A SUMMER TRAINING REPORT ON MADURAI ARKAY ROCK PRODUCE PRIVATE LIMITED, MADURAI.

Submitted in partial fulfillment of the requirement for the award of the degree of Master of Business Administration

By

JUHIL SUSANNA.C

(2014MBA21)

Under the guidance of

Dr. M. Nagarenitha

DEPARTMENT OF MANAGEMENT STUDIES

Fatima College (AUTONOMOUS)

Mary Land, Madurai-625018

(College with Potential for Excellence)

JUNE - 2015

Fatima College (AUTONOMOUS)

DEPARTMENT OF MANAGEMENT STUDIES

Mary Land, Madurai-625018.

Bonafide Certificate

This is to certify that the project work entitled `A Summer Training Report on Madurai Arkay Rock Produce Private Limited, Madurai`, is a bonafide record of work done by Juhil Susanna.C (2014MBA21) submitted in partial fulfillment of the requirement for the Degree of Master of Business Administration, 2014-2016.

Signature of the Faculty Guide Signature of the Director

(Dr. M. Nagarenitha) (Dr. P. Uma)

Fatima College (AUTONOMOUS)

DEPARTMENT OF MANAGEMENT STUDIES

Mary Land, Madurai-625018.

JUHIL SUSANNA. C

(Reg No: 2014MBA21)

DECLARATION

I hereby declare that the project done under the title A Summer training Report Madurai Arkay Rock Produce (P) Ltd, Madurai submitted for the award of the degree of Master of Business Administration is my original work and that no part of this report has been submitted fully or partly for any other recognition earlier.

Signature of Candidate

ACKNOWLEDGEMENT

First and foremost I would like to thank God almighty whose blessings made me to complete the training successfully.

It is a great pleasure to acknowledge my sincere thanks to Sr. Fatima Mary Kanikai, Principal, Fatima College, Madurai for giving this great opportunity.

I express my sincere thanks to DR Sr. G. Celine Sahaya Mary, Dean Professional Courses, Fatima College, Madurai for giving the opportunity to get practical knowledge about our theoretical studies.

I also thank Dr. P. Uma, Director, Department of Management Studies for the successful completion of this project work.

I am indeed greatly thankful to my faculty guide for guiding me to successfully complete the project.

I wish to express my gratitude to all the staff members in the Department of Management Studies for their encouragement in completing this training.

I express my deepest gratitude and special thanks to the MD of Madurai Arkay Rock Produce, MR. Sri Ram who allowed me to carry out my summer training at their esteemed organization.

I express my deepest gratitude to the staffs at Madurai Arkay Rock Produce for helping me & giving necessary advices and guidance during my training period.

(TABLE OF CONTENTS)CHAPTERISATION

S.NO

CONTENT

PAGE. NO

CHAPTER 1

1.1

INTRODUCTION

1

1.2

OBJECTIVES OF STUDY

5

CHAPTER 2

2.1

COMPANY PROFILE

6

2.2

FLOW CHART

10

2.3

ORGANISATION STRUCTURE

11

CHAPTER 3

3.1

PURCHASE DEPARTMENT

12

3.2

PRODUCTION DEPARTMENT

15

3.3

EXIM DEPARTMENT

26

3.4

MARKETING DEPARTMENT

29

3.5

FINANCE DEPARTMENT

33

3.6

HUMAN RESOURCE DEPARTMENT

37

3.7

MAINTENANCE DEPARTMENT

43

3.8

DESIGN DEPARTMENT

46

3.9

ADMINISTRATION

47

.

CHAPTER 4

4.1

OBSERVATION

48

4.2

SUGGESTION

49

4.3

CONCLUSION

50

CHAPTER 1

INTRODUCTION

1.1 INTRODUCTION

Granite is a light-colored igneous rock with grains large enough to be visible with the unaided eye. It forms from the slow crystallization of magma below Earths surface. Granite is composed mainly of quartz and feldspar with minor amounts of micas, amphiboles and other minerals. This mineral composition usually gives granite a red, pink, gray or white color with dark mineral grains visible throughout the rock.

Many people recognize granite because it is the most common igneous rock found at Earth's surface and because granite is used to make many objects that we encounter in daily life. These include counter tops, floor tiles, paving stone, curbing, stair treads, building veneer and cemetery monuments. Granite is used all around us - especially if you live in a city.

SCULPTURE AND MEMORIALS

In some areas granite is used for gravestones and memorials. Granite is a hard stone and requires skill to carve by hand. Until the early 18th century, in the Western world, granite could only be carved by hand tools with generally poor results.

A key breakthrough was the invention of steam-powered cutting and dressing tools byAlexander MacDonaldofAberdeen, inspired by seeing ancient Egyptian granite carvings. In 1832 the first polished tombstone of Aberdeen granite to be erected in an English cemetery was installed at Kensal Green cemetery. It caused a sensation in the London monumental trade and for some years all polished granite ordered came from MacDonalds. Working with the sculptor William Leslie, and later Sidney Field, granite memorials became a major status symbol in Victorian Britain. The royal sarcophagus atFrogmorewas probably the pinnacle of its work, and at 30 tons one of the largest. It was not until the 1880s that rival machinery and works could compete with the MacDonald works.

Modern methods of carving include using computer-controlled rotary bits andsandblastingover a rubber stencil. Leaving the letters, numbers and emblems exposed on the stone, the blaster can create virtually any kind of artwork or epitaph.

(1)The rock known as "black granite" is usuallygabbro, which has a completely different chemical composition

GRANITES IN INDIA

India is a treasure-trove of natural stones, covering a wide spectrum like Granite, Marble, Sandstone, Slate, Quartzite etc., and spread all over the country. The quality deposits are outstanding and Indian stones are known for their strength and vibrancy. Indian Stones confirm to the highest International standard and provide excellent uniformity and consistency and have been used in several well known buildings all over the world.

India is also amongst the largest producer of raw stone material and the sector is quite developed and vibrant in the south as well as in Rajasthan and Gujarat.

The Indian Stone Industry has evolved into the production and manufacturing of blocks, flooring slabs, structural slabs, calibrated ready to fix tiles, monuments, tomb stones, sculptures, artifacts, cobbles, cubes, curbs, pebbles and landscape garden stones, while being the 3rd largest exporters of the stone in the world. India is also among the largest consumer of stones and stone products with a well established distribution network within India, the Indian Stone industry caters well to the domestic demand and rising aspirations of the growing demand of India.

Indian Stone industry has a long history behind it. There are many century old monuments, temples, forts as living examples of our art and architecture. To mention a few among them are Taj Mahal, Red Fort, and Temple of Dilwara at Mount Ab

Lengthy, dangerous and expensive process is to excavate the granite from the ground, or quarry. These quarries are often hundreds of feet deep with jagged razor sharp edges of solid rock. Water drains into these massive holes creating a large pool at the bottom.

Different types of granite are quarried differently and in various parts of the world, but the main process is essentially the same. High magnitude explosives are placed in drilled holes in order to break apart the granite strategically so that it can be preserved for good use. These immense blocks of granite are then hauled out of the quarry and sent to the manufacturing plants where they are then cut using precision machines and diamond tipped blades. Once the granite is quarried it is transported to the manufacturing plant.

GRANITES IN TAMILNADU

Tamil Nadu is a prominent place for quarrying in India because of two reasons. First, the state has some finest deposits of granite and other natural stone. Second, it has international seaport with excellent export infrastructure, facilitating an effective shipment for international destinations. The most abundant natural stones in the state are:

Granite Black, Blue, White variants

The greater part of Tamil Nadu is occupied by hard crystalline rocks. The state is thus bestowed with vast resources of granite deposits. The black granites are confined to northern districts viz. Kancheepuram, Tiruvellore, Vellore, Dharmpuari, Krishnagiri, Salem, Erode, Perambalur, Villupuram, Trichy and Tiruvannamalai. The multi coloured granites are spread over southern districts and in Salem, Krishnagiri and Dharmapuri Districts.

The export of granite depends upon various factors such as uniform colour, grain size, free from inherent defects viz. hairline cracks, joints, fractures, capacity for polishing and recoverability of large size blocks.

The granites of Tamil Nadu have established a unique place in the world market and realized considerable amount of foreign exchange to the country. The production of granite has shown a steady increase.

The commercial names of granite are derived from area, colour, pattern etc. Some of the important varieties of granite in Tamil Nadu are Kashmir white, Raw silk, Paradiso, Colombo Jubrana, Tiger skin, Kunnam black, Thuraiyur blue, Pink multi and Madura gold.

The mining and processing techniques of granites have improved but need further improvement / up gradation so as to enable the Tamil Nadu granite to compete in the International markets

The Granite Conservation and Development Rules, 1999 was brought to ensure uniformity and stability in quarry leases for granite and facilitate scientific mining with proper planning, utilization and management of granite resources.

Granite is an important sector which provides employment opportunities to rural people and artisans.

In order to achieve systematic economic growth in the field of granite and granite based industries and to promote private sector participation with due regard to the conservation of minerals, safety of labours, mines and environmental protection, the existing procedures will be simplified to offer quick decision with optimum transparency.

2

4

1.2 OBJECTIVES

To learn the functions of various departments.

To observe the traits and role of the managers.

To know the organizations culture and its environment.

To gain practical knowledge.

5

CHAPTER 2

COMPANY PROFILE

2.1 COMPANY PROFILE

MADURAI ARKAY ROCK PRODUCE PRIVATE LIMITED was established as a partnership SSI firm in September 1992 with the name ARKAY ROCK PRODUCE by the young entrepreneurs / engineering graduates Mr.R.SriRam and Mr.R.Muthusankar to manufacture and export Granite Monuments. The Partnership firm became a Private Limited Company in 1997. The Company was then converted into a 100% Export Oriented Unit in 1998. The Company is holding One Star Export House Status. Initially the firm was doing business in the local market exporting was done through merchant exporters and then it started doing direct export in the financial year 1993-1994.

The Company procures raw granite blocks based upon orders / requirements from various parts of world or within our Country from states like Tamil Nadu, Kerala, Andhra Pradesh, Karnataka and process the procured blocks into monuments and sculptures of different shapes, sizes, thickness and exports it to different countries. The company is exporting their products to USA, UK, Germany, Ireland, France, Australia and New Zealand. It has around 270 employees. The manufacturing unit is located in Sholavandan Road, Nagari. The skilled and dedicated work force and the advanced machineries with strict process planning and execution ensures in transformation of clients requirements to a good finish and scheduled delivery of monuments. Company established twenty years back aims at perfecting their operations to give maximum satisfaction to their customers.

MISSION STATEMENT

Your Memories + Our Materials & workmanship = Your Memorable Monumentswe at our factory reflect your memorable memories on granite stones and our satisfaction lies in yours. We carefully select granite materials as required by you, process them with the help of computer drawings and templates on appropriate machines with quality consumables imported for the purpose

6

Corporate Identification Number

U26999TN1997PTC039345

Company Name

MADURAI ARKAY ROCK PRODUCE PRIVATE LIMITED

RoC

RoC-Chennai

Registration Number

39345

Company Category

Company limited by shares

Company Sub Category

Indian Non-Government Company

Class of Company

Private Company

Authorised Capital (in Rs.)

10,000,000

Paid up capital (in Rs.)

9,000,000

Date of Incorporation

31 October 1997

100% Export Oriented Unit

1998

Whether listed or not

Unlisted

Company Status (for eFiling)

Active

Location

4/48, Sholavandan Road, Nagari 625221,

Madurai,

Tamil Nadu,

India.

COMPANY INFORMATION:

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GROUP COMPANIES:

DUNITE ROCKS PRIVATE LIMITED (100% EOU) Granite Slabs

Dunite Rocks started few years back is an associateof Madurai Arkay rock produce. Ideally situated at Madurai amidst bustling quarries in south Tamil Nadu Dunite rocks is agranite slab processing plant with obsession for high quality. Complementing this is the state of the art machineries imported from Italy and skilled and trained manpower. The strategic and geographic location ensures proximity to most quarries of India which are concentrated in the Deccan plateau and the Tuticorin port

VIKATRAM GRANITE MINES Granite Quarry Operations

Vikatram Granite Mines export granites from their own quarries and also have processing plants for monuments and slabs in all finishes and sizes. Their main products include Jet Black and Visage Blue

MEMORIALS AND ROCK PRODUCE UK LTD (Pvt Company formed under UK Law)

Granite Monument Distribution

ACHIEVEMENTS

1st prize of VISVESVARAYA AWARD sponsored by MADITSSIA-AIMO for the years 1995, 1999 and 2003.

Export Award for excellence in export, increase in export in new markets and new items in SSI sector during the year 1996 from the Department of Industry and Commerce, Government of Tamil Nadu.

CAPEXILs Certificate of Merit for Export Performance for the years from 1997-1998 to 2012-2013.

MEMBERSHIPS

IMMA - Indian Monument Manufacturers Association.

(8)MBNA - Monument Builders of North America.

DIRECTORS:

Mr.R.Sriram,B.E.,

Mrs.K.Geetha Sriram, B.E., M.Tech.

MANAGING DIRECTOR

Mr.R.SRIRAM, Managing Director of the Company is in-charge of the overall management of the company including organizing staff, strategic planning, business planning, budgeting and other operational needs to support the company.

Roles and Responsibilities of Managing Director

To lead and promote the welfare of the company and motivates employees for better operation.

He Plans for the future of the company, provides better opportunities for the employees.

He Provides recommendation, develops and implements plans

He directs his subordinates.

Conduct meetings and reviews report.

Provide the updated information about the companys annual objectives and goal.

To develop new business ideas, how to have potential customers and how to increase the organizations profit.

Maintain business relationship with customers and suppliers.

Keeps an eye on his workforce and provide facilities to his employees to retain them.

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FLOW CHART

2.2 WORK FLOW CHART:

10

ORGANIZATIONAL STRUCTURE

2.3 ORGANIZATIONAL STRUCTURE

11

CHAPTER 3

DEPARTMENTS

PURCHASE DEPARTMENT

3.1 PURCHASE DEPARTMENT

Hierarchy:

PURCHASE DEPARTMENT:

Purchase department works in collaboration with other departments to purchase the required raw materials, machines, tools, and equipment etc for smooth running of business. The main work done in purchase department includes placing orders, finding suppliers, negotiating deals, grant contracts that ensure that the right amount of the product or service are received when it is needed.

Personnel in Purchase Department researches sales records and inventory levels of current stock, find foreign and domestic suppliers, and state any changes in supply or demand of products and materials.

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Functions of purchase department:

Analyze the requirement: The purchase department receives demand/requisition of material from various departments. After receiving the indent from departments it examines in details and takes action according to the need and urgency of any item.

Selection of vendor: Selection of vendor is mainly based on the timely delivery of the required material as the company follows Just In Time inventory control. Its also based on the proximity, price, availability of material, other services provided by the vendor.

Receive Quotation: As soon as the purchase requisition is received in the purchase division, sources of supply will be located; quotations from prospective suppliers are obtained.

Place order: Next step is placing the order. It must contain details regarding specifications of the material, Quantity Transport and packing charges and shipping instructions, Name and address of the supplier, Date, time and place of delivery, Price, discount and terms of payment, the name and address of the buyer.

Delivery: its the purchase department's responsibility tofollow-up the order and takes delivery of goods on time.

Verify invoice: the purchase department check the invoices and accordingly advise the accounts department for clearing the payment to the parties concerned.

Inspect: On receipt of the materials from different suppliers, they are to be inspected as per specifications indicated in the purchase order to verify their quality and quantity.

Maintain purchase records and report to top management.

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Managers Duties and Responsibilities:

He aims to find the best merchandise at the lowest possible purchase cost. Negotiates and executes contracts with the vendors as per requirement of quality, cost and delivery.

He manages day-to-day functioning of purchasing department.

He Reviews purchase orders to ensure adherence to quality and procedures

He ensures required stock is maintained at the workplace.

He supervises assembly process thoroughly to ensure that the material is delivered JIT

He forecasts the needs of materials and relates those to production programs and stock required for the daily production round.

He represents purchase department in Board meetings to chart out strategies aimed at improving overall integration of purchasing assets and accounts payable.

Manages the creation and maintenance of Equipment Bill of Materials. Without a complete and accurate BOM, decisions regarding material planning and replenishment are often made in an information vacuum, resulting in excess inventory levels, stockouts, significant expediting charges and expensive downtime

Managing the shipping, handling and storage requirements on components to ensure high quality items are received and issued to the appropriate departments.

He maintains constant touch with the regular suppliers and alternative suppliers to ensure that the required material products remain in constant stock as required.

Supports the Product Design Group with supplier negotiations, supplier timing plans, and cost forecasts to achieve the most cost effective component delivery.

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PRODUCTION DEPARTMENT

3.2 PRODUCTION DEPARTMENT

Hierarchy

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PRODUCTION DEPARTMENT:

Production is an intentional act of producing something in an organized manner. It is the fabrication of a physical object through the use of men, material and equipment.

Manufacturing System:

The company follows intermittent production system where the goods are manufactured specially to fulfill orders made by customers rather than for stock. The production system requires high skilled operators and high investment.

Plant layout:

The company follows Functional or Process Layout where the machines and equipments performing similar operations are grouped together in the same department.

Material Handling:

Material Handling refers to the movement and storage of materials effectively with minimum effort, Maximum safety and in the shortest Time. The material handling equipment used by the company is Forklift Truck. If mounted on the truck they can move the goods from one location to another. They also use crane to load and unload goods from the container or Lorries.

Safety Measures:

To prevent accident and health hazards, the workers are provided with goggles, gloves, exhaust fan, apron, ear plug, shoes, and first aid, mask and fire securities

Cleanliness:

To maintain cleanliness and avoid dust the firm follows a dust clearing mechanism with the use of exhaust fans and water spraying

Water Treatment:

(16)Water treatment plant is installed in the company to recycle the used water and again use it in the process of production. Thats how they save water.

GRANITES USED IN PRODUCTION;

BLACK MATERIALS

Black

Black - E

Black Galaxy

Regal Black

IMPORT MATERIALS

Amadeus

Balmoral Red

Butterfly Blue

Emerald Pearl

Karin Grey

Lanhelin

GREY MATERIALS

Colombo Juparana

Mudugal Grey

Sadahalli Grey

Wavy Mist

Sira Grey

RED MATERIALS

Himalayan Blue Red

Indian Aurora

Indian Juparana

Lillet

Mapple Red

Paradiso

(17)Raw Silk

Red Multi

Red Samuka

Romantica

Ruby Red

Twilight Red

GREEN MATERIALS

Classic Green

Hassan Green

Kerala Green

Kuppam Green

Mint Green

Soft Green

Star Green

Orissa Green

WHITE MATERIALS

Imperial White

Kashmir White

M.P. White

Mist White

BLUE MATERIALS

Lavendar Blue

Lavendar Light

Ocean Blue

Osiris

Silk Blue

Vizag Blue

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YELLOW MATERIALS

Madurai Gold

Millenium Cream

T.L.Yellow

Vyara Gold

Yellow Clouds

BROWN MATERIALS

Cats Eye Brown

English Teak

Indian Mahogany

Sapphire Brown

Tan Brown

SAND STONE

Rainbow

Teakwood

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FUNCTIONS OF PRODUCTION DEPARTMENT

1. Procurement of required colour of rough Granite Blocks

As per the customers order specific type, size and color of granite is chosen by the production department and they start producing the product with the help of man and machine. Materials movement and handling are done with the help of crane and forklift.

2. Plan Production Capacity

Production management must select the right production capacity to match the demand for the product. This is because more or less capacity will create problems. The production manager must plan the capacity for both short and long term's production. He must use break-even analysis for capacity planning.

3. Production Planning

Production manager main function and responsibility is production planning. Here, the production manager decides about the routing and scheduling.

Routing and scheduling are planned by the following mangers with the help of their subordinates

Deputy Manager Primary Cutting

Deputy Manager Edge Cutting

Deputy Manger Polishing

Deputy Manger Quality Control

Deputy Manager Packing

And every Deputy Managers have some subordinates depends upon their work load who may call supervisors and in-charges.

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5. Production Control

The manager has to monitor and control the production. He has to find out whether the actual production is done as per plans or not. He has to compare actual production with the plans and finds out the deviations. He then takes necessary steps to correct these deviations.

6. Quality and Cost Control

Production manager also includes quality and cost control. Quality and Cost Control are given a lot of importance in today's competitive world. Customers all over the world want good-quality products at cheapest prices. To satisfy this demand of consumers, the production manager must continuously improve the quality of his products. Along with this, he must also take essential steps to reduce the cost of his products. They inspect the quality of the product; reject the damaged or defected product for rework.

7. Inventory Control

The production manager must monitor the level of inventories. There must be neither over stocking nor under stocking of inventories. If there is an overstocking, then the working capital will be blocked, and the materials may be spoiled, wasted or misused. If there is an under stocking, then production will not take place as per schedule, and deliveries will be affected.

The company follows Just in Time Inventory Control its an inventory strategy that companies employ to increase efficiency and decrease waste by receiving goods only as they are needed in the production process, thereby reducing inventory costs.

Just-in-time manufacturing goes hand in hand with concepts such as Kanban, continuous improvement and total quality management (TQM)

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THE MONUMENT MANUFACTURING PROCESS

The granite procured by the Purchase department is ready for further monument process. The large blocks of granite are sawn to smaller pieces by cutting machines depends upon their sizes. This saw can be adjusted to cut in many different thicknesses.

For the monument industry the typical thicknesses are four, six, eight, ten and twelve inches. If once these slabs are cut, they need more detailed cuts as required by designs; a diamond wire saw is used to cut specific shapes. The granite is then separated into categories of granite quality and purposes. Some granite is allocated for uses such as street curbing, architectural and monumental uses.

The next stage is smoothing or polishing the stone. This process consists of buffing and grinding the stone with large machinery and water. It requires many stages before it shows the glossy shine that we see on many memorials. An unpolished (steeled) stone also needs to be taken through this process in order to smooth it down, but it would not go through as many levels of the grinding and buffing stages. The stones are then cut into the proper shape. There, they pass under polishing heads which begin with very coarse diamond abrasives, and then move to finer and finer grit abrasives until polished.

What many people don't know is when granite is in its natural form, it does not have the colorful huesthat one see in the finished product. Only when this step is completed are the reds, blacks, blues etc. are visible. Then there is a final buffing, which make the piece glossy and show its luster.

Next, they add the designs and engraving to the stones. A drawing needs to be made beforehand of where everything will go on the stone. This is often done on computers now, but some are still done using architectural tools. This is then approved by the customer to guarantee accuracy. The design can then be put on the stone using sandblasters, lasers or hand carving tools depending on the design.

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Some designs are too intricate to use sandblasters and therefore must be hand-carved by quality craftsmen. These sculptures can take many man hours depending on the intricacy of the design. For the designs that are able to be sandblasted, a rubber stencil is made of the design. This stencil is attached to the stone using a light adhesive. The letters and design parts are peeled off and a sandblaster is used to penetrate the stone and create the depth and shadowing of the letters and design.

The immense and heavy product still needs to be washed, crated, transported and delivered to the cemetery plot. Since the granite weighs hundreds and even thousands of pounds sometimes, it must be handled using cranes and dollies. Even though it is heavy, it is also delicate and needs to be handled with care. The monument is now ready to be installed, but before it can be installed, a foundation must be dug and built days in advance so that the cement is solid to eliminate sinking and tipping. This is generally done by the cemetery. It is at this point of setting the stone when porcelain portraits and any other additional features like display cases, vases and vigil lights may be installed.

This lengthy process starts with a raw material and ends in a beautiful work of art. It is also a dangerous process that includes jagged rocks, deep quarries, hazardous dust and heavy lifting.

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1. MAIN CUTTING

In this process, the raw granite block is cut into many slabs of different thickness using diamond saw blade. A total mass is cut into lot of small slabs. The manufacturing process begins by sawing the rough granite blocks into slabs that are 6 to 12 inches thick. This is accomplished by utilizing diamond rotary saws with blades up to 11 feet in diameter and containing 140 or more industrial diamond segments. These saws, using tons of water as a coolant, cut the rough granite blocks at an average rate of 25 square feet per hour.

2. EDGE CUTTING

In this process, the irregular slabs obtained from the previous process are cut to the required regular sizes taking into consideration of allowances and minor defects. Manual Edge Cutting machine is the unique equipment for accurate dimension and specification, including straight and smooth edge with flexible movement of blade. With combination structure, rotatable cutting head, the cutting head of main drive in Manual Edge Cutting Machine can rotate 45 degrees, and oil-immersed sealed rails, the great strength and high efficiency of the Special-Shaped Edge Cutting Machine makes it possible to process various granite edges. The Manual Edge Cutting Machine is compact in structure and applicable for edge trimming and chamfering of small slabs, slab bars and thick slabs.

3. DRY CUTTING

Granite blocks after primary cutting and edge cutting then goes to Dry Cutting department. This section takes care of drafting the final design of the products as per orders. In this process some skilled labours takes care of the process with help of some man handling machinery.

4. CARVING

This functions subsidiary one of dry cutting, this process take care of very special designs through carving. This is also called as sculpturing work.

The unit manufactures mainly monuments which involve numerous shapes. In making these shapes, process of Carving is involved.

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5. POLISHING

In this process, the sawn and carved slab is polished to obtain mirror polish by using different grades of diamond abrasives.

a). MACHINE POLISH

In this process the slabs are polished on surfaces and sides to the based on design and sizes of the monuments. The company had well trained employees for doing this. This is a process semi machinery work. Each employee runs one machine for polish.

b). HAND POLISH

In this process, the intricate/inner sides of the slab, which cant be polished on a polishing machine are polished using a hand-held machine fitted with tools.

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EXIM DEPARTMENT

3.3 EXIM Department

As the company is mainly engaged in export business, the role of EXIM department is vital in carrying out various activities that are crucial for its survival. The import/export manager must be aware of the import/export laws and procedures, and their role required within the organization, in which the role can have emphasis on any or all of the following aspects: sales, purchasing and buying, finance, legal, administration.

Duties of EXIM Manager

Shipping activities:

The EXIM department manages the movement of products/equipment/materials in and/or out of the country in accordance with organizational policy and procedure, and to comply with relevant local, country and international law and process.

Prepare documents:

The necessary documents are prepared by the EXIM manager with the help of his subordinates. Online forms are also filled for the efficient, cost-effective and lawful execution of all import/export activities. The documents prepared by the department includes

Shipping schedules

Letter of Credit

Licenses

Declarations

(26)Packing

Transport and safety documents

The documents must be prepared timely with error.

Secure information:

The department collects information related to changes in Government laws, policies, procedure, tariffs, duties, Licenses etc. related to export and import, share with colleagues as appropriate, personal knowledge of all relevant import/export law and procedures; tariffs and duties; licenses and restrictions will help the company to sustain in the market. Maintain personal ability in, and appropriate use of, all relevant ICT (Information & Communications Technology) and other systems within the import/export function.

Foreign Exchange:

EXIM Department manages the financial and currency processes and transactions in accordance with policy and law, and to optimize cost-effectiveness of activities.

Liaise:

Manager is the liaison link between the top management and external authorities. The department Communicates with export and import and related authorities, and customers and suppliers, Government, shipping authorities in all relevant territories and countries, as necessary to ensure efficient, positive and lawful relations, support and activities.

The department Manage/liaise with stock control, warehousing and distribution activities influenced by or reliant upon import/export activities. Manager manages all staff reporting to the position so as to effectively recruit, train, evaluate, motivate, delegate and monitor their activities.

The EXIM Department integrates with all departments mainly accounts, purchase and marketing department to carry out the business activities smoothly.

Forecast:

The manager anticipate research and report on future changes in import/export laws and in relevant local territory practices, and ensure such knowledge is factored into the planning of the department's own strategy, resources and procedures.

Monitor, record, analyze and report on activities, trends, results and recommendations relating to import/export activities.

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Plans and Implement:

The manager plans and implement import/export strategy and activities consistent with overall aims and requirements of the organization. Investigate, plan and implement strategically effective and relevant transport methods, which meet optimally the needs of the organization and its suppliers and customers.

He Plans and manage the effective and necessary conversion of weights, sizes, values, and quality standards interpretations between importing and exporting systems and territories.

Insurance:

Maintain effective and lawful insurance provisions relating to import/export activities.

Communication:

The department Negotiate contracts for sales/purchases and manage renew, review contracts as required to enable effective trading, operations and customer/supplier relations.

Also manages language and communications translation issues and activities as necessary to enable effective relations, distribution and integration of imported/exported material, product, equipment within the supply chain of importer and exporter, (for example handling instructions, operating manuals, etc).

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MARKETING DEPARTMENT

3.4 MARKETING DEPARTMENT

Hierarchy

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MARKETING DEPARTMENT:

Marketingiscommunicatingthe value of a product, service or brand tocustomers, for the purpose of promoting or selling that product, service, or brand.

Memorials and sculptures of different designs, structure, shapes and sizes are produced according to the customer needs.

Pricing, packing and logistics are the main activities carried out by the marketing department.

The managing director travel oversees to find customers around the world.

The demand for the product is constant as death is inevitable.

The company follows relationship marketing by building long term mutually satisfying relations with key parties- customers, suppliers, agents, bankers etc

They use mail communication to connect with their customers around the globe.

CUSTOMERS:

Their main customers are from UK, New Zealand, Ireland, France, Germany, Europe and USA.

COMPETITORS:

A Blue hill Granites (India) Pvt Ltd, Arkay Glen Rock Pvt. Ltd., Himalaya Granites Ltd., Selva Stones, Wonder Granites Private Limited, SVG Exports Private Limited etc.

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PRODUCTS

Sculptures - theartofcarving,modeling,welding,orotherwiseproducingfigurativeorabstractworksofartinthree or fourdimensions.

Memorials - a statue or structure established to remind people of a person or event

PACKAGING: Once the products are ready for shipment, they are packed very carefully by covering the bubble sheet then by wooden crates. Quality control persons also monitor the method of packing.

LABELLING: The labels are pasted with the companys seal on the packages that contains information about product or seller. The companys label consists of the type of granite, company seal, serial number, recipient details.

DESIGN: Customer determines the design, size, quality, quantity, shapes and colour of the granite required by them.

PRICE

Granite Monument industry is different from other industries. Prices are different for each and every pieces of monument as it depends upon the design, size and colour. So they first receive the order then the manager works price for the monuments depending upon the design, size, colour and special works involved in the production. Both the parties confirm price before the sculpture or memorial is produced.

PROMOTION

The company follows direct marketing where there are no Intermediaries involved in promotional activities. The MD travels overseas to find customers and get orders.

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PHYSICAL DISTRIBUTION

The company loads the finished goods into the containers and sends it to Tuticorin Port for shipment. It has customers from USA, UK, Germany, Ireland, France, Australia and New Zealand. They have competitors around the world.

TARGET CUSTOMERS

Target customers of Arkay Rock Produce are who make funeral arrangements, business firms, etc

DISTRIBUTION CHANNEL

Production is for consumption. Having produced the products these need to be made available to the final users of the product i.e. the consumers scattered in large geographical areas.. Network or distribution channel is the process or steps undertaken by the firm, which includes the movement of finished goods from production point to the consumption that is to the final consumers. Since its inception Madurai Arkay Rock Produce follows the direct marketing.

LOGISTICS:

(32)The sized blocks are carried from the suppliers place or from port through Lorries or containers. The finished products are sent through containers to port to be shipped in case of exports.

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FINANCE DEPARTMENT

3.5 FINANCE DEPARTMENT:

(33)Hierarchy

Finance Team

Finance Team is headed by a manager who is in charge of the deputy mangers and a team of accounts executives. The duty of accountants is to prepare spending reports, wages and expense accounts for different departments. These executives report back to the Accounts manager so that he may use the information to ensure that no one is using departmental funds inappropriately and that all applicable laws are not being violated. The information will be integral when the accounts manager submits his annual report.

Functions of Finance Managers

Finance Manager is one of the members of the top management team, and his or her role, day-by-day, is becoming more pervasive, intensive and significant in solving the complex funds management problems.

Allocate Resources

Managers may allocate resources to each department according to their needs and requirement to carry out smooth functioning of business activities without delay.

Reporting of Financial Transactions

Finance Managers are in charge of reporting to the government authorities and the companys top management regarding financial activities in the company.

Finance managers prepare account statements, profit and Loss statement and balance sheet to take crucial investment decision, to know the fair position of the company and to submit such statements to the government. The manager must carefully prepare them and avoid errors which could lead to fines against the business.

Finance managers compile spending reports from supervisors and others for budget review meetings. These meetings may include monthly budget updates, quarterly meetings and yearly reviews. Such reports are important for taking crucial decisions.

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Budget preparation

Finance managers are in charge of overseeing and employing company's operating expense, which includes analyzing the spending pattern in various departments to determine the companys worthiness to meet its financial goals. His role is important in determining the financial needs in future. Mangers prepares monthly and yearly budget and reviews it.

Asses Risks

The Finance managers assess the risk factors involved in the transaction. The companys financial risk management policy seeks to ensure that adequate financial resources are available for the development of the Companys Business whilst managing its risks. The company operates within clearly defined guidelines that are approved by the Board and the Company Policy is not engage in the speculative transactions.

The main areas of financial risk, faced by the company are as follows:

a) Foreign Currency Risk

The company is exposed to foreign currency risk as a result of its normal trading activities where the currency denominations differ from the local currency.

b) Credit Risk

The credit risk is controlled by monitoring procedures and by internal credit review where credit risk is material.

c) Liquidity & Cash Flow Risks

The company ensures that there are adequate funds to meet all their obligations in a timely and cost effective manner.

d) Interest Rate Risk

The companys interest rate exposure arises principally from borrowings. The interest rate risk is managed through the use of fixed and floating rate financial instruments.

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Other functions of Finance Team

All Banking activities like Monetary Transaction and Normal Banking activities are carried out by the finance team

In case of Long Term Expansion the Finance Department helps the organization in arranging a Term Loan.

The creditors payments are calculated and notifications are sent to them.

The Collection from the Debtors are calculated and collected.

Duties like Central Excise, Sales & Income Tax and Insurance are calculated and paid to the Government at the proper time and date.

Custody and safeguarding of Securities, Insurance Policies and other Valuable Papers.

Record keeping and reporting

Software used

Tally is the software used by the company to record and process all the transactions happening in the company.

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HUMAN RESOURCE

DEPARTMENT

3.6 HUMAN RESOURCE DEPARTMENT

Human Resource Managementis the process of recruitment, selection of employee, providing proper orientation and induction, providing proper training and the developing skills, assessment of employee (performance of appraisal), providing proper compensation and benefits, motivating, maintaining proper relations with labour, maintaining employees safety, welfare and health by complying with labour laws of concern state or country. HR executive sees to that all the HRM activities are carried out in accordance with the government and companys policies. He acts as a bridge between the top management and the employees. He also plays a vital role in solving disputes and providing fair compensation to the employees.

HR POLICIES

No child Labour.

No female employees.

Local labour is mostly preferred.

Selection is based on skill, experience, educational qualification and values.

Training is given at all levels.

Promotion is on the basis of merit.

Salary is paid on 7th of every month.

Workers work on 3 Shifts.

Sunday is a Holiday.

JOB DESCRIPTION

The Human Resource Manager determines the job description for each class of work after thorough analysis of Job. He determines the roles, responsibilities, Specification of skill, educational qualification, and salary range of each position at work.

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RECRUITMENT

Recruitment refers to the overall process of attracting, selecting and appointing suitable candidates for the job in an organisation. The entire process of recruitment is monitored by Personnel manager; his duties consist of job posting, hiring, conducting test and interviews.

Recruitment Process:

The HR manager identifies the need for recruitment, vacancy and gets into the process of Recruitment after MDs approval. Identifying the Vacancy in the recruitment process begins with the receipt of requisition for recruitment from different departments.

Sources of Recruitment

The sources within the organization itself to fill a position are known as the internal sources of recruitment. Recruitment of candidates from all the other sources is known as the external sources of recruitment.

a) Internal sources:

Promotion: The employees are promoted from one department to another with more benefits and greater responsibility based on efficiency and experience

Employee referrals: employees can refer their friends and relatives for some position in their organization and the Management select suitable candidate for the job.

b) External sources:

Educational institutions: Various management institutes, engineering colleges, medical Colleges etc. are a good source of recruitment. Well qualified executives, engineers, can be selected by conducting test and interviews.

Labour Contractors: Machine operators are recruited through contractors who maintain close contacts with the sources of such workers.

Unsolicited Applicants: Job seekers who send their requests for appointment against a vacancy are appointed.

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SELECTION

Selection is the process of picking up individuals (out of the pool of job applicants) with requisite qualifications and competence to fill jobs in the organization. The selection process is as follows;

Application scrutiny: The application that consists of personal, educational information can be screened to weed out unqualified candidate for the job

Selection test: Cognitive ability tests are conducted to assess abilities involved in thinking (e.g., reasoning, perception, memory, verbal and mathematical ability, and problem solving).

Interview: one to one interview is conducted by the HR manager and the department managers to select a candidate

Reference Check: Reference checks and background checks are conducted to verify the information provided by the candidates. Reference checks can be through formal letters, telephone conversations.

MD Approval : If a person gets through all the above his selection decision is made with the MDs approval

Issue the Appointment Letter: Job offer to those applicants who have crossed all the previous hurdles. It is made by way of letter of appointment.

Joining formalities: Contract of employment is signed.

Personnel File Creation: Details about the employees are stored in the companys database.

TRAINING

(39)Training is given at all levels of employment. Both On the Job and Off the Job training are given to the employees. On the Job training is given by the superiors. Off the Job training are given by experts in the form of lectures when new technology is introduced. Induction and orientation are the initial periods of training, wherein the employees get to know about the work culture of the company.

MOTIVATION AND PERFORMANCE APPRAISAL

Motivation triggers the performance of an employee. The Personnel manager conducts sessions and lectures that keep the employees aware about the growing competition in the market and the need to constantly upgrade the skills of the employees.

The performance of employees is constantly monitored over a monthly or yearly basis by their superiors. Rewards, gifts, and prizes are distributed for exceptional performances, at the time of AYUDHA POOJA celebrations.

SALARY AND PAYROLL NEGOTIATIONS

Payroll is prepared by the HR department that contains the list of employees and the amount of money they are to be paid. Any issues related to salary and payroll is handled by the HR manager in collaboration with Finance Department as he is more aware about the ability, experience, and skills of the employee. Salary is paid to the employees on 7th of every month. Salary is credited to the employees bank account.

EMPLOYEE SATISFACTION AND FEEDBACK

HR manager handles important matters related to employee satisfaction and any issues that are causing unrest among the employees. Manager tries to solve it smoothly.

HR accepts feedback from the employees and this leads to an efficient management of the workers.EDUCATIONAL REQUIREMENTS

A graduate level degree in labour laws, social sciences, human resources, and industrial laws is considered for entry-level jobs in the firm. Fair amount of work experience is also considered before hiring. A master's degree or an MBA in this field with 3-6 years of professional experience are eligible for senior level positions. Courses related to humanities, like public administration, psychology, sociology, political science, and economics are also considered by the firm. Diploma in IT, B.E, even Certificate courses in Auto CAD also accepted for CAD Designing department. Local Labours are trained and used to operate machines.

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EXIT INTERVIEW

The exit interview is not required by law, but the company uses it as a means of determining reasons for losing employees. It is conducted by the HR Manager, at this time; the personnel manager explains rights regarding issues such as health insurance, settlement of accounts. The personnel manager also asks questions regarding working experience with the company.

EMPLOYEE BENEFITS

I. Security Payments

HR department monitors Employers contributions to old age, pension, survivor, disability, health and unemployment insurance, Payments as per the Workmens Compensation Act, accident insurance, Retirement benefits such as pension, provident fund and gratuity payments, Contributions to health and welfare funds etc.

II. Payments for Time not Worked

Rest Period: Normally Rest period known as Coffee break is allowed to employee to allow them to relax.

Holidays: There will be weekly holiday i.e. Sunday as per factories Act 1948. When a worker comes to duty even on a weekly holiday, he will be given a compensatory holiday. Besides, certain days in the year are stipulated as paid holidays.

Sick Leave: Sick Leave is given to employees for certain number of days in a year say 15 days a year. Employees during their illness can avail such leave with full pay.

On Duty Pay: Employees may not be involved in work actually but will undergo training for which pay will be given.

III. Monetary Benefits

Monetary benefits such as Bonus, incentives and allowance like Food Allowances, Overtime Allowances, Transport Allowances, and Educational Allowances are paid to their employees.

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IV. Awards

Awards are given at the time of AYUTHA POOJA celebration like safety awards, Suggestion awards etc.

V. Health Benefits

Various health benefits are provided by organizations not only to its employees but also to their family members. The various health benefits are provided under Employee State Insurance Act, 1948. Benefits under the Act include the following;

Sickness Benefits.

Disablement Benefits.

Dependents Benefits.

Medical Benefits.

VI. Welfare and Recreational Facilities

Canteen, accommodations, employee Counseling, uniform are some of the other welfare activities provided by the company.

OTHER IMPORTANT DUTIES OF HR MANAGER

Job Posting.

Talent Management.

Office Time Management.

Payroll, Benefit and Compensation management.

Safety Policy implementation.

Statutory Activities.

Liaison with Government.

Query and grievance handling of the employees.

Participating and Discussing with Management regarding the new policies.

Monthly updating of the Leave records of all the Employees on the Biometric System. & follow up for the Leave applications with the Employees.

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MAINTENANCE DEPARTMENT

3.7 MAINTENANCE DEPARTMENT

Hierarchy

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MAINTENANCE DEPARTMENT

The maintenance department takes care of all machineries either electrical or mechanical. There are two separate teams in the company to ensure smooth running of machines i.e. Mechanical Team and Electrical Team. They carry out predictive and preventive maintenance strategies.

Maintenance engineers Job description

Maintenance engineers are responsible for the continuous running of equipment and machinery. They use computerized systems to oversee routine maintenance and organize repairs.

Electrical Engineers Job Description

Electrical engineers design, develop and maintain electrical control systems and/or components to required specifications, focusing on economy, safety, reliability, quality and sustainability.

Objectives of Plant Maintenance

To maximize the amount of time the assets will be available for use for the purpose for which these were procured.

To plan and schedule maintenance work so as to anticipate and prevent interruptions in operations.

To preserve the value of assets by reducing the rate at which they deteriorate.

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Functions of Maintenance department

They inspect the machines and equipment regularly.

They do the fitting, erection, repair, lubrication and overhaul work.

They Design maintenance strategies, procedures and methods;

Asses the capacity of machines and maintain it accordingly.

They Carry out routine scheduled maintenance work and responding to equipment faults;

They Diagnose breakdown.

Arranging specialist procurement of fixtures, fittings or components;

They safeguard and Control the maintenance tools, stores and equipment;

Maintenance costs is monitored and controlled by them.

They must be prepared to deal with emergencies, unplanned problems and repairs;

They work to Improve health and safety policies and procedures;

They must identify or design new systems that makes the work better;

Reading design specifications and technical drawings are done by them.

They Research suitable solutions and estimate costs and timescales.

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48

DESIGN DEPARTMENT

3.8 DESIGN DEPARTMENT:

Design department is where the product takes shapes based on the specifications given by the customers. This department receives orders from the customer and the design is drawn in templates with the help of AUTO CAD by engineering professionals. The customers may prefer a catalogue model or they may send a customized detail regarding the shape, size, design, letter design etc. once the template is done it is sent to the customers for approval. If they get the approval they will proceed on to the next work. Some of their CAD Templates;

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ADMINISTRATION

3.9 ADMINISTRATION

Role of senior administration manager

Supervise and manage all day-to-day office administrative activities.

Vendor Management & Office Administration (Adequacy of Stationary / Provisions / Refreshments / adequacy of Sub Staff) Courier & Dispatch (Inward / Outward / Outstation) / also making record of local maintaining.

Co-ordination and maintenance of systems related to Housekeeping.

Managing vendors and keeping track of cycle of all maintenance contracts and AMCs.

Keeping records of Visiting Cards, Utility Payments, Printing of Stationary.

Maintaining record of AMC (Computers, AC, Cars, Pest Control, and Insurance) & taking care of corporate office & Branch Office.

Update the Assets List of the company.

Handling complete Facilities and infrastructure of office and liaising with contractors and interiors for the same.

Liaison with external agencies (police / municipalities / corporation / premise security agencies / Premises Co-op Society) and government bodies.

Coordinate with Travel Agencies for Airlines & Railway bookings, Hotel bookings & Car arrangements for employees & guest.

.

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51

CHAPTER 4

OBSERVATIONS, SUGGESTIONS

AND CONCLUSION

4.1 OBSERVATIONS

They carry out intermittent manufacturing system as they produce products based on customers order and not for stock.

They machines are arranged in process layout.

JUST IN TIME, inventory control method is followed.

The plant location is suitable for cheap labour and procurement of raw materials as there are many quarrys in and around Madurai.

The working environment is kept clean and neat, free from dust and wastes

The tools, equipments and machines are stationed in a uniform order.

Employees strictly adhere to the safety measures by wearing masks, gloves, coats, goggles, ear plug while they work.

Preventive and predictive maintenance is carried out by the maintenance department.

Workers are on time at their workplace. Biometric system is used for attendance purpose.

Workers work on 3 shifts so the employees are not overloaded or exhausted.

Direct marketing is carried out by the company.

They use water treatment plants to recycle the used water to avoid wastage.

There is less social interaction among the employees during working hours.

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4.2 SUGGESTIONS:

Job rotation for machine operators can be given, to relieve them from doing monotonous job for a long time which may result in Job dissatisfaction.

Grievance addressal system can be implemented to make the employees feel that they are cared by their employer.

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4.3 CONCLUSION:

Sculpturing is an art which has been in the veins and blood of the Indian Culture from the ancient times. Being a part of a company which belongs to monument industry is a something to learn about as it involves lot of focus, thought process and its a continuously evolving industry with the development in technology and demands. The summer training report is believed to have portrayed the functioning of various department of Madurai Arkay Rock Produce (P) Ltd.

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Receive orders

CAD drawing

Template

Cutting

Polishing

Insurance

Letter of credit / payment

Packing , labeling

Inspection

Shipment

MD

Production manager

EXIM manager

Finance manager

Marketing Executives

HR Executive

CAD

Deputy manager

Supervisor

In Charge

Operators

Deputy manager

Supervisor

In Charge

Operators

Deputy manager

Accountant

Deputy manager

Supervisor

In charge

Maintenance Engineers

Electrical Engineers

MechanicalEngineers

Fitters , Technicians

Fitters , Technicians

Purchase Manager

Deputy manager

Subordinates

Purchase Manager

Deputy Manager

Subordinates

Production Manager

Deputy Managers

Supervisors

In Charge

Operators

Main Cutting

Edge Cutting

Dry Cutting

Carving

Polishing

Marketing executive

Pricing

Packaging

Logistics

Subordinates

Subordinates

Manufacturer

Customers

Finance Managers

Deputy Managers

Accountants

Maintenance Engineers

Electrical Engineers

Fitters , Technicians

Mechanical Engineers

Fitters , Technicians

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