Organizational Structure

S.D.M. Institute of Information Science BBA/BCA College, HUBLI - 24

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GOVT. FIRST GRADE COLLEGE RAJNAGAR

HUBLI

ORGANIZATIONAL STUDY

UNDER TAKEN BY, FLOWSERVE MICROFINISH PVT. LTD. HUBLI – 30

SUBMITTED BYSHILPA.B.RAYANAGOUDAR

REG NO.09B10121

INSTITRUTE GUIDEMADWESH MUGALIHAL

GOVT. FIRST GRADE COLLEGE RAJNAGAR HUBLI.

INDUSTRY GUIDEMR.NISHANTH.R.LALKA

Organizational StudiesUnder Taken By, Flowserve Microfinish Pvt. Ltd. HUBLI - 30

DECLARTION

I MISS.SHILPA. B.RAYANAGOUDAR here by declare that

project titled “ORGANISATIONAL STUDIES” at Flowserve Microfin-

ish Pvt. Ltd. HUBLI - 30. Is submitted by me under the guidance of

Prof. MADWESH MUGALIHALthe PROF of GOVT FIRST GRADE

COLLEGE. Institute of Information Science BBA/BCA College,

HUBLI – 32 is my original work and is not submitted elsewhere for

award of any degree.

The matter in this report is based on the data collected by me at

“FLOWSERVE MICROFINISH” under the guidance of MR.NIS-

HANTH.R.LALKA

Date: 20/01/2011 MISS.SHILPA B RAYANAGOUDAR

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Place: Hubli B.B.A III Semester


ACKNOWLEDGEMENT

THE ATTITUDE BLISS AND EMPHASIS THAT ACCOMPANIES THE SUCCESSFUL COMPLETION OF OUR TASK WOULD BE INCOMPLETE WITHOUT THE EXPRESSION OF APPRECIATION TOWARDS THOSE WHO HAVE RENDERED HELP AND GUIDANCE THROUGH OUT THE PROJECT WORK.

WE OWE A SPECIAL DEBT OF GRATITUDE TO MR.DEEPAK.VIKAMSI. THE PROJECT COORDINATOR WHO HAS BEEN KIND ENOUGH TO PERMIT US TO TAKE UP THE PROJECT WORK AT “FLOWSERVE MICROFINISH PVT. LTD.” AT THE VERY OUTSET, I THANK FLOWSERVE MICROFINISH PVT, HUBLI. FOR THEIR INVALUABLE HELP & SUPPORT. CANDIDLY IT INSPIRED ME TO TAKE UP THIS PROJECT, THANKS TO MORAL SUPPORT FROM MY EXTERNAL PROJECT GUIDE MR.NISHANTH.R.LALKA, SHE HAS BEEN A REAL GUIDING FORCE.

NONETHELESS I AM ALSO GRATEFUL TO THE PROFOF GOVT.FIRST GRADE COLLEGE RAJ NAGAR HUBLI “PROF.MADWESH MUGALIHAL” COLLEGE OF B.B.A FOR GIVING US OPPORTUNITY, AND OUR GRATITUDE WILL NOT BE COMPLETE IF WE DO NOT THANK THE ALMIGHTY GOD & OUR LOVING PARENTS WHO HAVE BEEN SUPPORTIVE THROUGHOUT THE PROJECT.

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PREFACE

This project report of the IN-PLANT TRAINING done in FLOWSERVE MICROFINISH Pvt. Ltd. HUBLI includes the in-depth study of orga-nizational structure and departmental organizing and functioning.

This project is made according to the direction and guidelines of KARNATAKA UNIVERSITY, DHARWAD.

I tried my best to accomplish this task sincerely and honestly by giving my best efforts to analyze and describe my work according to the guidelines and criteria given by the university.

Even after this if any kind of negligence occurs or appears then I sincerely oblige for……….

JANUARY 2010 2011

MISS. SHILPA .B.

RAYANGOUDAR


CONTENTS

1. Industry Profile_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _5

2. Company Profile _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 7

3. Product Details _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _8

4. Vision, Mission & Policy _ _ _ _ _ _ _ _ _ _ _ _ 12

5. 7’s Models _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 14

6. Organizational Structure _ _ _ _ _ _ _ _ _ _ _ _17

7. Different Departments

a. Sales & Shipping _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 18

b. Planning & Purchasing _ _ _ _ _ _ _ _ _ _ _ _19

c. Production & Assembling_ _ _ _ _ _ _ _ _ _ _20

d. Stores_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _29

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e. Quality Assurance_ _ _ _ _ _ _ _ _ _ _ _ _ _ _30

f. Administration & Accounts _ _ _ _ _ _ _ _ _ _31

g. Human Resources _ _ _ _ _ _ _ _ _ _ _ _ _ _ _39

8. SWOT Analysis _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _40

9. Conclusion _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 41

10. Learning Experience _ _ _ _ _ _ _ _ _ _ _ _ _ _ _42

11. Bibliography _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 43


Industry Profile_ _ _ _ _

Microfinish was set up in the year 1971 by Thilak Vikamshi. The Microfinish is manufac-

turing a industrial pumps and valves. Microfinish is known for its quality product and has got

certificate of ISO 9001. In 1998 Flowserve Pvt. Ltd. of USA came to India by entering into a

joint venture with a Microfinish of Hubli. As Microfinish is known for its quality product

world wide, the Flowserve Corporation made a technical collaboration with the Microfinish

valves. Flowserve Pvt. Ltd. came to India and gave technical and management training to the

employees of the Microfinish in the year 1996 and commercialized its business in the year

1998. The training they gave was of high standard and then later Microfinish of Hubli was

able to produce spare parts of high quality. Flowserve Pvt. Ltd. inspected the spare parts,

which came out to be more than their expectation. Later Microfinish started its separate 100%

exporting unit and came to be known as a Flowserve Microfinish Pvt. Ltd. Hubli. Now the

Flowserve Microfinish Pvt. Ltd. exports to more than 15 countries to name few,

1. USA 5. SOUTH AFRICA 9. AUSTRALIA

2. U. K. 6. TIAWAN 10. HONGKONG

3. GERMANY 7. BELGIUM 11. KOREA

4. BRAZIL 8. MEXICA 12. SINGAPORE

Values & Pumps Industry

A valve is a device that regulates the flow of fluids (either gases, fluidized solids, slurries or

liquids) by opening, closing, or partially obstructing, various passageways. Valves are used in

a variety of applications including industrial, military, commercial, residential, transportation,

etc. They are mainly used for safety purposes in steam engines and domestic heating or cook-

ing appliances. Others are used in a controlled way in Otto cycle engines driven by a

camshaft, and they have a major part in engine cycle control. A Pump is a device that man-

ages the needs of fluids (gases, fluidized solids, slurries or liquids) by pumping. Pumps are

used in a variety of applications including industrial, military, commercial, residential, trans-

portation, etc.

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Business Environment of the Industry

Indian market for Industrial Pumps and Systems has been a mature market since years. India

has been a reliable, technically competent, competitive and enterprising outsourcing option

for many multinational companies in the field of industrial Pumps and Systems for outsourc-

ing to countries such as USA, Germany and Holland.

Pumps.

Systems.

Pump Components and sub-assemblies

Cast and machined, fabricated and finished, molded, customized and/or mass-pro-

duced.

Basic and Applied research and analysis employing also CFD techniques.

A Valves & Pumps industry deals with Business Marketing. They are widely used in chemi-

cal & process industries, refineries, petrochemicals & fertilizer plant, pharmaceuticals, oil ex-

ploration, thermal & nuclear plants, food & beverage industries, effluent treatment & sewer-

age plants, water treatment, cooling water & water supply plants, mining industries etc.

Future of the Industry

Valves & pumps are tremendous growth opportunity in the areas of chemical & process in-

dustries, refineries, petrochemicals & fertilizer plants, pharmaceuticals, oil exploration, ther-

mal & nuclear plants, food & beverage industries, effluent treatment & sewerage plants, wa-

ter treatment, cooling water & water supply plants, mining industries etc.


Company Profile

Name & Address of the Industry Flowserve Microfinish Group of company’s Pvt. Ltd., 568/1, Industrial Area, Gokul Road, HUBLI – 580030. India.

Status of Organization Private Limited (100% EOU)Date of Registration 19th April 1996 CTS no 568/1Date of Commencement 1st June 1998Availability of Communication Facility Telephone, fax, internet, printer, hard copy,

P.O.Cost of Project (Initial Investment) 3 croresExporting Capacity 20000 valves Turn Over Per Year 30 croresApplicable Act 1. factory act

2. provident fund 3. ESI(Employee state insurance)4. bonus act5. payment of gratuity

6. product processing orderBank 1. Canara bank.

2. Bank of India.Email Address [email protected]

[email protected] area 3 ½ acres,

Built up area: 15000 sq. ft.Manpower 76Branches Pumps Pvt. Ltd., and Valves Pvt. Ltd.,Agencies Foreign System Pvt. Ltd. – Germany

Panel Kena – South Africa Uni World Logistics – USExport Freight – Singapore.

Tel & fax no. 2233202, 2332301/ Fax - 08362333205Certificates ISO 9001, ISO 2008 and PED 97/23/EC,

CE MARKING, ILO, API-60, SIL, ASC.Table 2.1: Company Profile.

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mailto:[email protected]

mailto:[email protected]

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Product Details

Introduction of valves:

By definition, valves are mechanical devices specifically designed to direct, start, stop, and

mix or regulate the flow, pressure, or temperature of a process fluid. Valves can be designed

to handle either liquid or gas application.

By nature of their design, function and application, valves come in a wide variety of styles,

sizes and pressure classes. Today’s spectrum of available valves extends from simple water

faucets to control of the process.

Types of valves:

a. Ball valves

b. Globe valves

c. Piston valves

d. Gate valves

e. Plug valves

f. Butterfly valves

g. Diaphragm valves

h. Fire safe valves

i. Cryogenic ball valves

Among these valves Flow Serve Microfinish Valves Private Limited., manufactures only Ball

Valves and Plug valves.

Basic Functions of Valves:

Starting and stopping flow.

Regulating flow volume (frequently called throttling).

Preventing reserve flow (called anti-back down).


Changing flow direction.

Product Component Size Range(mm) Max. Pr. Rating Material of construction

1 BALL VALVE 15-200 to 15-50 #300 to #800 CS/SS

2 PLUG VALVE 15-300 to 150-300 #105 to #300 CS/SS

Table 3.1: Product Description.

Fig 3.1: Ball Valve Fig 3.2: 38 series

Ball

Valve

Fig 3.3: Ball Valve

Fig 3.4: Flanged Ball Valve

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Ball valves:

Ball valves find application mainly as stop valves. As stop valves it has following attributes.

1. It has a smooth, uninterrupted flow when it is open. This enables the ball valve to be

used with slurries, solids suspended in gases or air, and dry powers without concern

for buildup of solids.

2. It is manufactured in wide range of sizes, pressure classes, and materials, sizes range

from half inch to thirty six inch. Ball valves can handle fluid from vacuum to over

2500 psi, and they are available in most types of valves materials: bronze, steel, and

corrosion resistant alloys. They are usually made of CI.

3. It can be used with all fluids, liquids, gases and vapors (including steam), weather

clean or dirty. Fluid temperature is limited only by the materials of construction.

4. Its quarter-turn operation and low required operating force make it preferable for ap-

plication in which frequent operation is required and make it easy to acute.

Drawbacks:

The full port valve is large from end and takes up more pipe line space than does a gate valve

of the same size.

1. With soft seats ball valve has fluid temperature limitation.

2. With metal seat leak free seating cannot be assured and the cost of the valve is higher.

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Fire safe Valve:

Fire safe valve are those valves designed for hydrocarbon services that withstand a direct fire

of 7600C to 9800C for 30 minutes. The through valve seat leakage and external leakages are

well within the limits of standard and such valve are operable even after fire and leakages are

within limits of standard after operation


Vision, Mission & Policy

Vision:

Our vision is to manufacture quality valve products for the process industry worldwide. We

embrace the concept of total quality and people involvement to enhance “TOTAL QUAL-

ITY SATISFACTION” and commit to maintain this standard of excellent through continual

improve and use of quality management system.

Mission:

Our Mission Is To Manufacture Quality Valve Products for the Process Industry World Wide.

Quality Policy:

Quality refers to the degree of perfection as perceived by the user of a product. At Flowserve

Microfinish, the objective of the Quality Assurance department is to maintain a consistent ap-

praisal of the quality of the product at all stages of manufacturing till the product is dis-

patched.

The company’s quality policy is to maintain the same high quality all through for our cus-

tomers worldwide and to adopt higher quality test standards & high grade quality testing tools

& techniques to achieve greater quality all through in future.

Environmental Policy:

Environmental Policy of M/S Flowserve Microfinish Group of Company Pvt. Ltd, is comply-

ing with accepted environmental practice including the commitment to meet applicable legal

and other requirements to strive for continuous improvement in their environmental manage-

ment system and to minimize the creation of waste and pollution through better management

of their process, their materials and their people in order to reduce the environment impacts

associated with their work.

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Top management ensures that the work environment has a positive influence on the perfor-

mance of the personnel in order to enhance the performance of the organization. Considera-

tion is given on:

a. Following the safety rules.

b. Providing adequate lighting facilities.

c. Ensuring the proper air circulation.

d. Maintaining cleanliness at all the areas.


7’s Models

The 7-S-Model is better known as McKinsey 7-S. This is because the two persons who devel-

oped this model, Tom Peters and Robert Waterman, have been consultants at McKinsey &

Co at that time. Thy published their 7-S-Model in their article “Structure Is Not Organiza-

tion” (1980) and in their books “The Art of Japanese Management” (1981) and “In Search of

Excellence” (1982).The model starts on the premise that an organization is not just Structure,

but consists Seven elements with a complex relationship between them.

Fig 5.1: 7’ Model Structure.

For successful implementation of a strategy- large or small the management needs to take ac-

count of all seven factors. They are all interdependent, if one element changes then this will

affect all the rest.

For example, a change in HR-systems like internal career plan and management training will

have an impact on the organizational culture (Management style) and thus will affect struc-

tures, process and finally characteristic competencies of the organization.

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STRUCTURE

SYSTEMS

STYLESKILLS

STRATGEY

SHARED VALUES

STAFF

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STRUCTURE

Organizational structure refers to the relatively more durable organizational arrangements and

relation ships. It prescribes the formal relationships among various positions and activities.

Arrangement about reporting relationships, how an organizational member is to communicate

with other members, what roles he is to perform and what rules and procedures exist to guide

the various activities performed by members are all part of the organizational structure.

It has been observed that at MICTROFLOW there exists both Formal and Informal type of

organizations. The Informal organization exists in the form of social relationship, which is

developed through social interactions between the employees at work place. In the Formal or-

ganization there are well-defined jobs, each bearing a definite measure of authority, responsi-

bility and accountability. The structure is consciously designed to enable the organization

members to work together for the accomplishing common objectives of the company.

SYSTEM

It includes all the processes and information flow that link the organization together, consist-

ing of Production Planning and Control Systems, Cost Accounting Procedures, Capital Bud-

geting Systems, Recruitment, Training and Development Systems, Planning and Budgeting

systems, Performance Evaluation Systems.

SKILLS:

Skills refer to the fact that employees have the skills needed to carryout the company's strat-

egy. Training and Development - ensuring people know how to do their jobs and stay up to

date with the latest techniques.

STYLE:

The style of an organization, according to McKinsey framework refers to the “Reporting Re-

lationship” between the superiors and the subordinates. It also conveys the flow of communi-

cation between them.

Reporting Relationship at micro flow follows a Formal channel. The communication follows

the routes formally laid down in the organization structure and deliberately associates with


the status or the position of the sender and the receiver. Both Downward and Upward com-

munications follow the path of formal channel.

Different organizations practice different decision making style like participative and authori-

tative decision making. At micro flow annual production target is fixed by taking in to con-

sideration of production & planning dept. The decision is taken at participative basis by in-

volving all the concerned employees while fixing the Annual production targets. The employ-

ees are allowed to provide suggestion on all matters such as purchasing machinery, related to

inventory and others. The suggestions are reviewed and if the suggestions are feasible and

profitable the employees are rewarded.

STRATEGY:

a. Waste Elimination.

b. Micro flow has an effective strategy for waste elimination which is as follows accord-

ingly (product wise).

STAFF:

Staffing is the process of acquiring human resources for the organization and assuring that

they have the potential to contribute to the achievements of the organization’s goals.

It includes Selection, Placements, Training and Development of appropriate qualified em-

ployees.

SHARED VALUES

Super ordinate goals refer to a set of values and aspirations that goes beyond the conventional

formal statement of corporate objectives. They are the fundamental ideas around which a

business is built.

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Organizational Structure


MANAGING DIRECTOR

MANAGING DIRECTOR

PLANNING & PURCHASE INCHARGE

PLANNING & PURCHASE INCHARGE

PRODUCTION & ASSEMBLY INCHARGE

PRODUCTION & ASSEMBLY INCHARGE

RECEIVING QUALITY ENGINEER

RECEIVING QUALITY ENGINEER

QUALITY ASSURANCE INCHARGE

QUALITY ASSURANCE INCHARGE

SHIFT I INCHARGE

SHIFT I INCHARGE

SALES & SHIPPING OFFICER

SALES & SHIPPING OFFICER

BOARD OF DIRECTOR

BOARD OF DIRECTOR

ADMINIS-TRATI-ON & ACCOUNTS IN-CHARGE

ASSISTANT ACCOUNTANT

PLANNING & PURCHASE ASSISTANT

STORES OFFI-CER - I

STORES OFFI-CER - II

LOCAL PUR-CHASER

SHIFT II IN-CHARGE

MAIN-TAINENCE IN-CHARGE

ASSEMBLY SUPERVISOR

ASSEMBLY SUPERVISOR

INPROCESS QUALITY EN-GINEER

FINAL PRODUCT ENGINEER

FINAL PRODUCT ENGINEER

DEVELOP-MENT ENGI-NEER

PERSONNEL OFFICER

Different Departments

a. Sales & Shipping

PROCESS MODULE FOR CUSTOMER RELATED PROCESS ENQUIRY HANDLING….

OBJECTIVE:

Is to ensure that both technical , commercial , regulatory, legal aspects of customer related

processes & amendments are reviewed for adequacy, deviation and capability, including re-

quirements of PED 97/27 EC and to ensure that client is aware of his responsibility to provide

any information necessary to carry out & hazard analysis and category evaluation of the

valves as per.

SCOPE:

Applicable to both types of orders, both written as well as verbal.

RESPONSIBILITY:

Manufacturing manager for approval, all functional in charges for review, S&S officers

recording and follow up.

INPUT:

Customer enquiries, order amendments, handling, packing, preservation and delivery instruc-

tions, competency & crane operation, statutory & regulatory guidelines, customer complaints.

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b. Planning & Purchasing

PLANNING DEPARTMENT:

Planning is the backbone of any organization. Success of any organization depends on how

well things are planned. It is a process of chalking out the patch for attaining the ultimate pur-

pose of business undertaking. It is done for usage of resources and to meet the delivery com-

mitment.

TYPES OF PLAN:

a. TENTATIVE PLAN

b. FINAL PLAN

OBJECTIVES:

For usage of resources to meet the delivery commitments.

SCOPE:

Applicable to all work orders & related activity of Dept. with respect to monthly manufactur-

ing plan.

RESPONSIBILITY:


Planning & Purchase In

Sales & Shipping

Planning Assistant

Store Officer I Alloy

Store Officer

Local Pur-chaser

1. Planning & Purchase in charge is responsible for drawing tentative & final “monthly

manufacturing plan” through planning assistant.

2. Production & Assembly in charge is responsible for modifying to meet urgent cus-

tomer requirements.

PURCHASING DEPARTMENT:

OBJECTIVES:

To ensure that all purchase/processed items & services meet the specified requirements.

SCOPE:

Applicable to all raw materials, bought out items, sub contracted items, capital goods, con-

sumable & services to be produced.

SUB CONTRACTOR:

He is one who carries out processing on material/components supplied by FMVPL.

VENDOR:

He is one who supplies some specific components.

SUPPLIER:

All vendor & sub contractor are considered as suppliers.

RESPONSIBILITY:

1. P&P in charge is responsible for approval of supplier.

2. P&P in charge is responsible for approval of purchase order.

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VENDORS RATING:

The purchase dept is responsible to carry out the vendors ratings to know the status of the

vendor with regard to quality, delivery and service and to feed back rating results for the ven-

dor’s improvement. It is applicable to all the approved vendors. Respective purchase officer

are responsible to carry out the vendor rating of concerned vendor within 15 days of comple-

tion of rating period and have to submit the same to the head of the department for review

and approval of the vendor rating results and vendor rating format. Rating is done every 3

months of financial year for the entire approved vendor’s and if the performance is unsatis-

factory, the vendor’s name is deleted from the list of approved vendor’s.

The criteria for vendor rating are:

1. QUALITY : 70%

2. DELIVERY : 20%

3. SERVICE : 10%


c. Production & Assembling

PRODUCTION:

INTRODUCTION:

The production dept ensures that production process is identified, planned and carried out un-

der controlled conditions in accordance with monthly manufacturing plan. The objective of

this dept is to improve the productivity, to reduce the cost of production without any compro-

mise on quality and to manufacture non defective quality products by training the people.

OBJECTIVES:

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PRODUCTION & ASSEMBLY

PRODUCTION & ASSEMBLY

SHIFT

SHIFT

SHIFT

SHIFT

MAINTAINANCE

MAINTAINANCE

ASSEMBLYASSEMBLY SHIFT IISHIFT II

MANCHINE OP-ERATION

MAINTAINANCE

ASSISTANT

FILTERS MANCHINE OPRATION

HELPERS HELPERS

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1. Productivity improvement.

2. To reduce the cost without compromise on quality.

3. To manufacture “non defective product” by training.

INSTRUMENTS USED:

1. Vernier Calipers.

2. Vernier Height Gauge.

3. Vernier Depth Gauge.

4. Pressure Gauge.

5. Depth Gauge.

6. Dial Vernier Calipers.

7. Digital Vernier Calipers.

8. Outside Micrometer.

9. Depth Micrometer.

10. Shell Thickness Gauge.

11. Inside Micrometer.

12. Bevel Protractor.

13. Combination Set.

14. Feelers Gauge.

15. Dial Gauge.

16. Steel Scale.

17. Bore dial gauge.

18. Engineer Square.

19. Spring Balance.

20. Plains Plug gauge.

21. Torque wrench.

22. Thread Plug gauge.

23. Thread Pitch gauge.

24. Weighing machines.

25. Surface plate.


PRODUCTION PROCESS:

The production process is carried out in the following 3 steps:

1. Control of customers supplied product.

2. Process Control

3. Production Planning Process.

1. Control of Customers supplied product:

It is the responsibility of the cell in charge or production planning assistance to collect the

customer supplied product from the store for incorporation into the valve product. He collects

these products from stores against every requisition while ensuring that the particular work

order for which it is meant.

2. Process Control:

The Production dept ensures that the manufacturing process is carried out in accordance with

monthly manufacturing plan, provided planning. The production dept head plans production

operations.

Necessary documents are prepared by the cell in charge for the production process which af-

fects the quality. The dept head will ensure the suitable maintenance of equipment for contin-

uous process capability. Equipments are verified as capable of production in accordance with

products specification.

The product and process characteristic are mentioned in the consultation with Quality Assur-

ance dept and any non-conformity products/components are duly identified and disposed off.

Any special/extra/services to the products are compiled with as against the customers de-

mand.

3. Production planning and process:

Upon the receipt or the work order copy, bill of material, monthly manufacturing plan etc, the

dept head instructs the production planning personnel to determine the material availability

with reference to bill of material.

If there is any shortage of material the production and planning personnel will place the mate-

rial shortage list to planning and purchase dept. There by they will refer to the production and

plan and collect the material from stores through material requisition note. If material in-

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tended and received is in excess, then the production personnel will return these material

back to the stores, with material return note.

The Head of dept will then prepare daily production schedule through which he schedules the

production and machine loading for the day. The cell in charge prepares and provides rele-

vant document and instruction for processed and other tolling in charge through his personnel

ensures the production facilities like machines, tools, fixtures etc, are available for production

when required.

TYPES OF MACHINES:

There are two types of machines which are used in the production department:

1. Conventional machines

2. CNC machines

1. Conventional machines:

All the operations in this types of machines are done manually work the cost of such ma-

chines are cheaper & the capacity is very less as it can handle only 1 operation at a there are

conventional machines of ac the 4 types of operations it maintains of such machines & it is

less safe than CNC machines.

2. CNC machines:

Computerized numerical control machines. This machines are operated automatically i.e. a

program is written for its function which is in assembly level language i.e. economic codes

which are not understood by human beings. In this type of machine there are 2 types,

a) X & Y sides (2 dimensional)

b) X, X and Z sides (3 dimensional)

c) X, Y side these machines can handle 2 operations at a time by the help of the program

feed in it.

d) X, Y and Z side these machines can handle many operations a time by the help of the

programmed fed in it.

These machines are costlier around 45 lacks & the maintenance cost is also very high &

many preventive actions have to be taken for its proper function.


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Work instructions for mechanical & electrical preventive maintenance of CNC Machines:

OBJECTIVE:

It provides the guidelines for carrying out the preventive maintenance of CNC machines.

SCOPE:

It covers all CNC machines in P&A dept.

RESPONSIBILITY:

The maintenance in charge along with his personnel is responsible for caring out the monthly,

quarterly, half yearly for mechanical and monthly for electrical preventive maintenance the

operator of the machine is responsible to carry out the daily preventive maintenance.

PACKING

OBJECTIVES:

The main objective of the packing is to carry the proper packing before dispatch.

SCOPE:

Scope of packing is packing of valves & valve spares seaworthy applicable.

RESPONSIBILITY:

Sales & shipping officer will study the packing slip through with respect to work order. Sales

& shipping officer decided the size of the box depending on quantity. Sales & shipping offi-

cer will collect the valve numbers from quality assurance department against packing slip.

Valve will be segregating as per packing slip and sales & shipping officer will ensure that all

valves have undergone final inspection before packing they are properly identify with respect

to purchase order. While checking the packing the following details are taken care.

1. Packing box markings.

2. Destination box markings.

3. Estimation of address.


4. Name of the transporter

5. Identification numbers (invoice number).

6. Supplier number.

7. Number of boxes.

During the formation of packing boxes the following

points are taken care:-

Planks are of treated with “anti termite” treatment by spraying wooden case which composed

one part by weight of hydrated arsenic, pentoxide, 3 parts by weight of blue vitriol & parts by

weight potassium, deliromate.

1. Silica get is used as moisture absorbent.

2. Boxes are lived with resin cloth with one coat of coal tar on an polythene and embed-

ded on jute nut.

3. Boxes are provided with felt and paper cutting as cushioning materials.

4. These are the objectives and scope of the packing and the precautions which taken

care while packing the valves and the spares of the valves and the chemicals which

are used on the packing box for prevent from the insects and other hazardous things.

DESIGN & DEVELOPMENT

OBJECTIVE:

To assist M/S. Flowserve Corporation Inc. for Plug Valves & Pumps, M/S. Microfinish

Valves Ltd. for Ball Valves, for development of components, from pattern stage to finished

component stage, based on designs provided by respective companies.

SCOPE:

Applicable to all new products being introduced at both the units i.e. Flowserve Microfinish

Valves & Pumps.

INPUT:

Drawings, specifications received from Flowserve / Microfinish, with a request of product

development.

INTERACTION:

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FMVPL / FMPPL with FCI & MVL within the units QA, Planning & Purchase, Sales &

shipping and P&A functions


OUTPUT:

1. Inspection Audit Reports from FCI / MVL.

2. Sample inspection / test reports.

3. Material specification.

4. BOM

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d. Stores

Objective:

To provide general guidelines for monitoring stock levels from material receipt stage through

finished components\ finished valves.

Functions of Stores Department

1. Verification of materials on receipt of material

2. Issue of raw-material and control of raw material

3. Finished components issued for assembly\dispatch

4. Handling


e. Quality Assurance

Quality Policy

Our mission is to manufacture quality valve products for the process industry

worldwide. We embrace the concept of total quality and people involvement

to enhance “Total Customer Satisfaction” and commit to maintain this stan -

dard of excellence through continual improvements and use of quality man -

agement system.

Functions of Quality Assurance Department

Incoming Material Inspection

Final Inspection

The following colors are used for painting:

Ball Valve - Oxford Blue

Gear Operator - Oxford Blue

Hand Wheel - Oxford Blue

Adapter Pipe - Silver

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Quality Assur-ance

Receiving Quality Engineer (RQE)

Final Inspection

Casting Inspection

Assembled Product

ComponentsSub Con-tract Items

Bought out Items

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Plug Valve - P.O. Red

Final Product Engineer is responsible to ensure that all outgoing components\ products are

subjected to dispatch inspection. He verifies the components\products material of construc-

tion, size; class, special requirements and metal tags etc with W.O. and ensure that the sample

tested valves are

Packed with identified box and note down the box Identification and then the inspection and

testing results are noted down in the ‘Dispatch Inspection Report’.

Inspection color codes used by the Q.A. Department:

Green : Conforming

Black : Accepted on Deviation

Yellow : Rework

Red : Reject

Dark Blue : Hold

Types of tests conducted by the Quality Assurance De-partment:

1. Hydrostatic Shell Test

2. Pneumatic Seat test

3. Pneumatic Shell Test

4. Dimension Test

5. Radiography Test

6. Ultra Sonic Test

7. Dye penetrate Test

8. Visual Test

RECEIVING QUALITY INSPECTION

Objective:


To ensure that various products characteristics of the incoming materials or

components confirm to the specified requirements and requirements of PED

97/23/EC.

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Scope:

It’s applicable to all incoming raw materials or components bought items.

Responsibility:

For inspection-quality inspector. For approval-quality engineer.

Input:

Quality plan, drawings, specifications, supplier reports.

PROCESS STEPS:

1. Receipt of PO

2. Receipt of material identification of material for PED 97/23/EC re -

quirement.

3. Inspection

4. Non-destructive testing

5. Verification of test reports

6. NC review

7. Monitoring and analysis


FINAL INSPECTION AND TESTING

(Assembled product)

OBJECTIVE:

To ensure that the finished products confirms the specified requirement and re-

quirements of PED 97/23/EC.

SCOPE:

All valves/pumps undergoing final inspection and testing.

RESPONSIBILITY:

1. For inspection-Quality Inspectors

2. For approval-Quality Engineer

INPUT:

Work instructions, monthly manufacturing plan, drawings, specifications and standards.

OUTPUT:

NC reports, Inspection report, Test reports.

PROCESS STEPS:

1. Receipt of monthly plan

2. Valve or pump testing CE-marking, name plates for valves

3. NC review

4. Punching and register entry

5. Dimensional inspection

6. Painting inspection

7. Dispatch inspection

8. Corrective or preventive actions

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FINAL INSPECTION AND TESTING

(Component)

OBJECTIVE:

To ensure that the finished products confirm to the specified requirements

SCOPE:

All components undergoing final inspection/testing.

RESPONSIBILITY:

a. For inspection-Quality Inspectors

b. For approval-Quality Engineer

INPUT:

Work instructions, monthly manufacturing plan, drawings, specifications and standards.

OUTPUT:

NC reports, Inspection report, SPC charts.

PROCESS STEPS:

1. Receipts of monthly plan

2. Inspection and segregation

3. NC review

4. Preparation of inspection and NC review report


Powers and Responsibilities of Heads of Departments:

1. Ensuring a high morale of personnel working in their department by responsible deci-

sions and personal example

2. Based on the projected sales, to set specific targets for the development and to ensure

these targets are achieved.

3. Keep up-to-date on technical and management methods by extensive reading and

study. Ensure customer requirements are met with the aim of enhancing customer sat-

isfaction.

4. Ensure observance of all rules and regulation with specific reference to the provisions

of company’s standing orders

5. Train and upgrade technical and administrative skills of the employees, serving in

their departments.

6. Ensure economy in their operation, so as to enhance profitability

7. Maintain the factory premises

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f. Administration & Accounts

1. Training

Objective:

Is to provide the adequate training to the personnel of all departments performing activities

affecting quality.

Responsibility:

Administration and Accounts (A & A) In-charge through personnel officer is overall

responsible to ensure that the training needs of personnel of all the departments are

fulfilled.

Personnel officer is responsible for identifying the appropriate trainer in consultation

with the top management for arranging the training. In charge of respective depart-

ments

2. Recruitment

Personnel Officer is responsible for recruiting the right person for the right job. He takes into

consideration the knowledge, skill and work experience of the person.


Administration and Accounts In

charge

Personnel Officer

(Factory and Per-

Account Assis-

3. Safety

Objective:

To ensure safe and healthy environment for personnel.

Responsibility:

Administration and Accounts in charge through personnel officer is responsible for safety re-

lated activities.

Procedure:

Safety committee meeting is conducted every quarter. Safety related training for staff and

workers is conducted once in two months such as Fire Extinguisher, Chemical Hazardous,

Personal Hygiene etc and first-aid facility is also provided for workers.

4. House Keeping

The FMVPL follows the 5’S concept of House Keeping system.

Objective:

To ensure good, healthy, clean, neat and safe work environment

Responsibility:

While the activities are coordinated by the personnel officer, each and every individual in the

organization is responsible for the implementation.

Procedure:

For effective implementation of the system, the entire premises of the company are divided

into sub-zones as Production and Assembly division, Quality Assurance division, Adminis-

tration and Accounts division etc. Each sub-zone is headed by a team leader and supported by

co-ordinates, supervisory staff and workers.

5’S:

SEITON : A. Place for everything B. Everything in its place

SEIRI : Sort out items and discard the unnecessary.

SEISO : Clean your workplace thoroughly

SEIKETSU : Maintain a standard

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SHITSUKE : Train people to be disciplined

The effectiveness of system is monitored by periodical internal audits, the frequency of which

is currently once in 15 days. Team leaders are given responsibility of conducting regular au-

dits and COO conducts unscheduled surprise audits.

ACCOUNTS [FINANCE]

FINANCE:

This department is playing a vital role by providing and maintaining the entire details of each

and every financial activities of the company.

Objectives of Accounts Department:

1. To provide accurate and complete systematic information of financial activi-

ties.

2. To maintain all the books of the accounts and other financial documents.

3. To prepare periodic financial statements of the company like Profit and Loss

Account and Balance Sheet.

FUNCTIONS OF ACCOUNTS DEPARTMENT:

1. Preparation of outstanding debtors and creditors list on regular basis.

2. Issue of bank guarantees, indemnity bond and follow up of expired bank guarantees for

cancellation.

3. Maintenance of account books, inventory on tally.

4. Writing of cheques.

5. Handling of cash payments and petty cash etc.

Books of Accounts maintained by the Accounts Depart -

ment:

It maintains its complete accounts in the TALLY software package and takes print copies of

following registers every year:

1. General Ledger Register.

2. Sundry Debtors Register.

3. Sundry Creditors Register.


4. Journal Register.

5. Cash Book with Bank Column Register.

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g. Human Resources

Functions of Administration Department (H.R):

4. Training

5. Recruitment

6. Safety

7. House Keeping

8. Other functions

Facilities provided by the Flowserve Microfinish to Its

Workers:

1. Employee State Insurance (E.S.I):

2. Provident Fund (PF)

3. Gratuity:

4. C.A (Casualty Allowances):

5. R.A (Regularity Allowance):

6. E.L (Earned Leave):

7. Medical Premiums:

8. Company Loan:

9. Bonus:

10. Safety Measures

11. Salary Payment Date:

Employees Date of Payment

Staff 31st of every month

Workers 5th of every month

Labor Force:

There are about 76 employees working in the organization.

Attendance:


This department records the time (i.e. the time of workers in and out of the company) through

Punch Card system right at the entrance.

SWOT Analysis

Strengths:

1. The company has excellent network, which provide good quality product with mini-

mum time.

2. ISO standard helps to marketing in International Level. The good HR system is their

like - Motivation, Training, to new employee etc.

3. Feed-back information is provided to all employees.

4. Benefits provided by government to 100% EOU Unit.

5. The company has unity of team work, good salary to workers.

6. Regular medical checkup & help to employees.

Weaknesses:

1. It is not having a separate marketing dept.

2. No direct exporting.

3. No international recognition by its own name.

Opportunities:

1. Potential market for spare parts is growing high.

2. Export order received is greater than what they are able to produce, so opportunity to

increase production capacity for which ready market is available

3. Whatever is produced is exported.

4. Opportunity to enter plug valve market.

5. International Customers shows more interest to buy Flowserve Microfinish products.

6. Company has a out Bond logistic Management & documentation.

7. They have excellent infrastructure facility to workers.

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Threats:

No threat in the sense, no competitors for it because it is not a independent firm but has got

JV with Flowserve USA. So threat may be any action of Flowserve USA on Microfinish like

taking back shares invested in m1crofinish or can stop giving export order to Flowserve Mi-

crofinish.


Conclusion

Life is a search for satisfaction and achieving excellence, it is necessary to find out what

makes any manufacturing unit to be successful in international market.

Our study conducted on Flowserve micro finish has explored, various factors lying behind the

success of the Flowserve micro finish in the manufacturing industry. Flowserve micro finish

industry which is basically into valves and pumps has been able to achieve high turnover, in-

ternationally recognized product and quick delivery within very short period of time.

Study on this exporting unit has given good knowledge on documentation, procedures of ex-

ports, logistics activities and also reasons and consequences of Joint venture by this unit with

Flowserve Pvt. Ltd. based in USA. The study has thrown light on serious implications of JVs

for which some recommendations are made for the company and also for nay Indian partner

having JV with MNC.

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Learning Experience

The Inplant training has provided me an opportunity to witness the day to day working. I

have got very valuable practical experience of management aspects of the plant. It utilizes

human, financial, raw material and technological resources to the fullest extent through suffi-

cient planning, organizing, leading and controlling.

The company is trying to build a bridge between the production, employees, management and

the outside world, and is focusing on meeting the challenges of market locally and globally,

by way of Quality Assurance, department in maintaining the quality of the product and it has

become the basis for competition with other companies. It takes utmost care for presenting

the best quality product to its customers. In spite of this, if they are received any customer

complaints then corrective action are taken on these complaints immediately.

The work environment is friendly. The company is an illustration of participatory manage-

ment because the workers are also involved in decision making and its implementation. These

in turn has given boost to individual performance. The rate of conflict is negligible. The pro-

duction is a coordination of group effort.

The leadership is considerate towards its workers. They show concern for subordinates and

attempt to establish a friendly and supportive climate.

The Inplant training has given me a chance to witness actual production process. The mea-

sures are taken to minimize the wastage; the company tries to reduce cost of production, fo-

cuses on controlling pollution and providing security to its worker so that there is increase

manpower productivity.

All together it was a good learning experience as we could see the theory which we study in

class is being put for practical use. Once we became familiar there was lot of corporation for

them. I have studied the various departments as mentioned in the circular. On the whole it

was a good experience.


Bibliography

Company Manuals:a) Work instruction.

b) Procedure.

Websites: www.flowservemicrofinishgroup.com

www.flowservemicrofinishvalve.com

w ww.google.co.in

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http://www.flowservemicrofinishvalve.com/

http://www.flowservemicrofinishgroup.com/

Date post:	03-Dec-2014
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