better tomorrow. They mean to go on and on in their quest to create
better ways to better healthcare.
3.4 VISION
To become a world class medical device manufacturer adopting
customer first approach in all business processes.
3.5 QUALITY POLICY
pg. 12
To maintain high quality products meeting customers and
requirements.
To design all products in accordance with international standards.
To ensure high quality at all the stages of the supply chain.
Terumo Penpol will contribute to society through health care.
Terumo Penpol is committed to continuously review and improve the
effectiveness of the quality management systems. The quality management
system of Terumo Penpol is certified according to ISO9001:2000, 1SO
13485, European Standards EN 46001 and European Medical Device
Directive 93/42/EEC.
3.6 QUALITY OBJECTIVES
Ensuring strict compliance to good manufacturing practice.
Improving the product quality through continuous technological up
gradation.
Enhancing the product performance by sustained analysis of customer
feedbacks.
Maintaining high degree of quality awareness among employees
through periodic training programs.
3.7 AWARDS
Awarded the national award for best research and development efforts
in industry from government of India for the year 1995.
Won the top exporters award for medical disposable and surgical
items for the year 1995.
pg. 13
Won the second best award for medical disposable and surgical items
for the year 1996.
Won the top exporters award for medical disposable and surgical
items for the year 1997.
3.8 Voluntary Blood Donation Services
The solution is to increase the number of regular voluntary donors in
India. So their main aims are:
To create awareness and educate the public on the need for regular
and voluntary blood donation
To safe guard the interest and welfare of the blood donors.
To promote voluntary blood donation among all sections of society.
To reach out to peripheral rural areas so as to make them self-
sufficient `rural blood donor forums.
3.9 ACIVITIES
Donor Motivation Seminars, Blood Grouping Sessions.
Publication and Distribution of Promotional Material on Voluntary
Donation.
Networking of existing Forums and Institutions.
Annual Conferences/Workshops to promote Voluntary Blood
Donation.
3.10 PRODUCT PROFILE
pg. 14
TPL has a wide range of products. It consists of blood bags, urine
bags, blood bag equipment; blood bag management software etc.TPL is an
ISO 9000 company for manufacturing and marketing blood bags. The
most important quality of maintaining the
quality of blood is the container in which it is stored. TPL’s blood bag
reaches a customer after undergoing 41 physical and biological tests that
ensures safety in use. Its product range consists of single bag, double bag,
triple bag, quadruple bag, triple and quadruple bag with SAGM-2.
3.11 PRODUCT CATEGORIES
1. Blood Bags & Accessories
2. MSG (Medical Systems Group) PRODUCTS
3. Storage Equipment for Blood Banks
4. Blood Collection Devices
3.12PRODUCTS
Blood bag and accessories
Blood bag collection devices
Storage equipment for blood bank
Blood processing devices
Portal ( blood bank management software)
Portable donor couch
Tube scalar
Plasma expresser
Blood weighing scale
Platelet agitator incubator
Safello urine bag
pg. 15
Mini blood storage cabinets
Deep freezers
Terumo automatic components extracting
Refrigerated centrifuge
Limugrated 3 PL
Limugrated 3 PC
Trima Equipment and Accessories.
TrimaDisposibles.
A. BLOOD BAGS
The TERUMO Blood Bag systems are high quality products designed
for optimum blood management during collection, separation, preservation
and transfusion. Various types of blood bag systems with improved storage
period of blood and blood components are available.
A new range of Blood Bags provides the Blood Banks with a large
choice of safety features. Carl Walter and W.P. Murphy, introduced the
plastic bags for blood collection in 1950, a system which replaced the
previously used blood bottles .Terumo Penpol uses K72 PVC (Polyvinyl
chloride) as raw material for blood bags. This contributes to their high
quality, stability and tensile strength. Plasticizers aid in converting highly
brittle PVC resin into softer flexible compounds. The use of plasticizers
for increase in softness and flexibility. DEHP (Diethyl hexyls
phthalate) Preferred plasticizer for medical grade PVC.
Types of Blood Bag
Single Blood Bags
pg. 16
Single bags are mostly used for the collection and transfusion of whole
blood. The anticoagulant used is CPDA
Double Blood Bags
Double bags are primarily used to separate blood into two main
components, packed red cells and plasma. The two bags are called as
primary bag (used to collect blood), and transfer bag (used to transfer the
separated component after centrifugation) respectively.
Triple Blood Bags
They are used for whole blood collection followed by separation into
three components, packed red cells, plasma and platelets. The triple bag kit
contains one primary bag and two transfer bags (for platelet and plasma).
Quadruple Blood Bags
Quadruple bags are used for components reparation into packed red cells,
plasma, platelets. The kit contains one primary bag and three transfer bags
(plasma, platelet, and Buffy).
TAB (Top and Bottom) blood bag
Thus, during component separation process, the top and bottom
components (plasma and packed red cells) move simultaneously into their
respective transfer bags, leaving the Buffy layer in the primary bag.
Penta Blood Bags
The Penta blood bag system contains 5 bags It is designed for pediatric /
multiple
Transfusion it reduces the risk of multiple donor exposure to pediatric
patients.
pg. 17
Top & Bottom BB with Leukocyte filter for CRC
The Inline filter bag is incorporated into the Quadruple bag system . The
filter is encased into a soft plasticized PVC housing which minimizes the
possibilities of bag damage during storage, transport and centrifugation
B. PORTIA (Blood Bank Management Software)
PORTIA significantly improves safety, productivity, quality and cost
effectiveness enabling solution to problems inherent in conventional blood
management methods. It is available in single and multi-user versions. It
also gives the details of
Blood Bags which the company producing. Details regarding the Blood
Bags are available as a database which includes the capacity volume of
blood bags.
Setting up of Blood Banks
Setting up or modernizing a blood bank requires a lot of time,
investment and effort on the part of the person in-charge. It spans across a
wide range of complex activities starting from preparation of the project
proposal to ensuring uninterrupted day-to-day functioning of the Blood
Bank. Each of the activities requires expertise without which the cost and
time involved can shoot up to very high levels. TERUMO PENPOL Limited
has over 17 years of experience in Blood Banking. During these years the
company has interacted with many Blood Bank professionals and
manufacturers from across the world; and understands the operations of a
Blood Bank. This knowledge, combined with the expertise of a team of
highly trained managers, engineers and blood bank professionals, help
pg. 18
Terumo Penpol in providing the best solution to the blood banking needs.
Terumo Penpol helps to set up a fully functional blood bank that not only
conforms to Drug Rules but also to GMP as well as International Standards.
SAMPLING AND SAFETY FEATURES
Occupational exposure to blood remains a serious concern during the
blood donation process. In order to address the safety issues concerning the
blood bank personnel, we have introduced a range of features in our blood
bags. The sampling and safety features are available on all configurations of
blood bags.
Blood Sampling Arm
This simple design eliminates the need for cut and drip sampling.
Needle Injury Protector
Reduces the risk of needle stick injury from both donor and sampling
needles .It provides immediate shielding of needle on withdrawal from vein.
Luer Adapter and Tube Holder
Facilitates safe in-line sampling. The unique LUER adapter needle
provides for a safer sample collection using vacuum tubes. It reduces the risk
of needle stick injury from sampling needle.
Pre-donation Sampling Bag
Our skin houses millions of bacteria commonly called as skin flora
which can cause contamination of the collected blood on entering through
the needle during Phlebotomy. Ideally 25ml of blood to be diverted to
achieve.
pg. 19
A. Fig 3.1Process at Blood Bank
Source: http://www.terumopenpol.com
C. MSG (Medical Systems Group) PRODUCTS
Tube sealer
Radio frequency sealing quality, easy separation of tube segments after
sealing procedures as hermetic seal hence no contamination , no warm up
time required.
XS1010
The XS1010 model heavy-duty radio frequency bench top sealer
provides wide, reliable, snap-apart seals. This lightweight compact tube
sealer conserves space in the
pg. 20
work area and has international safety certification of EN61010-1.It
produces hermetic seal by waves minimizing contamination and haemolysis
of blood and blood components and the sealing head is easy to clean.
Features
Heavy duty radio frequency bench top sealer ensures wide, reliable,
snap-apart seals.
Minimizes haemolysis of blood in tube segments.
Produces a hermetic seal preventing chances of contamination.
No warm up time required.
Compatible with the tubes of various manufacturers.
No variation in seal quality due to voltage fluctuation.
Splash guard provided (optional).
Plasma Expresser
Highly sensitive electronic sensor to prevent contamination uniquely
designed clamp mechanism ensures fast clamping at reduced power;
micro-processor based automatic collaboration for different type of tube
and bag.
Features
Uniquely designed compression plates exert uniform pressure on
the blood bag ensuring minimum layer disturbance for efficient
separation.
Same efficiency of separation across different brands of blood bags.
Powder coated mild steel cabinet.
Optimum performance ensured by Switch Mode Power Supply.
pg. 21
No contamination in separated components due to voltage fluctuation.
Compliance with international safety standards ensuring safety to
users.
Platelet Agitator Incubator
Ensure agitator at constant speed of 70+/-5 cycles/min .digital
temperature monitor, unique airflow system maintains uniform
temperature range. The Compo safe PA/PI200 is designed to meet all
international safety requirements of EN60601-1. This product stores
platelet concentrates in continuous motion at controlled temperature.
Digital temperature control monitor coupled with a unique air circulation
system maintains. Incubator at a uniform temperature of 22+- 2ºC within
the Incubator chamber as per FDA recommendation. There are visual
indications and audio alarms for temperature variation, open door and
agitator failure.PA/PI200 Platelet Agitators come in two options: 24 and
48 bag capacities.
Features
The flat bed agitator stores platelet concentrates in continuous motion
at controlled temperature.
Helps increase platelet viability, post transfusion recovery and
preservation of platelet morphology.
Agitation at constant speed of 75 +/ - 5 cycles/min.
No need for periodic calibration due to the digital temperature sensor
used.
pg. 22
Provision for connecting external remote alarm.
Visual indications and audio alarms for abnormal conditions like
temperature deviation, door open and agitator failure.
Compliance with international safety standards ensuring safety to
users.
Mini blood storage cabinets
Small capacity which is ideal for small-450ml blood bags power saver
ideal for remote location with frequent power failure.
Deep Freezer
Two models available- 400c and 800c high durability due to high impact
epoxy coating to resist scratches and rusting. Insolating sub lids to minimize
cold or during lid opening, clean fitter indicator light warns of fitter
clogging. Audible and visual power failure claims CFC free refrigerants and
insulation.
Refrigerated Centrifuge
Programmable memory for standard runs, Reduced maintenance
with brushless induction drive, Acceleration and declaration profiles.
Limuguard III-PL
pg. 23
To remove leukocytes and micro aggregates from up to ten units
platelet preparation. Only polyurethane fitter is used for highest bio-
compatibility. Unique air vent for convenient air removal.
Terumo Automatic Component Extractor
A highly flexible automatic blood component extractor for the
standardized processing of centrifuged blood according to good
manufacturing process. The device is designed to be used with all
common standard bag systems. Its top angled press with press position
detection ensures high stability of layers during extraction. It gives high
quality, non contaminated products with maximum component yield and
viability with a reduction in leukocytes through Buffy method.
Donor couch
It is designed for the comfort of the donor and the phlebotomist. Design
is based on haemoid dynamic principles (head high foot low position into
head low foot high position).
Blood collection monitor
Ensures better quality blood than that collected using manual mixing
methods. Clamp programmed volume, uniformed oscillation for optimum
mixing ensuring higher yield of components.
Safello urine bag
pg. 24
Conformity to ISO-8669 international standard for urine bag. Leak
proof no return value to prevent back flow of urine to minimize the risk
of infection.
Portable donor couch
Puts the voluntary donor where it belongs. Easy conversion from head
high foot low position to head low foot high position, no power
requirements.
Fig 3.2 Fig3.3
Donor Station (DC200) BLOOD COLLECTION MONITOR - D601
Making blood donation a safe Blood Collection and comfortable experience… made simpler .
…
pg. 25
Fig3.4 Fig3.5
TUBE SEALER- XS 1010 Portable Tube Sealer – LM100
Fig 3.6 Fig 3.7
Plasma Expresser – E300
Portable Sealer – LM100
BLOOD COMPONENT
SEPERATION…
pg. 26
Fig 3.8 Fig 3.9
Compo Scale CS300 E300 Interface with CS300
Fig 3.10 Fig 3.11
Cryo Bath (CB 100) PLATELET AGITATOR
WITH INCUBAT
4.1 ORGANIZATION STRUCTURE
The organization is working in three regions which includes corporate
office and logistics office at Sasthamangalam, blood bag manufacturing unit
pg. 27
at Puliyarakonam, and medical systems group at General hospital Jn:,
Trivandrum.
The organization has the following department that functions
effectively with a vibrant group of employees with the help of whom the
organization is able to shape up its future. The different departments that
functions are:
1. Production Department
2. Production & Engineering Department
3. Production Planning & Control Department
4. New Product Development Department
5. Maintenance Department
6. Accounts and Finance Department
7. Purchase Department
8. Stores Department
9. Quality Assurance Department
10.Export Department
11.Logistic Department
12.Marketing Department
13.Personnel and Administration Department
14.Human Resource Development Department
15.Corporate Social Responsibility
16.Medical System Group
Fig 4.1Organization structure
pg. 28
Chairman
5.1 PRODUCTION DEPARTMENT
pg. 29
Managing Director
Strategic planning
Corporate Admin
HR Legal Complianc
Executive Director
Corporate HR
Finance
GM MarketingVP Manufacturing
National Marketing Manager
Head Government Business
DGM Operation
PAD
Head of BBF
Materials
QA/QC
R&D
Technical Resource Manager
Administration and Accounts
Production
NPD
Safety
Maintenance
Application Specialist
Production
QA
Development
Purchase
Snr. Manager Institutional
National Sales Manager
All India Service Manager
Regional Manager
Area Manager
Sales and Service Engineer
The policy of production department is to manufacture
medical product as per the international standards strictly in compliance with
specifications laid down in the standard operating procedures with
minimum possible wastage of resources.
Production Process involves;
Selection of raw materials
Formulation
Processing
A .Raw materials used:
PVC
Plasticizers
Deoxidized oils
Stabilizers
Lubricants
Other additives
B. Formulation
This is a critical aspect that involves careful selection of raw materials
and proportions to be used to achieve the range of desirable properties. It can
be done by experiments followed by various studies.
C. Processing
Blood bags are made by welding together extruded plastic sheets. The
bags are subjected to autoclave sterilization at high temperatures and
pressures and freezing temperatures in the blood banks. They should also
pg. 30
withstand processes like centrifuging, used to separate the various
components of blood. Various parts like connecting tubes,
needles, outlet ports, special flow-regulating valves, filters, safety features
and sampling ports go into these bags, which are filled with an anticoagulant
solution that prevents blood from clotting.
Processing Steps:
1. PVC Sheet Extrusion
The raw materials for sheet extrusion are compounded PVC pellets. A
single screw extruder is used for the continuous process. The major zones of
the extruder are feed zone, meeting zone, recompression zone, adapter zone
and the dry zone.
2. PVC Tube Extrusion
The raw materials for tube extrusion are PVC compounded materials.
The inner diameter of tube is 3mm and outer diameter is 4.5mm. After
extrusion serial number is printed on the tube.
3. Injecting molding
The outlet port is manufactured through injection molding. The raw
material used is PVC pellets.
4. In process testing of sheet
pg. 31
This is done to confirm quality before being used in manufacture of
blood bags .The test on tube involves chemical test and element test. The
test on sheet also includes chemical test and element test.
5. Tube and compounding assembling
In tube assembling component of tube are broken off at junction
which have cuts provided at the stumping stage. Breaking of component is
done as per the specifications for each capacity and type of bag.
6. Welding\bag sealing
First the sheet is assembled with one embossed surface and plane
surface facing the inside of the bag to be made. Thus both the inside and
outside are embossed as well as plane surface, then between the parallel
arranged sheet. Then tube and sheet are ready for sealing.
7. New Process
This stage is relatively new in the TPL’s blood bag production
process. Two major reasons contributed to the creation of new process stage-
sticking and leakage. Leakage is tested by passing filtered air with the help
of specially designed machine. To avoid sticking of bag air is injected into
the bag as per the standard set by Q.A. Less amount of air leads to sticking
and more air effects the smooth flow of blood. Care is taken to ensure right
quantity of air is injected. This stage provided an added advantage by
different bags of different thickness and volume to be produced at same
time.
8. Labeling of bags
pg. 32
The labeling should be perfect. There are two types of labels Pressure
Sensitive Plastic Label (PSPL) and Heat Sensitive Plastic Label (HSPL).
The latter one has certain advantages over the other. It has a plastic coating,
which prevents shrinkage after sterilization. HSPL is exposed to 118 C and
therefore is not destroyed during centrifugation. PSPL is provided only to a
few old customers, who prefer it as it is cheaper. Majority of the labels are
HSPL. Prior to use the batch number are printed.
9. Preparation of anti coagulant solution
Anticoagulant solution is the one, which prevents clouting of blood.
Every blood bag should contain this solution in the required quantity, i.e.,
14% of the net capacity of the bag. The solution is prepared at TPL by using
inspected chemical like adenine (preservator), citric acid, citro phosphate,
etc. from the QC Department. Four types of
solutions are prepared, namely- CPDM, CPD, SAGM, ACD. CPDM
preserves blood for 35 days, CPD for 42 days. SAGM preserves blood for
42 days and has an additive to preserve blood cells.
10. Filling
The solution in collection tank is re-entered to sub tanks of capacity of
50liter each. From this the solution is channeled to blood bags via nozzles.
Sample of the solution from nozzle is taken for testing. During the process
of mixing, filtration, collecting, filling, the solution is least exposed to air to
prevent contamination. The bags filled with the solution are sent for packing.
11. Packing
pg. 33
Polypropylene covers are used for PVC blood packing. Packing is
done manually. Bags are inserted and the tube with needle, holding
assembly and donor tubes are coiled into the packet. Coiling is different for
Single, Double and Multiple bags. Packing of bag is followed by sealing.
Sealing is done manually or automatically.
12. Sterilizing
Packed bags are now brought in for sterilization. It consists of two
processes.
Auto claving
Drying
13. Final inspection
Pinch off, leak, weld leak stopper leak, transfusion leak, needle blend
damages, label rejection, CPDA stain \ color change and other defects are
checked.
14. Foil packing, Cartooning and Dispatching
The foil package for the blood bag is three layer packs;
External polyester
Middle aluminum
Internal polyethylene
pg. 34
Sheet Extrusion
Break off Value and Cover Tube
Tube ExtrusionInjection Molding
Printing
pg. 35
Assembling of Outlet
Ports
Outlet Caps & Inner Tube
Labeling
Sheet
Bag Sealing In Fully-automatic Sealing Machine
Bag Sealing In Semi-automatic Sealing Machine
Tube Assembly for Multiple
Tube Sleeve
Outlet Ports & Transfer
Y connector
Break off Value
Filling of Bag with Solution
Individual
Autoclaving
Bag Drying
Foil Packing & Cartooning
Polypropylene Covers
Dispatching
Fig 5.1Production Flow Chart
5.2 PRODUCTION AND ENGINEERING DEPARTMENT
Production and engineering department is concerned with the
introduction of new machines and new technologies for manufacturing in the
pg. 36
Chief Production Manager
Production Manager
Deputy Production Manager
Plant Manager
Foreman
Supervisors
Assistant Plant Manager
Work Assistance
factory. The introduction of machines, technologies is done carefully so as to
minimize risk involved.
New machine introduction
PED refers 3 processes before introducing new machines;
Installation Qualification
Operational Qualification
Performance Qualification
Kaizen
It is a Japanese term with the meaning continuous improvement. It
followed in Terumo Penpol for improving the quality of finished product. It
is practiced in PED with participation of employees in production
department.
5.3 PRODUCTION PLANNING AND CONTROL DEPARTMENT
Production Planning and Control can be viewed as the nervous system
of the production operation. This function aims at efficient utilization of
pg. 37
VP Manufacturing
DGM MSE
Head BBF
Deputy Manager (PED)
Executive (PED) Executive (PED)
materials resources, people and facilities in any undertaking through
planning, co-ordination and controlling the production activities that
transforms the raw materials into finished products or components as a most
optimum manner. Production planning and control comprises the planning,
routing, scheduling, dispatching and follow up function in the productive
process. Terumo Penpol has a blood bag manufacturing plant at
Puliyarakonam with a capacity of 11 million. The present capacity
utilization is 10.5 billion. Terumo Penpol
has a well functioned production planning and control department.
The major function of production planning department are:
Coordination with marketing activities.
Production planning i.e. preparation of yearly, monthly, weekly
and daily production schedules.
Finalize production planning
Preparation of work order system
Revise plan when production activities cannot confirm to original
plans and when revisions in scheduled production are necessary
because or rush orders.
Keeping up-to-date records scheduled and in process.
The important production control functions are:
1. Inventory control
2. Reduction of idle time
5.4 NEW PRODUCT DEVELOPMENT DEPARTMENT
pg. 38
The future of every organization depends upon the successful launch
of new innovative products and services although new product development
is a key competitive capability for manufacturers worldwide, many
companies are unable to launch a new product on a timely basis. They have
a well functioning NPD department it is the policy of NPD division to
enhance customer satisfaction by designing, developing, and manufacturing
products meeting quality standards and making them available to customers
on schedule.
Functions
Designing and developing products meeting quality standards
Empowering personnel’s with the right knowledge, technique and
tools
Put together a working environment conducive to creativity,
efficiency and team work.
Developing business through products and services which are new
i.e. not in existence now.
pg. 39
Chief Manager
Assistant Manager
Deputy Manager
Manager
5.5 MAINTENANCE DEPARTMENT
The policy of maintenance department is to upkeep all production
machines and utility equipments by periodic maintenance and providing
utility services.
Quality Assurance Procedure
Preventive Maintenance
Breakdown Maintenance
Environmental Maintenance
Preventive Maintenance
Purpose to conduct preventive maintenance of utility equipment to
support daily production activities. Operating procedure of all the preventive
maintenance other than GMP requirement are detailed and recorded in each
department.
Planning
Preventive Maintenance is planned on the basis of the following:
Machinery manufacturer’s recommendations available with the
firm in the form of instruction manual.
Analysis of Breakdown.
pg. 40
Assistant Executives
Junior Executives
Chemists
Experience gained by maintenance staff.
Maintenance Department prepares schedule for the Preventive
Maintenance of utilities equipment for a period of one year. At the end of
one year and considering the information received from breakdown analysis,
if necessary changes are incorporated in the maintenance procedure. For
carrying out certain Breakdown and Preventive
Maintenance activities, services are sought from external agencies. Service
done to equipments are filed equipment wise.
Breakdown Maintenance
The purpose of bring down the machine/equipment to efficient working
condition in the shortest possible time. According to information received
from various departments find out the machine/equipment on which
Breakdown Maintenance is to be carried out. All maintenance activities are
recorded in respective machine history records. Frequency of maintenance
requirement is also recorded. Breakdown Maintenance which cannot be
attended on regular working days and which are not so critical shall be
postponed to holidays.
Environmental Monitoring
Control of environment in a clean room area is essential to keep the
bio-burden at a low level, so that the microorganism can be excluded during
processing and packaging of sterile products. Sterile products is of high
quality standards and purity, must be free from microorganism, particulate
matter, etc. All components and processes involved in the preparation of this
should be clean and selected to eliminate, as far as possible, contamination
of all type. Environmental cleanliness is of primary importance to control
pg. 41
microbes and particulate matters in air. Thus conditioned monitoring of
operating environment is essential. Following procedure outline the method
to be followed for testing – filters, UV lamp efficacy, fumigation, pest
control, painting of all the manufacturing areas and factory premises.
Fig 5.3
Maintenance Department
5.6 ACCOUNTS AND FINANCE DEPARTMENT
Finance is the life blood of any business. Organizations should
understand the importance of finance as a component of the strategic
decision-making process. TERUMO PENPOL has a well functioning
finance department.
pg. 42
Executive Director
VP Manufacturing
Head BBF
Head Plant Engineering
Executive Maintenance
Executive Maintenance
Executive Maintenance
Executive Maintenance
Department policy
The policy of Finance Department is” to ensure provisions of timely
finance to various departments, without any delay and as per plan and to
exercise necessary financial controls and to maintain and record all financial
transactions of the organization accurately, systematically and to provide all
statutory reports and returns to concerned statutory agencies, and to provide
internal information reports on time to management and measuring
organization performance and for decision making.”
DUTIES AND REPONSIBILTY
Plan and manage fund flow, cash flow to cover critical expenses,
purchases and statutory obligation of the company.
Attend to all bank matters liaison with bank and financial institutions.
To scrutinize all payments and approve the same.
To collect dues to the company in time.
Compliance of internal audit report.
Preparation of balance sheet and monthly profit and loss account.
Effective financial control.
Budget preparation & Preparation of annual accounts.
Attending to income tax, central excise and sales tax.
Accounting executive general capital accounting, depreciation
statement.
Maintenance of updated capital asset register check, verify and ensure
proper and correct purchase accounting and journal accounting.
Analysis of creditors accounts to check out various unsettled
advances.
pg. 43
Functions
The various functions of finance department are:
To provide financial assistance to the various departments.
Relation with bank and financial institutions.
To collect money from debtors.
To maintain accounting records.
To comply with various statutory formalities.
To provide management information.
pg. 44
Document Preparation
Transaction
Fig 5.4Process of Accounts and Finance Department
FINANCE DEPARTMENT
pg. 45
Filing of Documents
Accuracy Checking
Document Verification
Transaction Approval
Transaction Accounting
Finance Advisor
Finance Manager
5.7 PURCHASE DEPARTMENT
An average commercial enterprise disposes of more than half of its
income on materials, supplies and services. A five percent saving in material
costs in a business organization can thus equate with an increase in turnover
of 25%. Effective purchasing is therefore the key to the overall profitability
of a business. The Purchase department in TPL coordinates all purchasing
activities. The policy of the purchase department is to provide
materials/services to the quality and the delivery as acceptable to the
requisitioned, procuring them at economical or convenient terms and to
maintain good professional business relationship with sub-contractors.
The main activities of Purchase Department include:
Purchase order execution
Receipt of materials
Bill passing and release of payment
Purchase Order
pg. 46
Deputy Finance Manager
Assistant Finance Manager
Section Officers
Based on the approval of subcontractor the purchase executive
prepares the purchase order in favor of the selected subcontractors with all
relevant purchase date. PO is prepared in six copies. The requisitioned is
expected to check his copy of the PO and if any discrepancies are observed
regarding specifications, quality, delivery dates in the order purchase
department is to be notified. PO is maintained in three series for raw
materials, consumables and capital goods. The orders are normally send by
post but to local subcontractor it may be handled over personally.
Receipt of materials
After the PO is placed the sub contractor are contacted through phone,
fax or letter to confirm the receipt order. The subcontractor dispatches the
materials are agreed. If deemed necessary remainders are end a week before
due date of dispatch. The dispatch
details are entered in material dispatch register. This is maintained for
a period of two years. To cover transit insurance, weekly statement of
dispatch is prepared and sent to insurance companies. Dispatch documents
are obtained from the subcontractors if the payment is through bank. Prior to
taking delivery the consignment are checked for any damage or loss. If any
damage or loss occurred the insurance company will immediately informed
and the insurance survey is arranged. A claim is lodged on insurance
company if there is any actual damage. Then the consignment is collected
and delivered to the stores.
Bill passing and release of packing
The particulars in the invoice are compared with that of purchase
order discrepancies, if any is noted on the reverse of the invoice then
pg. 47
concerned purchasing executive is informed comparing the invoices\bill
with the purchase order and it is ensured that the bill can be passed on the
receipt of accepted GRN. Such invoices is recorded in the Invoice Catalogue
Register and kept in pending bill file. As soon as GRN copies are received
from stores it is in warded in GRN Control Register. The information of
purchase invoices no: and bill amount is registered on the reverse of the
invoice having appropriate GRN. Endorsement for passing the bill is made
on the reverse side of the bill. Such passed bill and corresponding GRN are
forwarded to finance department as per agreement mentioned in the
purchase order the request for the payment are duly signed by purchase
executive and is
sent to finance department, to the release of payment on the due date.
After releasing the payment the finance department returns the second copy
of the request for filling in the payment details.
5.8 STORES DEPARTMENT
Sound stores management is a key to the running of every profitable
and efficient organization. The policy of the store is to store and preserve
materials in good condition by maintaining optimum level of inventory,
issue the same to the user and manage the finished goods till it is dispatched
to the customer.
Functions
Receipt and storage of materials
Issue of materials
Preservation
pg. 48
Receipt and sale of scrap
Packaging of finished goods
Issue of materials
All the sections in various departments are given separate requisition
book. Based on the requirement the requisition is made by the concerned
department. The stores assistant based on FIFO approves all the requisition.
The items kept for issue will be verified by the stores clerk and signed by the
stores in charge. After taking store copy of receipt note material is
transferred to the plant by stores assistant. Items to outsiders are given with a
material movement pass.
Dispatch of finished goods
Junior executive who intimates the marketing office regarding daily
stock position by fax generates daily stock position of finished goods from
computer. Marketing office furnishes in return the details of finished goods
to be distributed by dispatch advice note. The superior directs the head load
worker to load goods batch wise as per Performa invoice. Goods are taken to
the lorry – base by trolley and thereafter manual loading into
the truck should be done. The vehicles in which bags are loaded should be
free from dust and should be clean. Goods loaded are counter checked by
invoice. A non-returnable
material pass is prepared for the quantity to be dispatched by superior.
Materials movement pass is handed over to the security
pg. 49
Deputy Manager
Fig 5.5Stores Department
5.9 QUALITY ASSURANCE DEPARTMENT
In manufacturing, quality control or quality assurance is a set of
measures taken to ensure that defective products or services are not
produced, and that the design meets performance requirements. It includes
the regulation of the quality of raw materials, assemblies, products and
components; services related to production; and management, production,
and inspection processes.
The policy of the QAD department is to ensure quality by adopting
high standard of testing with respect to pharmaceutical standards. ISO
Department policy
standards in house specification and to develop the implement system
for imposing quality as per quality objectives of the company. The firm has
pg. 50
Supervisor
Junior Executive
Data Entry Operator
TechnicianStores Assistant Store Clerk
a well equipped QAD at the factory assuring the quality of finished goods as
well as raw materials.
Functional areas of QAD Quality control Quality assurance
Quality control: This section deals with final inspection of goods i.e.
whether the finished goods passed or failed the quality checks.
Their inward inspection includes:
Inspection of PVC pellets
Inspection of PP cover
Inspection of blood bags labels
Their pharmaceutical inspection includes:
Inspection of water for injection
Inspection of citric acid and Inspection of adenine
Inspection of mono basic sodium phosphate
Inspection of sodium citrate
QC checks sample of raw materials and they have to approve its
quality before production. Inspection of solution is done before they are
filled into the bags.
Quality Management System
Terumo Penpol has implemented QMS considering all aspects of
personnel inputs, apt technology and machinery for various operations.
Functions such as NPD, production engineering, purchase and stores, QAD,
pg. 51
production, maintenance, HRD and marketing are smooth functioning. QMS
is applicable for any sourced operation or process that Terumo Penpol may
engage from time to time.
5.10 EXPORT DEPARTMENT
More than 65% of Terumo Penpol sales come from the export market.
Terumo’s market share comes around 20-25% of the world market Terumo
Penpol exports goods to more than 82 countries of the world.99% of the
export constitute blood bags and 1% constitutes equipments.
Achieve excellence in customer service by providing
Timely and accurate information
On time deliveries for all orders
Technical and promotional support
Means of export
pg. 52
Executive Director
VP Manufacturing
Head BBF
Deputy Manager QA/QC
Deputy Manager
Deputy Manager
Executive QA
Executive QC
Assistant Manager
Assistant Manager
95% of the company’s export is through Sea and the rest is
through air.
Export incentives
The practice of giving export incentives is virtually universal, and
India is no exception. Terumo Penpol enjoys a number of export incentives
such as:
DEPB (Duty Entitlement Pass Book)
EPCG (Export Promotion Capital Goods)
ADVANCE LICENSESales return
Sales return owing to quality complaint is taken as per procedure for
product recall. For sales return other than quality complaint prior approval
from Executive director is obtained.
Customer complaint handling
Complaints related to product should be communicated to quality
assurance department or export department. Complaint is forwarded to the
quality assurance department for blood bags for the study of
complaints .within 24 hours of the receipt of
complaint DM is authorized to replace defective bags free of cost to the
customers immediately on receipt of the complaint. If the complaint is of
biological nature QAD should arrange four testing of bags in house / by
external agencies if necessary. If the analysis of the quality complaint shows
that there is a batch problem. QAD should within 24 hours inform LC for the
pg. 53
product recall .Market returned products are delivered to the store fresh
stock will be supplied free of cost to the customer.
Service complaint
All the customer complaint other than product quality complaint is
termed as service complaint. All this include:
1. Short supply 2. Dispatch of wrong products 3. Non receipt of dispatch
document
4. Discrepancies in invoicing /dispatch documents 5. Damages in outer
packing over
6. Delay in delivery
Export Department Fig 5.7
pg. 54
Executive Director
Assistant Manager (Export)
Executive ExportExecutive Export
5.11 LOGISTIC DEPARTMENT
DUTIES OF LOGISTIC COORDINATOR
Order processing
Delivery status updating to customers.
Dispatch orders.
Exports shipmen of documentation.
Export incentives.
Verification and passing of freight bills.
Manager In logistics
Overall responsibility for sourcing of all products marketed by
Terumo Penpol.
Overall responsibility for warehousing and distribution.
Handling of service complaints.
Effecting delivery to customer on schedule.
Develop and establish genuine alternative subcontract for supply
and servicing and to evaluate them appropriately
Monitoring and implementing corrective action at depot.
Preparation and submission of tender document.
Issue of intends and convening contract review.
Updating information on sales on a daily basis.
pg. 55
Senior Executives
Updating of stocks of traded goods in the computer.
Maintaining the depots stock record.
Submitting of weekly and monthly stock statement and total
stock statement on time.
Registering purchase requisitions.
Maintaining purchase order register, bill passing register, checking
of all purchase bills and passing them arranging payments and
maintenance of
all registers and reports concerned Collection of dates and
calculation of incentives
Preparation of tender document and arranging to send them on
time
Registering purchase orders customers and maintaining records
Preparation of statement relating to monthly marketing review
meetings
Typing of all kinds of correspondence statements and mailing them
on a daily basis.
Communication with customers/depots.
pg. 56
Fig 5.8
Logistic Department
5.12 MARKETING DEPARTMENT
The policy of marketing department is to achieve excellence in
customer service by providing timely and accurate information, on time
deliveries of all orders, technical and promotional techniques.
Major functions of marketing department
Deciding price and discount revisions as appropriate from time to
time.
Handling of the enquiries (both domestic and export) generated.
pg. 57
Executive Director
Senior Executives
Manager Logistics
Senior Executives
Senior Executives Junior Executives
Issuing of the delivery order.
Coordinating with various other departments (finished products,
finance, and quality) for the proper execution of the order received.
Collection of payment towards of the order executed.
Conducting regular customer surveys.
Domestic market is divided into six zones
South 1(Kerala, Tamil Nadu)
South 2( Andhra Pradesh, Karnataka)
East
West
North
Gujarat
Manager Marketing. The products of Terumo Penpol can be sold only
to 3000 licensed blood banks of the country. Out of these 3000 blood banks
490 blood banks do component separation. Now the company’s major focus
is on them because they use multiple bags, which is profitable to the
company. Not only that the competition for multiple bags are very less
compared to single bags
Fig 5.9 Supply Chain of TPL
pg. 58
Terumo Penpol Ltd.
Depots
Direct Customers
Distributor
Sub-Distributor
Terumo Penpol has depots in five major cities of India including
metros. The depots are located at:
Delhi Chennai Kolkata Gujarat Thiruvananthapuram
From these depots goods are transmitted to distributors and from there
to final customers. These depots may sometimes have sub depots.
Sales promotion techniques
Development follows the various sales promotion techniques such as
direct mail campaigns, website, sales persons and also market research. But
the most important techniques are medical exhibitions and conferences
Product Group Blood Bags Blood Equipments(MSG) Equipments directly import from Terumo
Main competitors
At present the main competitor of Terumo Penpol is J Mithras
Industries, Delhi. The other competitors are HLL, Polimedicure, Eastern
Medi Kit, and certain local companies of North. But the competitors are not
matches for Terumo Penpol on account of its high quality.
Market Share
pg. 59
TPL is concentrating on both International and Domestic market.
Once TPL was the leaders in Market Share, but now they are concentrating
on profitability
Fig 5.10 Marketing Department13. PERSONNEL AND ADMINISTRATION DEPARTMENT
The work force is an instrument in the organization and the personnel
manager provides and shapes that instrument. This instrument work force
consists of human beings of varying types with complex and changing needs
and values. The personnel manager assists the organization in adapting
changes in mix and values. He searches for programs that have overlapping
interest for both the employees and the organization. Production department
is functioning in an organization under an efficient personnel manager.
Functions
To meet the manpower requirement.
pg. 60
Manager Institutional
Business
GM Marketing
Regional Managers
Technical Resource Managers
Sales & Service Engineers
Area Managers
National Sales Manager
All India Service Manager
To carry out the administrative function of the factory in
asystematic manner.
Preparation of payroll document.
Salary disbursement.
Responsible for company vehicle.
Handling of inward and outward letters.
Selection of security staff.
CLASSIFICATION OF WORKMEN
Permanent: - Whose work is permanent in nature and whose
appointment is duly confirmed by the management after he has
completed his probationary period. Probationers: - Is one who is
provisionally employed with the view to give permanent employment
by the company management
Temporary: - Temporary workmen include a person who is
employed for work which is temporary in nature and likely to be
ended with in a limited period.
Substitute: - Is a workmen who is appointed in the post of permanent
workman
or probationer who is temporarily absent on account of any reason.
Casual:-Is a person who is on a work of casual in nature, irrespective
of the length of the period of work.
Apprentice Trainee: - Is one who is engaged for any length of period
for the purpose of learning any work with or without stipend or any
allowances as maintained in the contract of appointment.
pg. 61
INDUSTRIAL RELATION
Industrial relation means the relation between any employee and
management. In Terumo Penpol a good industrial relations is maintained
through negotiations between management and group of employees,
commonly known as collective bargaining, that determine the conditions of
employment. The result of collective bargaining procedure is called
collective bargaining agreement. These agreements contain settlements
regarding wage structure, allowance; leave facility, rights and
responsibilities of employees, disciplinary procedure etc….
There have been four collective bargaining agreements in TPL. They
are from
1990 ---- 1992
1992 ---- 1995
1995 ---- 2001
2001 ---- 2006
2006 ---- 2011
There are four trade unions they are:
TP Employees Union (TPEU)
TP Employees Sang (TPES)
TP Employees Association (TPEA)
TP Employees Congress (TPEC)
TPEU was the first in the company, this was split into three unions TPES,
TPEA, TPEC.
pg. 62
PROBATION
Every workmen recruited by the management shall unless otherwise
specifically mentioned in the appointment order, be on probation for a
period which shall be 12 months initially subject to extension for a
maximum period of 12 months if demand specific for any reason which shall
be communicated in writing to the workman not less than 30 days from the
date of expiry of initial probation.
WORKING TIME
The working time will be as per the notice exhibited on the respective
notice board. The period and hours of work for all workmen for each shift
shall be exhibited on notice board. The management or the competent
authority has the right to require a workman or a group of workmen to work
extra time during any day beyond the prescribed hours of work during any
week beyond the 48 hour subject to the provision of any law and on payment
of overtime wages.
ATTENDANCE
It is the duty of every employee that he/she should attend the office
5min before the office time starts. The working time is fixed at 09.00hrs to
17.30hrs with 30minlunch break between 13.00-13.30hrs. It is the duty of
every staff to endorse there porting time and sign the attendance register at
the front office.
pg. 63
WORK SHIFT
There are two types of shifts ie, general and relay shift. As most of the
employee is ladies the general shift is from 8.30 am to 05.00pm. The relay
shifts are for gents from 6am to 2 pm, 2pm to 10pm and 10pm to 6am.
Inspections are carried from 4pm to 12
midnight. The workers are provided with transportation facilities at early
morning and night. Attendance is registered through punch card system.
WORKERS’ PARTICIPATION IN MANAGEMENT
The thought that participation of workers in management is inevitable
in the process of decision making for higher productivity in micro and macro
level and for the smooth functioning of industrial democracy has gained
much strength. It is because of the realization that labor is not only the factor
of production, but also the sensitive human element. In TPL workers
participation in management is through the following:
Works committee
Safety committee
Canteen committee
Recreation committee
Welfare fund committee
Grievance procedure
All grievances shall be handled in accordance with the procedure laid down:
The workman in person will first take up grievance with his
immediate supervisor.
pg. 64
If the workman is not satisfied with decision of the immediate
supervisor or fails to receive an answer from him within 7 days, he
will take the grievance to the next immediate superior officer.
If the decision of the officer is not satisfactory the workman will
present his grievance to the department head in writing in the
grievance note duly signed by the worker.
If the decision of the head of the department is not satisfactory the
workman will present a copy of the grievance to the head of the
personnel department.
The head of the personnel department or any person
authorized by him or by the management will take the final decision and
inform the in written format. Any representation regarding a grievance
which does not comply with the provision of these rules shall not be
considered.
Welfare facilities
The workers are granted with all statutory welfare facilities as per Factories
Act1948, Drugs Act and ESI. There is a highly subsidized canteen which
gives 75%subsidy for the workers. Festival allowances provided to workers
during festivals.
Canteen Facility
A fully-fledged canteen is functioning within the factory premises.
External team on contract basis undertakes the canteen. The contract is
usually for one year, which is decided on the basis of quotation, which is
fixed by management. Building, furniture, utilities, water, gas, etc are
pg. 65
provided by the organization. The payment is made as two sections,
payment of 1stto 15thon 20thof current month and payment of 16thto 30thon
10th of next month. Other allowances like P.F, E.S.I, V.R.S, etc are
also provided to the team. Employees are provided coupons, which are
available atRs.2.50, Rs.40 and Rs.50. The coupons are provided on
Mondays, Tuesdays and Saturdays unto 25th of each month. An employee’s
price menu is fixed and displayed in canteen. Employer’s contribution is
3/4thand employee’s contribution is 1/4th.
A canteen committee is functioning at Terumo Penpol, which
constitutes 4trade union representatives, 2 management representatives and
representatives of Personnel and Administrative Department. Committee
checks the functioning of the canteen, employee satisfaction, etc. A
complaint register is maintained at the canteen, for employee’s to register
complaints. The canteen committee does monthly review of complaint
register.
Healthy measures inside the factory
The company provides certain dress codes to worker in which they are
covered from head to toe except eyes. The dress is usually blue in color and
consists of pajamas, jubbahs, masks, Glovers, and rubber slippers. The
quality of personnel and administration department enhances the reputation
of the organization so far as its external stakeholders are concerned. Terumo
Penpol has a well managed personnel and administration department.
pg. 66
VP Manufacturing
Executive Director
Head BBF
Fig 5.11 Personnel and Administration Department
5.14HUMAN RESOURCE DEVELOPMENT DEPARTMENT
Organizations have proclaimed their human resources to be their
"most valued asset”. Human capital is a critical factor in promoting
competitiveness as it provides the required knowledge, skills and capabilities
for developing competitive strategies. The role of the human resource
function is to deliver the human competencies i.e. the internal capability
required to achieve the organization’s objectives. TERUMO PENPOL has a
well functioning HRD department. The main function of HRD department is
hiring, induction, training and performance appraisal in resonance with the
quality policy and organizational goals.
DUTIES AND RESPONSIBILITIES
Head of the Department
Recruitment of executives/managerial categories as authorized by
the management.
Administration of performance appraisal awarding increments,
performance rewards, promotion and grievance redresses of
employees.
pg. 67
Personal Manager
Deputy Manager Personal Officer
Planning, organizing and conducting training as per the training
plan and policy.
Initiating organizational development activities to bring the
manpower in line with the management vision.
Executive HRD
Responsible for generating all the MIS reports
Preparation of appointment orders and other office orders.
Coordinating with placement consultant and other internal and
external customers of HRD department as and when needed.
Assisting HOD (HRD) in day to day functions.
pg. 68
Fig 5.12Source: Department Journal
The major functions of HRD departments are:
Recruitment, Training, Performance appraisal
RECRUITMENT
Recruitment means searching for and obtaining potential candidates
insufficient numbers and quality so that the organization can select the most
appropriate people to fill its job needs. The two main aims of recruitment are
the attraction and retention of the interest of suitable applicants, and the
projection of a positive image of organization to those who comes to contact
with it.
Purpose
To ensure that the organization has adequate competencies in all
functional areas to meet its objective and goals. The sources of
recruitment are:
Notification press or advertisement
Campus interviews
pg. 69
Natural transfer and promotion
Reference by consultancy or professional bodies Employee referrals
Procedure
Recruitment is one of the most important activities of HRD.
Recruiting the right person for the right job ensures better productivity and
lesser hassles. Recruitment will be done on the basis of manpower budget.
Manpower budget for a financial year will be prepared by HOD (HRD) at
the time of preparation of business plan of the organization.
HOD (HRD) will consult the divisional head and the budget
and planning department for preparation of manpower budget. HOD should
forward the number of requisitions and initiate the process of recruitment if
the position is budgeted. If it is not special approval from the management
should be obtained. Recruitment will be done through internal database,
recruitment agencies, campus recruitment, advertisement etc. Selection
process involves written test, group discussion and interview. After short
listing the candidates, an interview panel will be determined and they will
conduct the interview. Interview panel contain s subject expert, department
head, HR representative
and divisional head. HRD dept will send the interview details along with
names, proposed salary and responsibility to the MD through ED for the
comments or approvals. The appointment order will be prepared and issued
based on this. On resignation an exit interview is conducted by the HOD
(HRD).
TRAINING
pg. 70
Training is very important for learning and development. HR
department should plan, organize and conducting training programs as per
the training plan, policy and needs.
Purposes
Identify the training needs.
Upgrade knowledge and skills.
Build up a line of competent confident people and to prepare them for more
responsible jobs.
Procedure
Training is done based on the identified training needs by the
reporting officer and by the associates. Training is done through
administering psychometric tests. Training calendar is prepared on the basis
of the identified training needs and cultural needs of the organization. The
training calendar depicts the training plan for the year. Based on this a
monthly calendar is prepared. Mainly there are two types of training:
Internal Training External Training
Internal Training
Induction training is an internal training. It is given to newly appointed
employees. In this training they provide details regarding company products,
market, and demand trends, marketing strategies, quality policies,
administrative policies and rules etc. Internal training is given to executives
on periodically. The main methodologies used are case studies brain
storming, debates group discussions, lectures and illustrations etc.
External Training
pg. 71
It includes overseas training and training conducted by training institutes.
Overseas training is a part of company’s business. Duration of training can
be from one week to one year. Good manufacturing practice training is
imparted to all the employees once in every six month recruited for
manufacturing activities. During these training personnel
will be made avail of general GMP requirements observed in
the pharmaceutical industry. Training imparted covers the requirements,
personal hygiene and behaviors, entry procedures after training a feed back
is collected. It gives an idea about the program, faculty, and the way the
program conducted. Training officer maintains training history card. Once
the training program is over, after one month the concerned reporting officer
of each program will provide a feedback to HRD dept. concerning his
assessment about individual improvement of performance after attaining the
training program.
ProbationAppointed workmen, unless specified in the order will be on
probation for a period of 12 months. The duration can be extended if seemed
necessary, but to be communicated to the workmen in writing not later than
30 days from the expiry of initial probation. No payment of compensation on
account of such termination is necessary. When a permanent workman is
promoted to another post he will be on probation of a minimum of 12 month
with a possible extension of 6 months which will be communicated to the
concerned person within 30 days of expiry of the initial probation.
pg. 72
Promotion
It is management’s discretion to decide as to a vacancy should be
filled in by promotion or by fresh outside recruitment. If promotion is
decided, the criteria for promotion will be suitably for the post, efficiency,
skill conduct, seniority etc... Of the workman in the lower post.
Record of service
The management maintains a record of each workman. Separate
records are maintained for permanent and temporary workman, staff and
executives. The company maintains the record of service will workman is
terminated or leaves the job.
Transfers
Every workman is liable to be transferred from one post to another,
from one branch to another, or from one place to another place, etc.
Workman may also be transferred to other subsidiary establishment of the
company whether at present existing or that may be established in future.
Resignation
Subject to the terms and conditions in the order of appointment,
workmen may resign his job, but the resignation can come into effect only
on accepting the same by the management or company without prior notice
given in writing to the competent authority.
pg. 73
Retrenchment
The management under such a situation issues a notice of
retrenchment to the workman on prescribed time before the actual process.
This process is however not practically possible due to clauses in the
industries that safeguard a workman’s labor. Also the political scenario here
is not flexible enough to stern actions against the labor community.
Termination of employees
A workman may be discharged of terminated from work at anytime
by the management if he is found physically or mentally unfit for the job he
is engaged in.
Dealing with cases of misconduct
Written charge sheet issued to worker as well as put on notice
board
A chance is given to each worker to explain his part.
If the worker has no explanation within the stipulated time the
management proceeds with the course of action.
If the worker has explanation, it is submitted and seen if it is
satisfactory
If not satisfactory, action is taken.
It is satisfactory, the punishment is withdrawn.
Management may entrust an enquiry committee for the same.
Then the committee is liable to furnish an enquiry report having
the proof of incidents under concern.
The management takes action according to the findings in the
enquiry report.
pg. 74
PERFORMANCE APPRAISAL
Purpose
To know the performance level of each person to the required level.
This help to reward or to take corrective measures.
Procedure
Performance appraisal is done for all executives and managers.
Assessing the performance of associates is very important for the associates
and reporting officers to know where he stands in performance. A midyear
review will be done in the month of September and final assessment will be
done in the month of March. Performance of trainee and probationers will be
assessed once in every six month. All the associates will be assessed
annually. The decision related to training, rewards, promotion etc will be
decided based on this assessment. For this process key result area will be
fixed for every executive. Competencies or potential of associate also will be
measured during end year assessment. The rating of associates should be
based on guidelines. Based on the marks there are four types of rating such
as outstanding, very good, good and below average.
Exit Management
When an employee decided to exit, detailed exit interview is
conducted by HRD and recorded in a form. Exit interview is conducted
mainly for analyzing the reasons of resignations and issues regarding salary.
This helps the employer to improve the working conditions
pg. 75
Fig 5.13Human Resource Development Department
5.15 CORPORATE SOCIAL RESPOSIBILITY PRACTICE
TERUMO PENPOL Limited business units have Environment,
Health, Safety and People policies that are appropriate to their
operations.TPL serves the community by complementing the growth &
success of business with contribution towards the social, environmental and
financial aspects of the society. At TPL, CSR is targeted for-Feel good
factor for Employees, customer satisfaction, brand visibility, recognition and
awareness and environmental sustainability.
Statutory compliance is also fulfilled. It includes-Employees State
Insurance, Provident Fund, Gratuity Scheme, Round a clock canteen with
75-percentage subsidy, etc. Safety is a high priority for the Company.
Electrical Safety audit, Weekly internal safety audit, Mock Drills, Safety
pg. 76
MD
Assistant Manager HR
Executive HR Executive Payroll
training programs and installation of Safety equipment were some of the
actions taken. In addition to this TPL also provides social services to
employees, pollution control measures, environmental protection measures,
customer welfare programmes, etc
Events organized by TPL for a cause-
World Health Day - 7thApril
World Blood Donors Day - 14thJune
National Blood Donation Day - 1stOctober
World AIDS Day - 1stDecember
5.16 MEDICAL SYSTEMS GROUP (MSG)
Medical Systems Group is a manufacturing unit of Terumo
Penpol.Marketing department interacts with MSG to assert the capability of
meeting specification of customer requirements and the delivery schedule
prior to acceptance of an order along with regulatory requirements.
Department policy
It is the policy of MSG of Terumo Penpol Ltd to enhance
customer satisfaction by designing, developing and manufacturing products
meeting quality standards (in- house) and making them available to
pg. 77
MD
PR & CSR Manager
Department Manager
customers on schedule. They supply the products to the hospitals and blood
banks. Penpol is India’s largest manufacturer of Blood Bags. The products
of MSG are commonly known by the brand name “Compo Safe TM”.
Penpol offers comprehensive range of equipments intended to make
operations at the Blood Bag, blood transfusion activities safer and more
effective. The “Compo Safe TM” range of products includes equipments
for collection and storage of blood and a software package for blood bank
management.
MSG manufactures three types of devices:
Collection devices-donor couch, blood collection monitor, tube
sealer etc
Processing devices –plasma separator, centrifuge etc
Storage device-refrigerator, defreeze, platelet agitator, incubator
etc
MSG consists of the following functional areas:
Production
Quality control
Purchase
Store control
MSG quality objectives
Designing and manufacturing of products meeting quality
standards.
Empower personnel with right knowledge, technical tools.
pg. 78
Put together a working environment conducive to creativity,
innovation and team effort.
Fig 15 Medical Systems Group
6.1SWOT ANALYSIS
A scan of the internal and external environment is an important part of
the strategic planning process. Environmental factors internal to the firm
usually can be classified as Strength or Weakness and those external to the
firm can be classified as Opportunities or Threats. Such an analysis of the
strategic environment is referred to as a SWOT Analysis. The Overall
evaluation of company’s strength, weakness, opportunities and threats is
called as SWOT analysis. It can do so by using a form which is called
marketing memo or an outside consultant can be hired. but it is always better
that then companies do their own SWOT analysis and accept their weakness
pg. 79
DGM Operations
VP Manufacturing
Accounts & Administratio
n
Purchase Departme
nt
Development
Production Department
QA Stores
and threats and review the marketing, financial, and organizational
competencies and rates each factor as a single strength, minor strength,
neutral factor ,minor weakness and major weakness.
Clearly, the business does not have to correct all its weakness nor
should it focus about its strengths. The big question is whether the business
should limits itself to those where it posses the required strength or should it
explore better opportunities might have to acquire or develop certain
strengths.
Sometimes a business does poorly not because its departments lack
the required strength but because they do not work together as a team. Every
year the company asks each department to rate its own weakness and those
of other department with which it interacts. Once each department’s
weakness are identified, work can be undertaken to correct them.
Strengths
1. Stable managementTPL has a well- mannered team of highly
qualified, experienced and dedicated management professionals.
Almost all of the managers possess an industrial experience of over 10
years. All the top level executives are serving the company for more
than ten years.
2. Sound financial position
Since inception, the firm enjoys a sound financial capability as it
enjoys an association with the MNC Terumo co-operation. All financial
pg. 80
matters are handled by a team of highly qualified and experienced
professionals.
3. Product quality and standard with Terumo Penpol brand image
TPL’s products have high quality and standard because they came
across highly sophisticated quality checks. TPL always ensures quality to
its products in all stages.TPL has got ISO Certifications and CE
("Conformity European) marking.
4. Maximum range of products – product mix
TPL is mainly dealing with blood bags and its variants like single,
double, triple, quadruple and Penta bags and its systems.
5. Good sales network of branch
TPL has a well equipped sales network covering both domestic and
international market. The department concerned is handled by a team
of professionally qualified, experienced and competent workforce.
6. Higher number of installations with strong customer base
TPL’s products enjoy a strong customer loyalty than the others. They
manufacturer’s products as per the customer’s need.
7. Very good after sales service with own service networks
TPL provides an appreciable after sales services to their customers
with the assistance of highly skilled technicians.TPL ensures effective
handling customer queries after sales.
8. Experienced financial services and strong customer relations
pg. 81
The firm is equipped with eminent and experienced financial
services professionals and the firm maintains strong relations with their
customers.
Weakness
1.High prices of blood bags compared to indigenous product and certain
imported brands
The prices of TPL’s products are comparatively more when compared
to the other market players. The other companies provide the same product
for fewer prices with warranties and offers.
2. Lack of complete product range – refrigerated centrifuge and cell
separator
TPL’s main product is blood bag and it lags some of the allied
products in the range. At this time the competing firms possess them.
3. Organized lobby by foreign companies
The market witnesses an organized effort from the part of certain
forces to capture market share for the foreign companies. These sort of
activities affects TPL’s product performance.
4. Servicing difficulties of blood bank equipment
The equipment used in this industry are highly sophisticated, it faces
servicing difficulties because of its complexity.
5. Servicing delays and additional cost in closing complaints
Servicing is a complex activity it is not an easy task and it requires
more time, effort and money to close them all. Some times the cost incurred
for complaint handling may be heavy.
Opportunities
pg. 82
1. High demand for products in domestic and international market
The product enjoys a high rate of demand both in domestic and
international market. This is a great opportunity for TPL because they rely
on delivering high quality and standardized product to the customers.
2. up gradation of blood banks
The blood bank services are to be upgraded to stay tuned with the
environment changes.
3. New blood bank projects
New blood bank projects are to be initialized to get more acquaintance
with the industry.
4. Value added features in blood bags
The products must be provided with value added features.
5. Large unexplored territory – blood bank equipments
This industry is now witnessing changes in connection with blood
bank equipments it throws a great opportunity to use.
Threats
1. Quality complaints of blood bags
Sometimes it may happen due to carelessness from the part of
employees.
2. Competition from Indian companies
Competition from the part of domestic firms like HLL is a real threat.
3. Free equipment as package along with projects by major competitors
TPL’s major competitors provide free equipments along with the
product this may affect the firm’s performance.
4. Centralized purchase plan by NACO for blood bags and blood banks
pg. 83
The centralized purchase plan by NACO for blood bags and
blood banks may reduce TPL's sales because of the price difference between
competitors.
7.1 FINDING
1. Terumo Penpol is the India’s largest manufacturer of Blood Bags and
its part of the Terumo Corporation.
2. They offer customers a wide range of Blood Bags and Blood Bag
Equipments and also products to meet specific requirements.
3. The company has a sound financial position and a stable management.
4. The product quality and standard is in line with Terumo Penpol brand
image.
5. The company believes in innovation, and produces a wide range of
products.
6. The products of Terumo Penpol have high demand in domestic and
international market.
7. The company has good sales network of branch and higher number
of installations with strong customer base.
8. It maintains very good after sales service with own service networks.
9. Terumo Penpol enjoys experienced financial services and strong
customer relations.
10.The company has a lack of complete product range – refrigerated
centrifuge and cell separator.
11.Terumo Penpol blood bags are highly priced compared to indigenous
product and certain imported brands.12.There is servicing difficulties
of blood bank equipments because the unavailability of Technicians.
pg. 84
12.The company faces servicing delays and additional cost in closing
complaints.
13.TPL serves the community by complementing the growth & success
of business with contribution towards the social, environmental and
financial aspects of the society.
14.14. TPL serves the community by complementing the growth &
success of business with contribution towards the social,
environmental and financial aspects of the society.
SUGGESTIONS
1. Measures like adoption of new technology, which reduces the cost
of prodction, can in turn reduce the price of product.
2. Improvised services to blood bank equipments can reduce the
exporting difficulties for the same.
3. Proper implementation of company’s quality policy may help to
reduce complaints based on quality of products.
4. Counter offers to that of competitors and reduced price may help to
with stand the competition in the domestic as well as international
markets
5. Timely servicing and smooth handling of customer complaints can
reduce additional cost in closing complaints.
6. Innovative and value added features in the products might contribute
to an increase in the existing potential market.
7. The appointment of technicians will reduce the servicing difficult
pg. 85
CONCLUSION
Terumo Penpol is the India’s largest manufacturer of Blood Bags and
its part of the Terumo Corporation a Japan Company having its presence
over 150countries. The company is one of the largest producers of blood
bags in Asia, other than Japan with a capacity of 13 million Blood Bags.
Terumo Penpol Ltd (TPL) has opened its new factory premises on 28 th May
2008 and this will enable the company to double its production capacity
from the existing 13 million. A significant portion of this output is exported.
The company’s strategy for growth envisages further expansion of capacity,
modernization of processes, adherence to strict quality assurance protocols
and a drive to boost efficiency in manufacturing. TPL has successfully
launched a whole range of medical electronic products for use in blood
transfusion centers and blood banks designed to significantly enhance safety,
quality and efficiency of blood transfusion
BIBLIOGRAPHY
BOOKS
1. Aswathappa K. 1999, Human Resource & Personnel Management,
Newdelhi,
Tata McGraw – Hill
Publishing Co. Ltd.
2. Kothari C.R. 2004, Research Methodology Methods & Techniques,
Newdelhi,
pg. 86
New Age International
Publishers.
3. Kotler Philip 2002, Marketing Management, Newdelhi,
Prentice – Hall of
India Pvt. Ltd.,
WEBSITES
www.terumopenpol.com
www.terumo.com
www.wikipedia.com
MANUALS
Annual reports, Department Manuals
pg. 87