Bhumika Alloy Castings Pvt.

Ltd

CHAPTER – 1

INTRODUCTION

1.1 Introduction

1.2 Objective of the study

1.3 Scope of the study

1.4 Methodology

1.5 Sources of data

1.6 Limitation of the study

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CHAPTER 1

INTRODUCTION

1.1 Introduction

Organization is setup by objectives, Rules and Regulation, policies.

The term organization indicates that control the overall activities of the
company. And it is the back bone of company for running successfully. Plan,
control, place and people are the elements of the organization. If the
organization going well in the company, the above elements are reason for the
successful running of the company.

The organization builds good relationship in employees and company.

As we know that the employees are the basic used of any company. If the
company fail to maintain the relationship with employees the company might
be lose their business. So, that organization is a basic aspect of any company.

The term organization can be used in different sense, It can be used as

a group of persons working together or as a structure of relationship or as a
processes of management. Organization study is a field that investigates the
impact that individual, Group and structure have on behavior within
organization for the purpose of applying such knowledge towards improving
organizations effectiveness. Every organization consist of people. It is
regarded as a collection of interacting and interdependent individuals who
work jointly under a group in order to achieve certain common objectives.

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1.2 Objective of the Study

 To study the various functional departments of the company.

 To know the theoretical background of the organization.

 To analyze the implementation of McKinsey`s7’s model.

 To evaluate the Strength, Weakness, Opportunities and Threats.

1.3 Scope of the Study

The scope of the study is limited for studying of Bhumika Alloy

Castings Pvt. Ltd. Srirampura Village, Sagar road, Shimoga. For the period of
20 days and this study tells us an overall view of organization and functions
carried out by different departments like manufacturing, human resources and
finance etc.

1.4 Methodology

In order to achieve the above stated objectives the data has been collected
both from primary and secondary sources.

1.5 SOURCES OF DATA

 Primary data

The Primary data is nothing but first hand do which were collected by the
company by having direct contact with MD, Manager, different department
heads, Employees, and through observations.

 Secondary data

Secondary data is a data, which had already exits and collected by others.
Secondary data was collected through company displayed in various

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developments in the factory Records Books, Annual Report, E –Source,

broachers etc…..

1.6 Limitation of the Study

 The scope of the study is limited to Bhumika Alloy Castings Pvt.

Ltd. Srirampura , Shimoga

 Time constraint.

 The study is based on information given by the members of the

organization and they give biased information’s.

 The workers were busy in their scheduled work; they were not ready
to give the accurate information.

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CHAPTERIZATION

Chapter-1 INTRODUCTION

Introduction, objective, scope of the study, sources of data collection and

limitation of the study.

Chapter-2 INDUSTRY PROFILE

Industry profile, Industry introduction, Mission, vision, Objectives, branch

profile, with different heads and structure Company profile deals with
introduction, Product profile, mission, vision, quality objectives, Awards
and achievements .

Chapter-3 ORAGANISATION STUDY

Production Department, Purchase Department, Human Resource

Department, Finance Department, Marketing Department

Chapter-4 MECKINSEY’S MODEL

Mckinsey’s 7’s model with frame work. Functional areas.

Chapter-5 SWOT ANALYSIS

SWOT Analysis, Strength, weakness, opportunities and threats.

Chapter-6 : Findings, Suggestion And Conclusion

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CHAPTER – 2

INDUSTRY PROFILE

2.1 Introduction

2.2 Types of product

2.3 Origin of casting

2.4 Meaning of casting

2.5 Global scenario

2.6 Company profile

2.6.1 Introduction

2.6.2 Details of the company

2.6.3 Nature of business carried

2.6.4 Vision, Mission, Quality Policy

2.6.5 Quality Policy

2.7 Machineries

2.8 Product Profile

2.9 Major customer of the company

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CHAPTER 2

INDUSTRY PROFILE

2.1 INTRODUCTION

In India the foundries are mainly contributing to the Indian economy. Steel is
used as a basic material in the manufacture of metal products, electrical
machinery, transport equipment, test tills and other machinery. India is
currently among the 10 largest producers of ferrous and non- ferrous casting
and regularly exports to the US, the UK, Canada and Germany among others.
India possesses an abundant iron ores, which are considered as one of best in
world, because of high iron content.

2.2 Types of Product

 Automobile components

 Metal gaskets

 Decanter Bowl Shells

 Seat Rings

 FC Ports

 Hinges

 Flow meters

 Ni Resist Castings

 Dental equipments

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 Others. ( Bushes, outlet tubes, tubes, valve & valve bodies, roller
tubes, SP machined parts, farm equipments& many more)

The industry made is real beginning with the establishment of TISCO (Tata
Iron and steel Corporation) now called Tata Steels in Skachi in Bihar in 1907.
In 1937 Steel Corporation of Bengal was setup, but it was merged with Indian
Iron and Steel Company 1952, with starting of 5 Years plan. The government
entered the field of Steel production and has now become most important
producer in the country.

2.3 Origin of casting

The Chinese had mastered the melting of iron since 500 BC, 2.000 years
before the Europeans. New excavations proved that they succeeded in the
mass production of cast tools and farm equipment after the development of
iron casting.

3200B.C.

A copper frog, the oldest known casting in existence, is cast in Mesopotamia.

2000B.C.

Iron is discovered.

800-700B.C.

First Chinese production of cast iron.

645B.C.

Earliest known sand moulding (Chinese).

233B.C.

Cast iron ploughshares' are poured in China.

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500A.D.

Cast crucible steel is first produced in India, but the process is lost until 1750
when Benjamin Huntsman reinvents it in England.The word of casting is
begun at Mesopotamia in the country of Iraq.

2.4 Meaning of Casting

Foundry is a factory which produces metal castings from either ferrous or

non- -ferrous alloys Metals are turned into parts by melting the metal into a
liquid, pouring the metal in a mould, and then removing the mould material or
casting. The most common metal alloys processed are aluminium and cast
iron. However, other metals, such as steel, magnesium, copper, tin, and zinc,
can be processed.

Melting of metal in cupola furnaces is the most energy intensive operation in

a foundry unit. The table below provides an estimate of the distribution of
energy consumption in the foundry process.

2.5 Global Scenario

There are about 35,000 foundries in the world with annual production of 90
million tonnes, providing employment to about 2 million people. USA tops
the list in alloy production followed by China, Japan, Germany, and the CIS.
In terms of number of foundries China has the highest score (9374), followed
by India (6000) and then CIS (4000). The share of Iron foundries is the
maximum i.e. almost 56%, followed by steel with 14% and then the non-
ferrous ones with 30%. The global market potential of metal is estimated to be
about US$30 billion. The growing environmental concerns and globalization
of economies have led to a closure of some 8000 foundries in Europe. These

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countries have been contemplating to shift their business to the low labour
cost centres i.e. the developing countries.

World Foundry market is becoming competitive as such France, USA and

Spain have established new companies in China and Mexico. Other European
total number of units unregistered is around 5450 units. As per estimation of
experts of the foundry sector, there are around 1500 unregistered foundry
units that are scattered across the country. This discrepancy in unregistered
units is mainly due to the fact that the 5450 units included all kinds of micro
and small units engaged in castings. Whereas the 1500 units data incorporates
only those foundry units that are engaged in grey iron casting and use
conventional cupola and excludes those units that are too micro in nature and
use crucible for melting of metals. Also several foundry units had closed due
to non compliance with the pollution standard set by the government for
example Howrah, Agra and nearby areas. The foundry produces a wide
variety of castings such as manhole covers, pipe and pipe fittings, sanitary
items, tube well body, metric weights, automobile components, railway parts,
electric motor, fan body etc. 90% of the castings produced are from the SSI
sector. Most of these units are situated in clusters, with cluster size ranging
from 30-500 units.

The break-up of production of different varieties of castings is as follows:

Grey iron 72%

Steel Castings 10%

SG Iron 10%

Aluminium castings 8%

On the eve of India Independence in 1947 total capacity iron and steel
industry was of the order of 1.3 million tons from TISCO and 0.3 million tons
from IISCO. By 1990-91 iron and steel industry had six integrated plants with

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an installed capacity of 10 million tons of steel ingots. From the point of view
of total investment, iron and steel industry, accounting for a total investment
of Rs.4000 Crores. Major portion of their investment is in the public sector
plants. Industry provides direct employments for to 2.5 lakhs workers. The
capital requirement for employing or workers works out to be Rs. 1200000. In
this sense, it is highly capital – intensive industry, inspire of the tremendous,
importance were given to the industry and heavy industry is made, it is pity
that the country has to import between Rs. 2500 Crores worth of iron and
steel every year. India was only 15th in the world ranking of steel producers.
Steel compares with 685kg in U.S.A., 428kg in USSR, 623 kg in Sweden and
494kg in Japan.

SAIL

The SAIL (Steel Authority of India Limited) was created in 1947. Made
responsible for development of steel industry and also for the major input for
the industry. SAIL was to bring about a co-ordinate and synchronized
development of the entire major units brought under its control, viz, units
brought under its control, viz, Hindustan Steel Works Construction Limited,
Bharat Cooking Cool Limited and National Mineral Development
Corporation Limited. The actual achievement was much lower than planned.

The progress of steel industry was quite rapid in the initial stage of planning,
but forms the third plan onward the rate of growth slowed down and targets
could not be fulfilled. During emergency (1975-77) there was better
utilization of capacity in all steel plants. Beside, there was greater availability
of coal, transport and power, apart from improvement in industrial relations
leading to greater discipline in the industry.

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Assessment of Industry in India

Initially, the developments of steel industry are regarded as an opportunity

and a challenge. In a way, the iron and steel industry has considerable
progress from 1.5 million tons of crude steel in 1950-95. The rate of growth
through impressive is highly unsatisfactory. India is now a leading importer of
steel.

An important feature of the growth of iron and steel industry in the growth of
research, design and development within the country. India it self-reliant and
depending on foreign Countries. For instance India set up the Bokaro Steel
Plant almost entirely on its own.

Secondly, the public sector is gradually becoming more significant in

production of steel in 1950-51, all steel production was in a private sector.
Now, public sector accounts for 85% of the total output.

Thirdly, the government gave license to set up electric 30% of the steel
production in the country, producing mild steel as well alloys steel. There are
179 mini steel plants with a total capacity of 5.6 million tons of steel during
1993-94.

Fourthly, India ha potentialities of becoming a good exporter of steel. The

value of exports of iron and steel had gone up from less than Rs.3 Crores in
1950-51 to Rs. 290 Crores in 1976-77 but later declined due to rising
domestic demand for steel. Instead, India has a leading exporter of iron are
amount to Rs. 1200 Crores to Rs. 1400 Crores per year.

Finally India has long importing steel to meet domestic demand kinds of steel.
During the sixth plan, for instance, total imports of iron and steel were of the
order of Rs. 5250 Crores. in 1994-95 alone India imported Rs. 3650 Crores
worth of iron and steel. There is considerably scope for iron and steel. There
is considerable scope for iron and steel increasing domestic production.

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Since, 1992-93 reforms in the iron and steel sector consisted of liberation of
import and export of steel materials, abolition of price and distributions
controls and successive reduction of import duties on iron and steel products.
The iron and steel industry is now facing a competitive environment. The
competitive pressure is likely to increase with further liberalization in trade
policy.

It is the government’s belief that the India Steel Industry, which has access to
the source of best quality iron are from domestic mines and substantial
proportion of cooking coal, would improve its efficiency and face fall in
competition successfully.

The industry too perform well in recent years due to recent liberalization
measures, such as abolition of steel department fund (SDF) steady reduction
of import tariff, the modernization and up gradation of technology, the
compulsory cost reduction through quality improvement and optimum
capacity utilization and switch to product mix of highly value.

Alloys and Steel

It has said that alloys steel is “A carefully made steel with sufficient alloying
metals added to it to modify usefully the properties of plain carbon steel” an
alloying element or compound is one that is more or less soluble in major
metal and that participates in physical or chemical reactions at various
temperatures and thus modifies the properties. Alloying metals may be
various the amount to alloying element added varies enormously, ranging
from very low (0.0005% Baron, 0.1% Vanadium) to very high (20%
chromium or more).

It is almost as hard to draw a clear line of demarcation between iron and steel.
Diverse definition have been set up legally for customs purposes and
commercially for statistical but more especially for pricing purpose.

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General Influence of Alloys

A statement frequently heard is that alloys steels are Valuable cheaply

because they may be hardened and strengthened by heat treatment without
incurring the brittleness associated with hardened plain carbon steel. Further,
it has frequently said that be economically justified, the alloys steel should be
in quenches and tampered sate. It will be shown below that the track function
of alloys in the engineering or machine steels is to get high strengthened and
toughness or hardness and toughness, simultaneously, either more easily than
they can be had in carbon steels or in sizes and shapes in which they cannot
be had in carbon steels.

Strong Structure Steel

Alloys falling in category are particularly useful in improving the mild steels
for shapes. These steels are usually been fabricated by the further heat
treatment. In fact, they must be rather incentive to heat treatment else
glancing and especially welding in produce lacking in required ductility.

Extra strength and correspondingly lighter sections such as are desirable for a
long span bridge or for railway or car bodies, can, off-course, be had by
increasing the carbon content, but this aggravates the problem of hardness.
Alloys are, off-course of most importance heat treatable steels, for an alloys
bar will harden under similar circumstance much more deeply than a
comparable carbon steel bar.

When steel are heated above their critical points of range of about 725C to
825 C, the crystal structure of alpha ferrite is transformed into a new one
called gamma iron, which has far greater solubility for carbide.

This high temperature solid solution of the carbides in gamma iron is called
acestenite. On slow cooling the temperature range and the annealed fairly soft

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and ductile steel are reconstructed, expect that the process may have refined
the grain.

Certain alloys have still another beneficial affect that of refining the grain
according to the laws of crystallography certain favored acestenite grains
should grow longer and longer stay at higher and higher temperature. First, a
considerable time is to deserve complex and sluggish carbides in the
acestenite, many seem to have a central particle that resists dissolution, and
these refractory particles disseminated through the mental effectively prevent
the natural growth of the solid solution.

To conclude, steel plants had been set up in different parts of the country to
augment steel, which is required for large integrated steel plants. Bhumika
Alloy Castings is one among those mini steel plants, which concentrates on
the manufacture of steel castings.

A study with reference to Bhumika Alloy Castings foundry makes an index

study of the overall process in quality steels casting and manufacturing. Steel
foundry provides employment for large number of people. This industry is
considered as a highly suitable venture in the Indian context. The major
problems faced by these units are to be effectively and timely tacked through
purposeful co-operation, co-ordination and collaboration among proprietors
government and other agencies in general. The study with reference to
Bhumika Alloy Castings foundry gives some basic information about
manufacturing and casting of steel. The result and discussion of this study
would highlight the overall functioning, management and future prospects.

Indian Scenario

The Indian metal casting (foundry industry) is well established. According to

the recent world census of castings by modern casting USA India ranks as 2nd
largest casting producer producing estimated 7.44 million MT of various
grades of casting as per international standards. The various types of castings

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which are produced are ferrous, non ferrous, aluminium, alloy graded, cast,
iron, ductile iron, steel etc for application in automobiles, railways, pumps
compressors and valves Diesel, engines, cement/electrical/Textile machinery,
aero and sanitary pipes and fittings etc and castings for special applications.
However Gray iron casting is the major share approx 70% of total casting
produced.

A foundry is where the elaborate metal casting process takes place. A metal
foundry may specialize in making one particular item or a variety of products
using different alloys. Based on the production requirement there are small
foundries that employ few people and large industrial foundries that employ
thousands of workers. Based on the production requirement there are small
foundries that employ few people and large industrial foundries that employ
thousands of workers.

Future outlay:

Focusing on design: First, improved design capabilities in metal casting is

critical to the industry’s ability to produce cast products that are competitive
nature.

Improvement in the metal casting process can be achieved by focusing on

interrelated areas.

 Preventing the sand through recycling.

 CNC machining and testing equipment will be upgraded to cater to the

increasing customer expectations.

 Capabilities to meet future needs and expectations of customers.

 Increase the revenue from overseas business segment substantially.

 To satisfy employee needs and improve infrastructural facilities.

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 Adopting proper plan of action at a right time.

Based on the production requirement there are small foundries that employ
few people and large industrial foundries that employ thousands of workers.

2.6 COMPANY PROFILE

2.6.1 INTRODUCTION

Bhumika Alloy Castings Pvt ltd. Modern alloy steel foundry geared to
manufactures of precision components by Lost Wax process by Centrifugal
casting and investment casting. The company is situated at Srirampura.

The foundry started commercial product in the year 1997 by Mr.

H.S.Diwakar. The company is equipped with one number of 100kg 150kg
connected with to a power pack of 450 kw medium frequency induction
furnace and one number of 150 kg .300 kg connected to power pack 175kw
medium frequency induction furnace will all accessories with this company
can produce quality casting weighting from 0.005 kg to 500 kgs single piece

The entire operation of the company right from placement of purchase order
for raw materials and consumables to invoicing of material and consumables
to invoicing of material manufactured by the company covered entire process
has been computerized in the process of company has developed good
information management system.

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2.6.2 Details of the company

Name of the company : Bhumika Alloy Castings Pvt. Ltd

Regd. office/ work address : Srirampura Village

Shivamogga – 577204

Karnataka, India

Phone No : 91 8182 600600, 8182 605050

E- Mail : [email protected]

[email protected]

Website : www.bhumikacastings.com

Technical director : Mr.Deepak .H.D

Products : Metal gaskets, insert rings, decanter bowl

shells , tubes/sleeves, roller tubes, FC ports
, dental equipments, flow meters , hinges,
valve & valve bodies, automobile
components and others…..

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2.6.3 Nature of Business carried

Bhumika Alloy Castings Pvt.ltd.is engaged in the manufacturing of

alloy steel castings, special alloy castings, and low carbon steel castings
accounting to customer requirements. The installed capacity of the unit is
3000 tons per annum, with a size range of 0.005 to 500 Kgs single piece. The
melting process is done through induction furnace and molding process by air
set process with or without carbon dioxide for process for baking.

2.6.4 Vision, Mission and Quality Policy

Vision

To achieve an international competitiveness through satisfaction of customer

needs by continuous improvement in the quality, cost and dispatch

Mission

 To meet the castings requirements of the country using latest state of

the art technology iron wide range of materials at competitive cost.
 Provide stable employment and development and highly skilled
technical labor and wide vender base
 Adopt environment friendly technology and create awareness on
energy conservation
 Serve the immediate community through welfare schemes.

2.6.5 Quality policy

“Bhumika Alloy Castings Pvt.Ltdis committed in building world class

manufacturing process through best practices and deliver superior value
components to its customers and to provide timely delivery with assured
quality”.

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Quality objective

 On time delivery to customers.

 Reduction in complaint and Rejection at customer level.

 Produce good quality of the product

2.7 MACHINERIES

Sl.No Machinery Size/Capacity

1 D.G Set 8 K.V

2 Blast Machine 100 kgs

3 Polishing Machine 2 HP

4 Shot Blasting Machine 500 kgs

5 H.T.Furnace 50 to 250 kgs

6 Bench Grinding 7.50 HP

Machine

7 Air Conditioner 1.50 to 3 M.T

8 Angle(Hand) Grinder 560 wats

9 Wax injection machine 12 to 35 M.T

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10 Sprue Maker 25 kgs

11 Pattern assembly table 3 mtrs X2 mtrs

12 Wax holding tank 50 kgs

13 Slurry mixer 100 Ltrs

14 Stucco machine 100 kgs

Source: Official website, www.bhumikacastings.com

Raw Material Testing

Sl.No Description Make Specification

1 Ferro Lab Ferro Lab

Excel

2 Sand Rammer VR Mold Testing

3 Permeability Meter VP Sand Testing

4 Mould Hardness Tester “B” VMH(B) Mold

Scale Specification

5 Rapid Moisture Tester VM Mold Testing

6 Clay Washer VCW Mold testing

7 Brinner Hardness Testing VCW 3000kg

Machine
8 Muffle Furnace Venus 3000*C

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Instruments 3.2KV

9 Muffle Furnace Venus 1200*C

Instruments

10 Carbon Apparatus Strolhien

11 Combustion Furnace Strolhien

12 Single Pan Electronic Balance Oriental 200grm

Balance

13 Chemical balance Oriental 200grm

Balance
14 Distillation Plant Local 2KW

15 Polishing Machine Bainpon

16 Microscope Westwox Range

50,100,150

17 Spectometer Metal Power CI & SG

Source: Official website, www.bhumikacastings.com

Alloy types

TYPE
GRADE

 Stainless steel A 890 GRADE 4A

A 890 GRADE 5A

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CF-8M (SS316)

CF-8 (SS304)

CA-15

CN-7M (ALLOY-20)

CF-3(SS3O41)

CF-3M (SS316L)

CD-4MCV

DIN-1

4408/1.458

 Nickel Alloy CW-12MW

N-12MV

CW 6M

INCONEL 625 (CW 6MV)

INCONEL 600(CY 40)

 Alloy Steel WCB, LCB,LC3,LCC,WC6,

WC9,C5,ETC.

Source: Official website, www.bhumikacastings.com

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2.8 Product Profile

Valve

We are instrumental in manufacturing and supplying high-grade Valve. The

Valves manufactured by us are highly demanded by the clients, owing to their
reliable performance and durable life. Valves that we provide are made from
premium raw materials, which are procured from well-known vendors in the
market. Our clients can avail these Valves at pocket.

A valve is a device that regulates, directs or controls the flow of fluid by

opening, closing or partially obstructing various passageways.

Centrifugal castings

Design one of the major manufacturers and suppliers of centrifugal castings in

India, the company offer a wide range of centrifugal castings to the clients.

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These centrifugal castings are skilfully engineered by our team of experts.

The centrifugal castings offered by us are available in different sizes and
specification as per the client’s needs

Mechanical Gasket

We are instrumental in manufacturing and supplying high quality mechanical

gaskets. The mechanical gasketsoffered by are produced from top-grade raw
materials, in order to ensure superior quality and reliable performance. These
mechanical gasketsare efficiently used in diverse industries for different
purposes.

Ni Resist

We are one of the major manufacturers and suppliers of Ni resist in India, the
company offer a wide range of Ni resist to the clients. These Ni resist are
skilfully engineered by our team of experts.

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Ni Resist castings can be specified in either a Grey Iron base material or a SG

Iron based material. These materials have been developed to offer good
resistance to sea water and alkaline corrosion, scaling resistance, thermal
expansion, frictional wear, oxidation, structural stability, cryogenic
applications and erosion. Ni Resist can also be used for applications where
non magnetisable features are required.

FLOW METER

The company is ranked amidst the major manufacturers and suppliers of flow
meter in India. Our superior quality flow meters are made using advanced
technology and latest machinery, to ensure better performance and long
lasting functionality.

A flow meter is a device used to measure the flow rate or quantity of a gas or
liquid moving through a pipe. Flow measurement applications are very
diverse and each situation has its own constraints and engineering
requirements. Flow meters are referred to by many names, such as flow
gauge, flow indicator, liquid meter, etc. depending on the particular industry;
however the function, to measure flow, remains the same.

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HINGES

We are one of the major manufacturers and suppliers of hinges in India, the
company offer a wide range of hinges to the clients. These hinges are skilfully
engineered by our team of experts.

A hinge is a mechanical bearing that connects two solid objects, typically

allowing only a limited angle of rotation between them. Two objects
connected by an ideal hinge rotate relative to each other about a fixed axis of
rotation. Hinges may be made of flexible material or of moving components.
In biology, many joints function as hinges like the elbow joint.

Ring Joint Gasket

The company is ranked amidst the major manufacturers and suppliers of ring
joint gasket in India. Our superior quality ring joint gasket are made using
advanced technology and latest machinery, to ensure better performance and
long lasting functionality. These ring joint gasket are largely used in various
industrial processes. The ring joint gasket can be availed at the most
competitive prices from us.

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These gaskets are made entirely of metal and relay on seating surface to
accomplish the seal. The metals own spring characteristics are utilized. The
gasket has metal wound outwards in a circular spiral with filler material
wound in the same manner but starting from the opposite side. This results in
alternating layer of filler and metal.

Auto mobile components

We are instrumental in manufacturing and supplying high quality various

automobile components. The automobile components offered by are produced
from top-grade raw materials, in order to ensure superior quality and reliable
performance. These automobile components are efficiently used in diverse
industries for different purposes. Our automobile components is made
available in customized sizes as per the client’s requirements at competitive
prices.

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Our certification

 ISO 9001: 2008 CERTIFIED from BSI group India

 Moving towards TS16949 for automotive components from BSI group

India

2.9 Major customer of the company

Sl.No. List of Customers

1 M/s. Pentair Water India Pvt. Ltd.,

2 M/s. Automotive Axles Ltd.,

3 M/s. Laxmi Machine Works Ltd.,

4 M/s. Turbo Energy Ltd.,

5 M/s. Perfect Alloy Components Pvt. Ltd.,

6 M/s. T.M.S India Pvt. Ltd., Unit No.1

7 M/s. Circor Flow Technologies India Pvt. Ltd.,

8 M/s. Efficient Environment Pvt. Ltd,

9 M/s. Nilyash Engineering

10 M/s. Mactech Engineering.,

11 M/s. SAP Parts.,

12 M/s. Laxmi Ring Travellers Ltd.,

13 M/s. Pentair Valves &Controls.,

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CHAPTER – 3

ORGANISATION STUDY

3.1 Organisation structure

3.2 Production department

3.2.1 Production of steel casting

3.2.2 Material requirement and procurement plan

3.2.3 Inward goods inspection and laboratory

3.2.4 Planning department and procedure

3.2.5 Process control and procedure

3.2.6 Production process flow chart

3.3 Human Resource Department

3.3.1 Objectives of HRM

3.3.2 Functions

3.3.3 HR Policy

3.4 Finance department

3.4.1 Objectives of Finance department

3.4.2 Finance (People)

3.5 Marketing Department

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CHAPTER-3

ORGANISATION STUDY

3.1 Organisation structure

Managing director

General Manager

Personnel and administration

Department

depar

Production H R Manager Financial

manager manager

Assistant’s Manager

Supervisor Asst. Manager

Worker

Worker Clerk

Source: company manual

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3.2 PRODUCTION DEPARTMENT

3.2.1 PRODUCTION OF STEEL CASTING

A) Preamble:

A business unit is established for the purpose of production and distribution of

goods and services. Production is an international act of producing something
useful in an organized manner. In other words, production is organized
manufactured for the converting of raw materials into finished goods.

Production management of Bhumika Alloy Castings Pvt. Ltd. Starts with the
purchase and proceeds with other for the effective production.

B) Supply of Raw Materials:

Before knowing about production process we have to study the process from
supply of raw materials to the last process of product. If starts from the
purchase department work.

Purchase function covers all activities relates to procurement of raw materials

and other materials of company The procurement shall be planned generally
based on the production plan. The purchase is to interact with planning,
stores, production, and quality control and raw materials are made from
approved vendors.

The director of the purchase function and Chief executive assists him. In
charge of purchase department will be responsible for all activities related to
procurement of materials in the company under authorized to send enquires
and orders.

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Main function of Purchase Department

 Receive the request for materials for stock from stores department or
planning department.

 Then the in charge of stores will coordinate with the stores and
makes the list of materials required for production.

 Refers to the venders who are associated with the supply of materials
to the company.

 Contact suppliers over phone as certain the availability of materials

price / rate and delivery schedule.

 Prepare purchase order in the standard format giving materials

specification, type class grade or other precise identification quantity
terms and conditions review and approved.

 Amendments in case of any change in requirement like change in

material specification quantity, terms and conditions, a fresh
purchase order withdrawn on consultation.

 Follow-up the in charge of purchase department will keep in touch

with suppliers over phone, in few cases it is also practices to send
reminders, and the same will be informed to the management.

 Receipt of materials the store department will receive the material

supplied by the supplier against the purchase order by handing over
the necessary documents. Purchase department will keep in touch
inception department and collect the acceptance or rejection report.
In case of rejection, the rejected materials will be sent back to the
supplier with necessary documents along with rejection report and
reason for rejection. The purchase department will again take up with
the supplier for replacement.

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 Supplier verification and sub contractor’s premises and customers

verification of subcontract and products are not practiced in the
company.

 Vender approval present list of suppliers who are associated with us

are treated as default vendors.

So, for the purpose of briefing whole purchasing function in detail

information is provided below.

3.2.2 Material Requirement and Procurement plan:

Collection of details on raw materials on raw material stock and raw material
procurement planning. Initiate procurement activity as per approved supplier
list Raise purchase order/indent for materials (for component production,
consumable etc) as required.

Role of Purchase Indent:

Purchase order/indent to include or make reference, to the applicable

specification, to the drawing and its revision, requirement of test certificate, if
application, quantity price delivery and other terms and conditions,

Review of purchase order for adequacy and approval, monitory delivery

performance from supplier. Amendment to purchase order in case of change
in quantity, schedule price requested by supplier, technical specification,
leading to price revision any other commercial changes.

Stores:

Stores function is responsible for storing raw materials and other

consumables, accessories and issue the same to production after receipts,
while maintaining first in first out and trace ability. In addition to this, stores
also maintain a list items with self-life, review and take necessary action.

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The in charge of stores receives the ordered material and cheeks against
delivery- challan/invoice, weight specification and prepares goods receipt
note. If the materials received, does not meet the requirement, reject the
material and attach a copy of inspection report to purchase as and when the
materials are accepted. The in-charge of stores has to update stock ledgers as
and when the materials are issued to other department. The materials, will
short life, is recorded and reviewed periodically and the feedback is given to
purchase department.

3.2.3 Inward Goods Inspection and Laboratory:

Inward Goods Inspection:

Department of inward goods inspection or testing of all incoming raw

materials and to assure the qualities of materials are as specified. This
procedure covers inspection and Testing of incoming raw materials, which are
used in production.

The in charge of inward goods inspection is authorized to inspect and text

incoming raw materials and is responsible for maintaining records.

Procedure:

 The in charge of stores offers the inward goods materials to inward

goods department.

 The in charge of inward goods inspection receive the goods receipt note
and other document and carries out visual inspection.

 Sample of materials for carrying test for acceptance is collected.

 The details of test carried are explained by the laboratory work

instructions.

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 In case the sample collected meets the requirements, stores department

is informed of the acceptance along with the inward goods inspection
report.

 In case the sample collected does not meet the requirement store
department is informed of rejection along with the goods inspection
report.

Laboratory:

Chief chemist heads the laboratory and he is the in charge of laboratory. He is

authorized to carryout activities like analysis of chemical properties
laboratory is responsible to give chemical charge for meeting materials as per
production plan as requested by production department.

Procedure:

 Raw materials, which are received from supplier after receipt at stores,
the in charge of stores, will offer the same materials to inward goods
inspection for analysis.

 In charge of laboratory receives the test bar sample of poured products

from inspection and testing departments and carries about analysis of
chemical and mechanical properties.

 Prepare analysis and report and record.

3.2.4 Planning Department and Procedure:

Production starts with planning. Planning function covers preparation of

production schedule as per the customer requirement and to meet the
production target. These functions also cover all the activities related to
customer’s requirement and make available the productions in time.
Customer’s requirement and specifications are received in the form of

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purchase order. Planning department prepare work order, releases the same
for execution, and prepares schedules / job cards for mould and core dispatch
to finished products to ensure delivery schedule.

Planning department also take up inception and testing for the dispatch of
finished products to ensure delivery schedule and updates purchase orders and
the same shall be sent to customers and when required.Chief executive is the
head of the planning function and is assisted by in charge of panning.

Procedure:

 Receive purchase order / drawing from customers through marketing

departments.

 Release of acceptance note / order acceptance.

 Prepare work order and release the same for mould and core making for
production departments.

 Prepare production schedule / job cards for mould and core dispatch of
finished productions to ensure delivery schedule.

 Updates purchase orders and prepare pending other and the some shall
be sent to customers as and when required.

3.2.5 Process Control and Procedure:

In this department they developed the process to obtain the part of produce or
product as per pattern through which molten enters the mould. This function
covers activities to develop process and prepare methods cards for prepares
mould and cores.

Development and process control, department analysis requirement to

develop the process, preparation of molds and cores and coordinates with
molding department to produce a product.

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Chief executive is the head development and process control and has full
authority for the above functions and he is assisted by the in charge
development and process control.

Procedure:

 Receive the patterns with corresponding drawings from customer.

 Inspect the pattern / core box as per drawing.

 Develop the process to obtain part or product as per week instruction.

 Develop method cards with reference groups.

 Prepare pattern mounting as per work instruction.

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3.2.6 Production Process flow chart

RECEIPT OF MOLDS/DIES /END COVERS RECEIPT OF RAW MATERIAL

INCOMING
MOLD/DIE /END COVER INSPECTION
INSPECTION

INSPECTION

DIE PREPARATION (HEATING) CASTING

PROCESS SELECTION OF RAW MATERIAL

APPLY COATING BY ROTATING MOLD CHARGE ESTIMATION GRADE WISE

MEASURE THE COATING THICKNESS MATERIAL MELTING BY INDUCTION

MELTING FURNACE

FIXING END COVER TO THE MOLD BY LOCKING PINS

LADDLE PREPARATION & LADDLE
PRE HEATING
ALLIGN THE FUNNEL AT ONE END OF THE END COVER
CHECK COMPOSITION OF MOLTEN METAL & POURING TO
COREE
ASSEMBLEDmoulds
ROTATE MOULD TO REQUIRED RPM SOLIDIFICATION OF POURED METAL IN MOLD/DIE (BY
SPRAYING WATER ON ROTATED MOLD & COOL)

CASTING REMOVAL BY EXTRACTION

ROUGH CASTING INSPECTION

HEAT TREATMENT (IF REQUIRED)

FINISHING ( PRE MACHINING IF REQUIRED)

NDT IF NECESSARY REJECTION (IF FOUND)

FINAL
SEND TO NC BIN
INSPECTION

PACKING (IF REQUIRED)

PRE DISPATCH INSPECTION REPORT & MATERIAL TEST REPORT

DESPATCH ADVICE

Source: company manual SHIPPING

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Manager is the head of the production function and he is assisted by the

production in charge. The function of this department is to produce the
products as per specifications and to meet the requirements of the customer.
This procedure covers all the production activities for producing the products
of different types in the company.

In charge of production, function is authorized to carryout activities like

requisition the moulds, cores, raw material, power, machinery, chemical
charge, melting cutting. In addition, offer for inspection and testing. He is also
responsible to manufacture the products as per quantity plan and follow the
work instruction.

Procedure:

 Receive production schedule / job card from planning and preparation

plan ship. Issue production plan ship to laboratory and request for
chemical charge.

 Receive mould and cores from mould and core making and ensures no
back moulds and cores are coated after 185 to 24 hours of curing and
used for production if CO2 moulds and cores are received the same
can be coated and used for production as and when required.

 Coat the mould and cores, which are required for production by using
painting brush / spray gun.

 Assemble mould and cores, as per schedule / job card.

 Collect chemical charges sheet from laboratory and prepare chemical

charge requisition to stores.

 Receive melting materials from stores as per chemical charge

requisition verifies check.

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 Select well-lined ladle and pre heat the same. Loading of melting
materials.

The drawn melting materials are loaded to the furnace as per sequence:

a) Return / Scrap

b) Raw materials / Charge

c) Alloying elements.

Once the melting materials attain the pouring temperature, measure the
temperature with the help of pyrometer and record. Then transfer of molten
metal to the pre-heated ladle and add de-oxidizing agents as per charge sheet.
The molten metal in the ladle is the transfer to the assembled mould. Place a
strip with heat number punched on the runner for the purpose of trace ability.
Pour one test bar for internal analysis purpose is each heat and give the
poured quality material grade, work order number, mould core number,
weight of casting, poured weight of casting and chemical charged details.

Knock out of the Mould

Poured molten metal moulds are not disturbs for 2-3 hours and later the same
is destroyed to extract the poured product and test bars are pouched with heat
numbers by identifying the strips placed and released for cutting. Cutting of
operations is carried out on the products to remove the runners / raisers gates
provided and after completing of the same products are usually inspected and
if found to meet requirement and the product will be handed over to
inspection and testing department for further processing if not the same will
be rejected at production department.

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I. Pre-Production Process:

 Raw Materials

Various raw materials required are s.s. Scrap, M.S. Punching Scrap,
Petroleum coke, Ferro alloys, Ferro Molybdenum, Ferro Titanium, Ferro
Silicon Zirconium, Aluminum, copper, Calcium Silicate and Cerium Mish
metal etc. These raw materials are available

These raw materials are available at Bangalore, Bombay, Chennai, Shimoga

and other places. All the materials are easily available and certain items like
nickel are routed through the Bangalore Venders. Excepting this all other, raw
materials are free from government control and no scarce of raw materials is
involved.

The other consumable like grinding wheels, tool tips, welding rods bolts, nuts,
cotton waste, lubricating oil, kerosene and cooling materials, silica and resin
etc., also available in Karnataka.

Labour

Which is employed in production process are about 80 people. Who are

almost from Srirampura and its surroundings.

A good and cordial relationship between management and labours can be seen
in the unit. Bhumika Alloy Castings Foundry believes that in keeping the
workers happy, they can have good end results and labour turnover can be
avoided.

The foundry is good in providing

a) Employee Health.

b) Employee Welfare.

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a) Employee Health:

The labours are provided with uniform, safety shoes, helmet, and furnace
gaggles and head makes during production process. And a periodical medical
Check-up is also held to avoid occupational diseases.

b) Employee Welfare:

Welfare provision like, provident fund, Medical allowance and workmen

compensation, Insurance benefits for the safety of employees have been
made. They are also getting drinking water, food, coffee or tea, and rest room
facility in the unit. Medical leave is also granted.

Power and Water:

Electric power required is 440kw provided by MESCOM.

Water requirement is depend upon the work; it is available from the open well
in the plot.

3.2.7 Plant and Machinery:

The main plant required is medium frequency coreless induction,

furnace. For this, the selection of the equipment is made after considering the
various factors like capacity, meeting rate, power and control systems etc.,

The various machinery like Compressor units sand Muller, hardness test etc.,
are selected from reputed manufactured.

Production activities, which understand is can be studied under several head,

which are as follows:

Molding and core involves systems of making mould. They are,

1) No-Back Binder.

2) CO2 Mode.

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3) Green Sand Mode.

4) Shell Mode.

In addition to sand is mixing the sand mixer. It is dividend in three

types.

Part-A: 2 to 2.3% of sand (2 to 2.3 kgs)

Part-B: 5 to 10% of part-A (100 to 200grms)

Part-C: 15 to 20% of part-A (350 to 400grms)

Mixing:

Take required quantity of sand in kgs and transfer it to the running sand
mixer, add 100-300grms of iron oxide to improve hot strength and mix for
one minute. Add mixture of Part-A and Part-B slowly, continue mixing for
two minutes, add Part-C slowly, and continue mixing for two more minutes.
Transfer the mixer sand to the pattern or core boxes, which are kept ready.

I. During the production Process:

Above all procedure consisted to after will doing the below process. They
are.

A) Moulds and core making process:-

No-bake sand is used for facing and silicate sand for packing purpose.
Keeps ready the patterns, chills, sprees, riser, selves, flow-off etc., as per
the respective method cards and provide them in the moulds. Transfer the
prepared No-back sand first on the patterns facing and silicate next for
baking. Ramming the sand pressure depending on the depth of the moulds.
As no-back, sand requires min 25 to 30 min for stripping, and ensures the
moulds are removed after 30 min.

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For core making, cheek the core boxes are damaged and select necessary
clamping devices. Clean codes boxes with emery paper. Place two halves
of core boxes and clamp. Fill code box with required quantity of mixed
sand used or former of pipes to make hallow cores to minimize sand
consumption make proper vent using different die vent rods. Strip the core
after setting. Tap the core box with wooden or rubber molten for easy
stripping. After stripping, keep it in the designated place

B) Coating of Mould and core:-

Before coating of moulds and core, it is necessary to prepare water base and
thinner base or zircon sand base or alcohol base. Water basing is the mixture
if 1kg paste and 1.0 lts water. Thinner base coating is the mixture of 1.0kg
paste and diluted with 1lts of thinner neutron cellular.

After preparing the bases, coat the mold and core by using sprayer or brush.
Alloy the coating to dry in air. The coating of bases in necessary to avoid
reaction between mould and metal. Assemble the mould and core as per
schedule or job card. Drag by bolding or damping keeping weights.

C) Melting and Pouring

Metal is melted in the cored less induction furnace. Furnace lining is prepared
by magnetic ramming mass paste by adding water and sodium silicate at ratio
6:1:2. Asbestos sheet is placed inside the furnace coil. Switch on the furnace
for 3 hours to remove moisture completely. Metal is melted in the coreless
induction furnace out of raw materials like selected grade punching scrap,
with alloy elements like Ferro chrome, nickel, Ferro molly, manganese, Ferro
silicon etc., (Note:- The raw materials and alloying materials are to be tested
before melting in the laboratory to understand the percentage of metal content
available with carbon percentage and other elements etc.,) While melting, the
power raised gradually until the molten metal reaches the desired temperature.

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The normal melting temperature is 1535c to 1600c as pouring temperature is

1630c to 1635c.

Ladle is the utensil or a container, which is used for carrying molten metal
from furnace to the mould. Outside surface of ladle with ramming lining,
paste about one inch. Once the molten metal’s reach the required temperature,
metal are transferred to add to the ladle. The per the job card from distance of
half feet (6 inches) height from the mould and at normal floor. Poured molten
metal moulds are not disturbed for 2 to 3 hours and later the same are
destroyed to extract and test bars are punched with heat numbers by
identifying the numbers the strips placed and released for cutting.

D) Cutting

This process involves cleaning the casting by using wire brush. Chipping sand
particles that are struck to runner, raiser, gating system by using chisels. As
per cutting reference provided, cut runners, raisers, and gating string cut the
runner, raiser and gating separately till chemical analysis carried out.

E) Fettling

Fully fledged in-house fettling shop with facilities for are cutting, gas cutting,
swing frames, die grinders, pneumatic tools, shoot blasting, sand blasting,
acid picking and passivation after cutting are moved for fettling for projected
runners, raisers and parting line. The position of runners, raisers and parting
line are ground properly with the help of grinders and the surface of final
product is matched.

F) Welding

It involves identification of surface defects on the casting, selecting

appropriate welding rods to weld on casting as per specifications. Cleaning
the surface of the casting to be welding. Carrying out weld repaired in casting

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by using welding current dressing, extra welding material with the help of
flexible hand grinders to match the surface.

G) Heat Treatment

Select one specific grade of material with corresponding test bar. Land the
casting along with the bar and push the bogie inside the furnace. Switch on
the strip chart recorded to keep heat treatment cycle details and set the
temperature control close the furnace, carry out process as per heat treatment
cycle details, also set the temperature controls, close the furnace, and carry
out process as per heat treatment cycle for different grade materials.

H) Short Blasting

The fitted castings are placed on the table of the short blasting machine and
the door is closed. The machine is set on for 5 min, after 5 min the casting
positions are charged add again short blasted for 5 min. Unload the casting
from short blasting and inspect, repeat the procedure if needed.

I) Quality Assurance program

Quality assurance Program followed by the foundry can be seen in the

following captions.

 General

The quality assurance program is designed and established to provide a

superior product to serve the best interest of the customers. Brief descriptions
of the various quality control procedures that are built into our foundry
practice to ensure good quality casting are detailed here below.

 Design

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Even at the enquiry stage, the technical details of the product are examined in
detail to ensure the feasibility of manufacture. In most cases the technical
officers visit the consumer organization to get acquainted with the application
of the casting. This helps in determining whether the specification stipulated
by the customer is an optimum specification or not.

After receipt of order, pattern donning is made of each casting taking into
consideration the meth ding, sand practice etc. If necessary consultations are
held with the customers regarding tolerance required etc.

Every pattern will be inspected for all the dimensions, and after the same is
found all right, the sample casting is produced and completely inspected with
regard to dimensional conformity to the respective drawing are found correct,
bulk production is started.

 Materials control

All the raw materials like scrap and Ferro alloys are stored separately. The
materials analyzed for the constituents as they received from suppliers. The
materials affecting the quality of the casting are separated from the charges.

All the generated scrap in the foundry will be properly identified with color
code and stored in separate appropriate bins.

 Identification retain as it is.

Each casting will have the following information cast into surface:

a) Part No.

b) Material Code

c) Serial Number, which could be linked to be date of pouring, that

number, the mechanical and other results of the heat, etc.,

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d) Manufacture’s identification marks

In addition to the above, other codes are required by the customers are cast
will the casting.

 Melting / Pouring controls

The charge is carefully calculated taking into account the raw materials and
alloy analysis of inputs and the final analysis required. It will also take into
account the losses which are expected during the melt and other additions
required to purify the liquid metal.

A sample from the molten metal is analyzed for its constituents and liquid
metal is tapped the final analysis is confirmed and the temperature required
for pouring is achieved, the temperature is measured by “Pt /PtRh
Thermocouple”.

In addition above sample are taken from castings, also to confirm the analysis.
Every mould / core is examined at each stage and extra care is taken while
setting the core and closing the moulds by using suitable gauges where
necessary.

 Cleaning and Heat Treatment

The castings are permitted to cool in the moulds for a sufficient period, after
which they are removed from the sand moulds. Gates and risers are removed
and castings re cleaned by shoot blasting, grinding, etc.

The castings are subjected to heat treatment depending on the requirements.

The heat treatment is controlled by digital indicator after heat finished as per
the drawings. The heat treatment chart will be made available for reference.

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 Final Inspection

Integrally cast test bars are separated and subjected to mechanical test and
hardness measurement as required by specifications. The casings are fully
inspected for visual defects and also by liquid dye penetrate tests or man flax
for subsurface defects. Dimensions are checked by using various measuring
instrument to confirm to the required specification.

Where machining is involved, the castings are subjected inspection again after
machining. Non-destructive tests like done wherever necessary. All the details
are maintained in records for later reference wherever required.

J) Sales and Dispatch

The production procedure is triggered by placing of order by its customers.

The customer or order givens to Bhumika Alloy Casting Foundry are Pentair
water India and Automotive Axles Company who are the major customers.

The whole production process is designed as per requirements of its

customers. The production department will be clarified and accentuated about
the type of product to be manufactured. After completion of production, the
prepared goods are moved into warehouse. After receiving the details and
clarifications like purchase orders or invoice and inspection from the
customers about quality and quantity products and number of products as per
order placed earlier.

After all the paper work, authorized person will receive the goods to transport
the manufactured product up to its determined destination. And, ambience
where the plant is located is useful to connect to state highway to transport
goods to its destination.

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3.3 HUMAN RESOURCE DEPARTMENT:

H.R. Department

MANAGER (HR)

DGM (HR)


Administration Officers
Assistant Manager

Source: company manual

The total man power for the sponge iron unit would be

80 persons.

3.3.1Objectives of HRM

 Social objectives

 Organizational objectives

 Functional objectives

 Personal objectives

Social objective

The social objective of HRM is to seek and to ensure that the organization
becomes socially responsive.

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Organization objective

It makes sure that HRM is not a standalone department but rather a

means to assist the organization with its primary objective.

Functional objective

It reminds the HRM that it has only functional value and should not
become too expensive.

Personal objective

It assists employees in achieving their personal goals.

3.3.2 Functions

 Planning

 Organizing

 Directing

 Controlling

Planning It is a pre-determined course of action.

Organizing It is essential to carry out the determined course of action. It is

execution of plan.

Directing The manager should direct the subordinates. The willing and
effective co-operation of employees for the attainment of organizational goals
is possible through direction.

Controlling The performance is to be verified in order to know that the

personnel functions performed in conformity with the plans and directions of
an organization. Control also involves checking, verifying and comparing of

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the actual with the plans, identification of deviations if any and correcting of
identified deviations.

3.3.3 HR Policy

 They continuously foster a feeling of community amongst their work-

force.

 They work as a collective force towards a goal that benefits everybody.

 A part form on-the-job training and technical training, numerous

programs on general management and behavioral topics are conducted
each year.

 Their remuneration and incentives match among the best corporate

organizations in the world.

Recruitment process

 In this organization the recruitment process consists both internal

factors and external factors.

 Whenever there is vacancies and need for employees they go for

recruitment process. Here the job analysis process begins and by
analyzing the mgt will come to now in what number the employees
needed and etc.

 They recruit from reference, employment exchange and consultancies.

Selection

 After completing the recruitment process then they step into the
selecting process.

 Here they are going to verify the applications which are received in the
recruitment process from the job seekers and they will screen the

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applications according to their job discrimination. In this procedure

among the received applications some of them are eliminated and some
of them are selected.

 They call upon the selected applications for the interview.

 In this procedure they try to analyze the applicant whether he is having

the required knowledge or not, he is suitable to work in this
organization or not, about his past experience if they got and many
more about his or her personal matters, etc.

 After completing the interview they have to attend the medical

examinations or tests conducted by the company and they have to
qualify in it.

Training and development

 After appointing the applicant if he or she is into functional level

training will be given to them. But if they are into mgt level
development programmed is conducted to them.

 As we know there are 2 types of training we have like on the job

training and off the Job training. Here in this organization they have
on the job training. Here they have to work in; team and with
experienced persons and they have to get the training from them. In
such a type of training the employee will observe each and every
which is going in the plant and he can have practical knowledge. Here
they can clarify their doubts immediately.

 As per as development program is concerned the mgt will arrange a

seminars from the experts in the related field.

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Employee welfare :-

Working environment

 Maintaining safety and cleanliness measures.

 Control of effluents.

 Convenience and comfort during work that is operative’s posture,

seating arrangements.

 Workmen safety measures like maintenance of machines and tools,

providing guards, helmets, safety glasses, etc.

Workshop sanitation and cleanliness, temperature, humidity ventilation,

lighting, etc.

Conveniences

 Providing of drinking water.

 Food, coffee/tea facility.

 Rest rooms, etc.

Workers health services

a. Dispensary

b. Ambulance

c. Emergency aid

d. Medical examination

e. Giving hints on health

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3.4 Finance department

Manager (finance)

Assistant Manager

Superiors Accountants Officers

Source: company manual

FINANCE DEPARTMENT

The finance function deals with the procurement of money at the time when it
is needed and its effective utilization in the enterprise

Money is the life blood to purchase of any enterprise as it is requires

purchasing machines and materials to pay wages and salaries to employee and
to allow credit facilities to customers.

An important requirement for the success of any business organization is the

provision of sufficient amount of funds or capital.

If cannot work unless it has got sufficient amount at its disposal to purchase
machine and materials, build premises and meet day to day expenses and
several other purpose.

The advent of capital intensive techniques has increased the importance of

finance the ambition planes of an industrial under taking will remain mere
dreams unless adequate finance is available to convert them into reality.

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Therefore it has become an important function of the enterprise. For

companies, which carry on production and distribution on a large scale
provision or adequate finance, is a very challenging task.

If affects all the business decisions where money is involved, since the large
commercial and industrial undertaking are set up in the form of companies,
the problems of finance for modern business is for all practical purposes of
the problem of corporate finance all the important financial decisions are
taken by the board of decisions of directors of company.

3.4.1 Objectives of finance department

Since financing is one of the function are of any business enterprise, the
objective of financial management must be in tone with over all objectives of
the enterprise the objectives of the finance department should be so devised
they contribute directly towards the achievement of the overall organization
objectives.

 Ensuring regular and efficient supply of the business.

 Ensuring a fair rate of return on capital to the supplier.

 Ensuring better utilization of capital by following the principles of

liquidity, profitability and safety.

 Co-coordinating the activities of the finance department with those of

the other department of the enterprise.

3.4.2 FINANCE (PEOPLE)

Manager A/c’s

Concerned with determining relevant cost and performing other analysis like
preparation of budgets and performance analysis based on budgets.

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Finance Manager:

Is responsible for overall financial planning and for raising capital he has
following function to perform major activities are financial, forecasting, fund
management and auditing capital budgeting.

POLICIES:

1. Account is prepared on historical cost ongoing concern basis the

company has adopted accrued concept in preparation of financial
statement.

2. Fixed assets are stated at cost less depreciation ends expenditure during
construction periods are debited to the capital WIP and the same will
be allocated.

3. Valuations of inventories like RM stores and spaces are valued at

weighted average late-finished goods including traded goods are stated
at cost/net realizable value well.

The advent of capital intensive techniques has increased the importance of

finance the ambition planes of an industrial under taking will remain mere
dreams unless adequate finance is available to convert them into reality.
Therefore it has become an important function of the enterprise. For
companies, which carry on production and distribution on a large scale
provision or adequate finance, is a very challenging task.

If affects all the business decisions where money is involved, since the large
commercial and industrial undertaking are set up in the form of companies,
the problems of finance for modern business is for all practical purposes of
the problem of corporate finance all the important financial decisions are
taken by the board of decisions of directors of company

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3.5 Marketing Department:

Marketing is a social and managerial process by which individual and

group obtain need through creating, Bhumika Alloy casting Pvt.Ltd,
marketing process consists of analyzing marketing opportunities, developing
marketing strategies, planning marketing programs and managing tools. There
is one person handling marketing activities with help of HOD and
administration. Bhumika Alloy Casting Pvt ltd. is well known its own way
and doesn’t need any market for its products customers not invited, they come
by themselves. It is responsible for following activities.

 Product analysis, competition analysis, determines customer

satisfaction, prize and order administration.
 Customer interaction, prize updating, customer complaint, handling to
study, enquiry and replay regarding feasibility,
 To co-ordinate for product prize finalization.
 It also responsible for other internal dispatch as operation.

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CHAPTER – 4

MCKINESEY’S 7’s MODEL

4.1 Introduction

4.2 Mckinesey’s 7’s structure

4.3 Structure

4.4 Strategy

4.5 System

4.6 staffing

4.7 Skills

4.8 Styles

4.9 Shared values

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CHAPTER-5

IMPLEMENTATION OF McKINSEY 7S MODEL

4.1 Introduction

The 7-s Model is better known as McKenzie’s 7-s Model. This is because of
two people who developed this Model, Tom Peters and Robert Waterman,
have been consultants at McKenzie’s &Coat the time. The model starts on the
premise that an organization is not just structure, but consists of seven
elements.

The 7-s Model is a tool for Managerial analysis and action that provides a
structure with which to consider a company as a whole so that the
organizations problems may be diagnosed and a strategy may be developed
and implemented the 7-s is a frame work for analyzing organizations and their
effectiveness. It looks at seven key elements that make the organizations
and'their effectiveness.

4.2. McCKINSEY’S 7’S STRUCTURE

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4.3 STRUCTURE:

The structure of the organization is democratic. Major decision however is

taken is at top-level management of the company. For analyzing and for
taking decision the top management will consult the functional managers
and the lower level staff. Performance of various tasks in departments will
be assigned to its functional.

4.4 STRATEGY:

By fixing the competent value, they attract the suppliers and customers by
offering the competent. By purchasing the more raw materials they keep
continuous production. They try to meet the customers demand as early as
possible.

At Bhumika Alloy castings they present their faith, they believe their core
values. They strive towards the achievement of their customer satisfaction, to
provide safe working environment, working condition, to maintain discipline
at all level, to provide a friendly, congenial working atmosphere, employee
satisfaction to the maximum. Their main concern is for their employees and
their welfare. Equal importance is given for the environment protection and
towards production .

To serve as an instrument of the national to achieve self reliance in the design,

development and Quality Production of Bhumika alloy casting. Products to
meet the customer’s changing and growing needs

 In fulfillment as this objectives, the company shall regard itself

fundamentally responsible design and developments, relying however
on such relevant facilities as are available in other National institution
but always holding itself basically responsible for the growth.

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 To conduct its business economically and efficiently that it contribute

its due share to the National Efforts to active self reliance and self
causing economy.

 Towards this end to develop, maintain an organization which will

rapidly respond to and adopt the changing Matrix as socioeconomic
relationship and where in a climate as growing technical competence.
Self discipline mutual understanding deep commitment and sense of
Bhumika Alloy casting. Ongingness will be fostered and each
employee will be encouraged to grow with accordance to his potential
for the furtherance as organizational goals.

 Consistent with the basic objectives of the state the personal

department of the corporate office has adopted certain specific
objectives, which will act as a source as inspiration and guidance in
evolving per sonnet policies and roaming rules and regulations for
growth and development or employees and to ensure their deep
commitment and sense of fasteners and allied product Songingness to
the company, and the objectives are stated fasteners and allied product
sow

1. Insure equality at all the levels and provide them the right work
Environment, job satisfaction and professional challenges.

2. Provide healthy blend or employee who have grown with original

those Selected from outside

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4.5 SYSTEM:

The company partially computerized. Production department depends upon

the manual work. Office work is computerized. An organized
purposeful structure that consists of interrelated and
interdependent elements (components, entities, factors, members, parts etc.).
These elements continually influence one another (directly or indirectly)
to maintain their activity and the existence of the system,
in order to achieve the goal of the system.

All systems have

 Inputs, outputs and feedback mechanisms,

 Maintain an internal steady-state (called homeostasis) despite a
changing external environment,
 Display properties that are different than the whole
(called emergent properties) but are not possessed by any of
the individual elements, and
 Have boundaries that are usually defined by the system observer

It’s required Top-level management has the ability to engage all work
groups in coordinated manner, which enhances productivity in all
departments.

The stores Department in Bhumika Alloy casting follow the Codex system
(Coded Control system). A card is maintained for each item and a number is
allotted. The card is attached to each article consists of amount balance, date
of issue, purchase etc. this is later recorded in separate ledger book. The
inventories are of different kind ranging from mechanical, spares, packing
items etc.

 This department has the following services:

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 It tries to maintain maximum and minimum level of inventory

 Ordinary and locally available commodities are maintained at

minimum possible level.

4.6 STAFFING

The company is having highly qualified and skilled staffs working together
to achieve the organizational goals. The company is covering its marketing
activities with general manager, assistant manager, supervisors and
employees. The staff have been recruited through predefined process,
selected, and observed through training. In co. there are 80 regular
employees excluding executives and other officers, supervisors and clerical
staff
The staff deals with the various personnel policies followed by the
organization . The personnel policies followed by the organization.

Personnel Policies:

There are around 80 employees working. There are various policies

followed. The Administrative department forms the policies.

 Recruitment and Selection:

 Due to registration, termination, retirement and transfers the concerned

department head will give the manpower requirements along with the
job description.

 The manpower sourcing is done through manpower consultant, and

employment exchanges and personnel reference

Promotion:

Promotion is on the basis of seniority.

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4.7 SKILLS:

The company is having number of skills Labours, which jointly and

effectively produce the end results. Most of the employees are multi
skilled; this makes the company working without any interruption. The
supervisions in the production department are having a positive attitude to
motivate the workers to achieve the organizational goal.

The middle level management both inside and outside the company is highly
dedicated. All the middle level management people are skilled and are
capable of taking decision whenever

1. ADMINISTRATIVE SKILLS:

The administrative skills are managing the resources of the organization,

communication skill, management information system, leadership quality
which are necessary office staff. The Bhumika Alloy casting is evaluated and
select suppliers based on their ability to supply product, which meet the
specified quality requirements. The organization training to all the personnel
in the company Maintain records coordinates with different functional heads
in identifying the training needs and prepare training schedule. The company
gives on the job training in every month. After the training the HOD’S
observe the training effectiveness and give correct comments for their
effective work.

2. TECHNICAL SKILLS:

Technical skills are directly concerned with the production activity smoothly.
The Bhumika Alloy Casting gives importance to their technical skills and
knowledge, personality, qualification etc. the company improves the
employees efficiency and knowledge of work. So it requires the different
training programs in all levels especially Technical skills. The personal also
attend some guest lecturers programs. It is helpful to get update their

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knowledge in industry level. The company identifies the training needs and
gives to all employees. After the training HOD’s Observe the changes in the
effective work of the employ. Then file it in a record of the company.

3. TECHNICAL STAFF:

These are the Staffs they are responsible for the Work related to technical
aspect in this Company 3 they are appointing Well qualified and Experienced
persons as technical staff

These are the distinctive competencies that are present in the organization it
is the design and development of products quality and service or viability of
product. The employees in this organization also have all the distinctive
skills that are required for the undertakings of research and development
activities. The Bhumika Alloy casting is improving the employee’s skills
and techniques through motivating them and giving proper training to them
also through giving proper working condition.

4.8 STYLE:

The company is following the participative and social type of leadership in

which all the level of managers interact with each other for achievement
towards the goal and report to the higher officials. Manager’s work together
as team to solve today’s and tomorrow’s problems in a significant manner

 Bhumika Alloy casting has top to bottom or top down style system.

 The style of organization is authoritarian. It means management cadre

follows authoritative.

The indicators of the style are:

• Follows rules and orders

• Reliable and dependable

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4.9 SHARED VALUES:

It refers to a “set of values and aspiration that goes beyond the convention
formal statement of corporate objectives”. Shared values are the fundamental
ideas around which a business is built. They are its main values the broad
motions of future direction that the way the top management as a team wants
to express itself.

The core or fundamental values that are widely share in the organization and
serve as guidelines that are important, these values have great meaning
because they focus attention and provide broader since of purpose.

The values of the organizations are

1) Customer Satisfaction.
2) Commitment to total quality.
3) Costs and time consciousness.
4) Innovative and creative.
5) Trust and team spirit.

6)Respects for individually.

7) Integrity

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CHAPTER – 5

SWOT ANALYSIS

5.1 Introduction

5.2 Strength

5.3 Weakness

5.4 Opportunities

5.5 Threats

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CHAPTER-5

SWOT ANALYSIS

Source: website, www.google.com

5.1 Introduction

The SWOT analysis provides information that is helpful in matching the

firm’s resources and capabilities to the competitive environment in which it
operates as such, it is instrumental in strategy formulation and selection and it
also provides a scan of the internal and external environment of the strategic
planning process.

Environmental factors internal to the firm usually can be classified as strength

or weakness and those external to the firm can be classified as opportunities

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or threats such an analysis of strategic environment is referred to as SWOT

Analysis.

5.2 Strength

Strength is defined as the positive attributes of the organization, which are

within the organization’s control. Such as, technical and experienced
manpower, improved infrastructure, efficient market network, well planned
layout, automated and highly sophisticated machines and major customers are
educational

 The company has adopted latest technology for production activities

the machineries are well equipment

 Maintaining quality standard.

 On time delivery of product.

 The company have good relationship between employer and employee

 The company protects employees by giving safety equipments.

 Easy availability of raw material.

 The Company has financially sound.

5.3 Weakness

The property of lacking physical or mental strength liability to failure under

pressure or stress or strain his weakness increased as he become older the
weakness of the span was overlooked until it collapsed.

 Lack of marketing actives.

 Less publicity.

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 Lack of facility like canteen.

 The company doesn’t have own brand product.

5.4.Opportunities

The property of lacking physical or mental strength liability to failure under

pressure or stress or strain his weakness increased as he become older the
weakness of the span was overlooked until it collapsed.

 By maintaining its quality of products, the company can enter different

foreign markets.

 Competitive environment calls for improvement and increase in

productivity.

 Skilled man power & Established process Standards.

5.5 Threats

Positive or negative aspects of the external & internal environmental, that is

under the direct control of a firm or a decision maker.

 Changing in preference of customers.

 Many competitors are entering to the market.

 Government policy towards the manufacturing industries

imposing environmental pollution restriction.

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CHAPTER – 6

FINDINGS AND SUGGESTIONS

6.1 Findings

6.2 Suggestions

6.3 Conclusion

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CHAPTER 6

FINDINGS AND SUGGESTIONS

BHUMIKA ALLOY CASTINGS PVT.LTD. is operating with the Social

responsibility concept bearing in the mind. It is the company which has good
name in the domestic area. After the completion of study in the BHUMIKA
ALLOY CASTINGS PVT.LTD. Following findings have drawn.

6.1 FINDINGS

 There is continuous training and developments to the workers.

 Lack of Transportation facility to the employees.

 Unplanned purchase of Raw materials in case of emergency.

 High Productivity.

 The co-ordination between management and workers is good.

6.2 SUGGETIONS

 It can improve awareness in the minds of employee through systematic

training.

 Company should concentrate on Purchasing of Raw Materials.

 Improve the house keeping

 Effective utilization of land and other assets.

 The company should arrange the transportation facility to the workers.

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 The company should improve it’s technology to gain more profit and
better production.

 The company should maintain the primary medical help when accidents
happen in the company.

 If any accidents taken in company premises the company should

immediately pay the compensation for the employees.

6.3 CONCLUSION

By study the various welfare measure providing to the employees we can say
that industry interested in the welfare of employees. So along with the
statutory and non-statutory welfare measure the industry is also providing
social security measures

It is clear that the statuary welfare measure provided to employees has lead to
increased satisfaction. But the non-statuary welfare measure has to be still
increased by the implementation of the facilities like the group insurance,
vehicles etc

The company also meet the standardization as per the Govt, rules and
regulation and also the company has delivering superior values to the
customer and other by providing good quality product.

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BIBILOGRAPHY

BOOKS

 Ashwatappa.K, Human resource management, Himalaya

publishing house

 Philip kotlar , Marketing management, Millennium edition

REPORT OF THE COMPANY

 Company manual

WEBSITES

 www.bhumikacastings.com

 http://www.indianfoundry.org

 http://www.google.com

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LEARNING EXPERIENCE

Doing internship at Bhumika Alloy Casting Pvt. Ltd, Srirampura was a

rewarding experience. The In Plant training period undergoby the period of
twenty days, where I have learnt so many things about organization. I
reported Mr.Deepak. H.D. technical director of the Foundry, Bhumika Alloy
Casting Pvt. Ltd, who gave instructions on how to behave in the factory
premises and instructed me to follow the rules and regulations of the
organization. The most significant lessons, which I have learnt from the
organization, is that employees are the most valuable assets of the
organization and it is very important to keep them satisfied within the overall
limits, set by various guidelines and also by maintaining set standards of
discipline.

Being in the organization for twenty days In Plant training, I came to know
the following:

 Managerial knowledge such as planning, organizing, directing,

controlling and decision making

 Production process of the manufacturing of the Casting Steel Iron

Components.

 Knowledge of rules, regulations, polices, procedures, etc. of the

company, which will guide in the work flow.

 By this organization I came to know how to motive, counsel and lead

the subordinates.

 Human resources skills, which indicate ability to deal with

subordinates in a human approach to their problem, develop personal
support and team spirit.

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 I also came to know about the importance of all the departments and
functions through studying about the administrative department. So I
come to know about the various administrative procedure and how
this department administrating the organization.

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