kel report
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KEL -ORGANIZATION STUDYINCLUDE INTRODUCTIONCOMPANY PROFILE----PRODUCT PROFILEDEPARTMENTS..SORT...PESTFINDING,SUGGESTIONCONCLUTIONTRANSCRIPT
AN ORGANIZATION STUDY AT KEL
1.1 INTRODUCTION
An organization study is a systematic and analytical cruise to seek
the truth of organization business, provide an insight in the practical field of
management. An organization is an engine that works together to the prosperity.
This is an organization study report a Kerala Electrical and Allied
Engineering company limited (popularly known as KEL), Kundara unit. Kerala Electrical
Ltd (KEL) was started as Electrical and Allied Industries Pvt. Ltd (EAIT) at Kundara in
1946 and later in1964 it was taken over as an undertaking of Govt. of Kerala engaged in
the manufacture of Electrical engineering goods.KEL has also a well organized quality
control division. KEL is one among the largest, most vibrant and productive public sector
undertaking, under the government of Kerala.
The prime consideration is selection KEL for the study is that, as the
company works for the past 98 years .It would be equipped with well established
organization structure department and facility. So study and analysis of this organization,
its status, various issue and responsibility of the individual in different levels will help to
obtain a vast level of Knowledge.
Thus studying this various aspects of organization is great benefit to
the management students. So this organization study helps me to understand practical
knowledge about the function of an organization.
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1.2 OBJECTIVES OF THE STUDY
Some of the objectives of conducting the organization study is as follows:
• To study about the organization structure.
• To understand about the function of various department.
• To know the financial position of an organization.
• To identify the strength , weakness, opportunities and threat faced by the
organization.
• To understand the different business operations carried out in the
organization.
• To know the various departments such as Marketing, Finance, Operations,
and Human Resource etc... and its activities and functions.
To conduct SWOT and Porter’s five for analyzing competitive strategies.
To relate theories and concepts in to practical and their by to identify and
Suggest feasibility solution and recommendation.
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1.3 METHODOLOGY
Both primary and secondary data were used for the study
Primary Data
In this organization study the role of primary data is important.
Because most of the data are getting through primary sources like direct
interview, face-to-face communication observation etc...
In this study the primary data sources are:
• Discussion with the department heads.
• Discussion with divisional heads.
• Personal interaction with workers in the company.
• Through observation of function of organization.
Secondary Data
In this organization study the secondary data is very important than
that of primary data. Published documents, journals and magazines are the
important secondary data. So these are also needed for the completion of the
organization study.
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1.4 SCOPE OF THE STUDY
Organization study is used to know the working of an organization and its various departments.
It helps to analyses how well the organization performed its activities.
This study helps to interact with the organization executive of the company.
Organization study mainly deals with the environmental analysis of the organization based on the assumption that both the External and Internal factors control the organization.
The organization study incorporates the structure, product, policies, the different activities and a SWOT analysis of the organization.
This study helps in practical aspects of the theories which are learned in the classroom.
1.5 LIMITATIONS
Organizational limitations
Most of the employees were very busy with their office work. Some of the
records were kept confidential so that data were unable to be collected.
Time constrains
This is a Fifteen day study and this time is not enough to study an
organization thoroughly.
Possibility of biased information.
In an organization there is a chance of giving biased information from the
executives to the researchers.
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1.6 CHAPTERISATION
CHAPTER 1 deals with the introduction of the topic .It contains the objectives of the
study, its scope, methodology and limitation of the study .
CHAPTER 2 deals with the industry profile.
CHAPTER 3 deals with the company profile and the various services provided by the
company.
CHAPTER 4 deals with the organization structure and the functioning of the
departments.
CHAPTER 5 deals with the objective wise analysis of the study.
CHAPTER 6 deals with the SWOT analysis and Porter’s five force model analysis.
CHAPTER 7 deals with findings, suggestions and conclusions
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AN ORGANIZATION STUDY AT KEL
2.1 INDUSTRIAL PROFILE
2.1.1 ELECTRICAL INDUSTRY
Introduction
The energy is neither be created nor be destroyed but it can be
converted from one form to another. The generation of an electrical energy is nothing but
the conversion of various other forms of energy into an electrical energy. The various
energy sources which are used to generate an electrical energy on the large scale are
steam obtained by burning coal, oil, natural gas, water stored in dams, diesel oil, nuclear
power and other non-Conventional energy sources.
The electrical power is generated in bulk at the generating stations
which are also called power stations. Depending upon the source of energy used, these
stations are called thermal power stations, hydroelectric power stations, diesel power
station, nuclear power stations etc...This generated electrical energy is demanded by the
customers. Hence the generated electrical power is to be supplied to the customers. The
electrical power industry provides production and delivery of electrical power (electrical
energy) often known as power or electricity in sufficient quantities to areas that need
electricity through a grid. Many house hold and business need access to electricity,
especially in developed nations, the demand being scare in developing nations. Demand
for electricity is derived from the requirement for electricity in order to operate domestic
appliances, office equipment, industrial machinery and provide sufficient energy for both
domestic and commercial lighting, heating, cooking and industrial processes. Because of
these aspects of the industry, it is viewed as a public utility infrastructure.
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In many countries electric power companies own the whole
infrastructure, from generating stations to transmission and distribution. For this reason,
electric power is viewed as a natural monopoly. The industry is generally heavily
regulated, often with controls and is frequently government-owned and operated. The
nature and state of market reform of the electricity market often determines whether
electric companies are able to be involved in just some of these processes without having
to own the entire infrastructure, or citizens choose which component of infrastructure to
patronize.
2.2 WORLD SCENARIO
Although electricity has been known to be produced as a result of
the chemical reactions that take place in an electrolytic cell, Since Alessandro Volta
developed the voltaic pile in 1800, its production by this means was, and still is,
expensive. In 1831Michael Faraday devised a machine that generated electricity from
rotary motion but it took almost 50 years for the technology to reach a commercially
viable stage. In 1878, in US, Thomas Edison developed and sold a commercially viable
replacement for gas lighting and heating using locally generated and distributed direct
current electricity.
The world’s first public electricity supply was provided in late
1881,when this streets of Goldalming in the UK were lit with electric light .This system
was powered from a water wheel on the River Wey which drove a Siemens alternator that
supplied a number of arc lamps within the town. This supply scheme also provided
electricity to a number of shops and premises.
Coinciding with this in early 1882, Edison opened the world’s first
steam powered electricity generating station at Holborn Viaduct in London, where he had
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entered into an agreement with the City Corporation for a period of three months to
provide street lighting. In time he had supplied a number of local consumers with electric
light. The method of supply was direct current (DC).
Tesla’s alternating current system remains the primary means of
delivering electrical energy to consumers throughout the world. While high voltage DC is
increasingly being used to transmit large quantities of electricity over long distances or to
connect adjacent asynchronous power systems, the bulk of electricity generation
transmission, distribution and retailing take place using alternating current.
2.3 INDIAN SCENARIO
Electrical Industry came into existence after the period of the First
World War, and the first one was a fan industry in Calcutta in 1921.The manufacturing of
the electrical equipments like Transformers, Generators, Insulators etc... took up later.
Heavy electrical industry covers units manufacturing large plants and machinery required
for power generation, transmission, distribution and utilization. These include turbo
generators, boilers, various types of turbines, transformers, motors and switch gears. The
major areas where the heavy electrical equipments are used are the large projects for
power generator including nuclear power stations, Petro chemical complexes, chemical
plants, integrated steel plants etc...The share of the domestic equipment is about 66% of
the country’s generation capacity.
The industry has also established a strong manufacturing base to
the requirement for the equipment for the equipment for the nuclear power plants in the
country. The domestic heavy electric equipment manufacturer are making use of the
developments in the global market with respect to the product designs and upgrading of
manufacturing and testing facilities. The industry is also competitive in the field of design
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and engineering as the skill sets available in the country are relatively less expensive.
2.4 STATE SCENARIO
The first public sector electrical equipment industry setup in Kerala
was the Metropolitan Engineering Company limited in Trivandrum in 1945. It was
followed by the starting of Electrical and Allied Industries Pvt. Ltd (EAIT) at Kundara in
1946. EAIT at 1964 was taken over by Govt., which was registered as a Govt. of Kerala
undertaking. At present there are five public sector electrical equipment industries
working in Kerala and they are:
• Metropolitan Engineering Company Ltd
• United Electricals Ltd.
• Traco Cables
• Kerala Electrical & Allied Company Ltd.
• Kerala State Electronics Development Corporation Ltd.
Table No: 2.1
No Company Name Products
1 Metropolitan Engineering Co.Ltd Isolators, Fuses, Switches
2 United Electrical Ltd Meters, Motors, Capacitors
3 Traco Cables Telephone cables, PVC Cables
4 Kerala Electrical &Allied Co.Ltd Alternators, Transformers
5 Kerala State Electronics Development Co.Ltd.
Capacitors, Resistors, Television
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3.1 COMPANY PROFILE
The Kerala Electrical & Allied Engineering Co. Ltd., popularly
known as KEL was established in 1964 in the State of Kerala, India and is fully owned by
the State Government. (KEL) is a multifaceted company fully owned by the State
government. Through its three production facilities, located in various districts of the
State, this ISO 9001: 2000 complaint company provides basic engineering services and
products to many of its clients besides executing projects of national importance for high
profile clients like various defense establishments.
The company manufactures and markets products like general
purpose brushless alternators, brushless alternators for lighting and air-conditioning of
rail coaches, medium power and distribution transformers, BLDC Fan as well as
structural steel fabrications The product categories for defense applications include high
frequency alternators, frequency convertors, special alternators and power packs for
missile projects. The power packs designed and supplied by the company for missile
projects like Falcon, Prithvi, Trishul and Akash have been pioneering efforts. The
company has also supplied special alternators to the Army (Military Power Cars) and Air
Force (Radar Applications.)
The company's all-India marketing network with regional offices in
all metro cities cater to major institutional clients like the State Electricity Boards, Indian
Railways and various defense establishments besides the general market clients. KEL is
one among the largest, most vibrant and productive Public Sector Undertaking, and is
fully owned by the Government of Kerala. A multi-product engineering company,
consistently catering to an envious client base, ranging from the army and air force of
India to world-renowned space research organizations, highly competent engineering
companies to mammoth institutions likes the Indian Railways. The company with three
state-of-the-art manufacturing units spread across Kerala has a pan India presence with
marketing offices in major metros and select cities.
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3.1.1 HISTORY
Kerala Electrical And Allied Engineering Company Limited
known as KEL was started in the year 1947 with 50% of the share for government and
taken over by government in 1964 as an undertaking of Government of Kerala engaged in
the manufacture of electrical engineering goods. Another unit was set up at Mamala
(Ernakulum District) as part of KEL’s expansion programmers which became operational
in 1968. KEL was also entrusted with the charge of Enclose, a sick unit in Palakkad that
was taken over by the government of Kerala in1977, which was developed as their 3rd
unit. In 1986, a High-tech mechanized foundry at Kundara was added to KEL group of
production units. In 1990 a new unit established in Bedradka (Kasargod District), Kerala
with latest technology and modern equipments.
3.2 CORPORATE PROFILE
The corporate office of KEL is located at Kochi. In addition to
these production centers a project division for execution of turnkey projects, an R & D
wing and centralized marketing network are having Head Quarters in the Corporate
Office. The organization has strength about200 qualified Managerial staff and about 1500
employees including special skilled works. The present product range of the company
includes Brushless Alternators for train lighting and air conditioning, ground power unit
(GPU) for aircrafts, high frequency alternators for defense application and Antarctica
expedition, distribution and power transformers, HRC fuses, switchgears, brushless ac
generators. The present sales turnover of the unit is about Rs. 20crores.
3.3 MANUFACTURING UNITS
Kundara unit, Kollam (dist), Inception: 1964
This is an ISO 9001 certified unit which was started in the year 1964
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imbibing technical know-how from EVR of France for the purpose of manufacturing
Statodyne Brushless Alternators used for lighting and air conditioning of Railway
coaches.
There are three divisions in this unit namely:
• Statodyne Alternator Division:
Statodyne Alternator Division manufactures Statodyne Brushless
Alternators used for lighting and air conditioning of Railway coaches. Statodyne
Alternator Division has installed capacity of 3000 numbers of alternators per
annum. More than 25000 alternators are in service with the Indian Railway
Station alone.
• Foundry Division:
Foundry Division has a capacity of 1500MT per annum and manufactures
Spheroidal Graphite Iron and Grey Iron Castings. This unit has fully mechanized
molding lines with sophisticated testing equipments to ensure quality castings.
• Battery charging systems division:
Manufactures brushless alternators for automobile battery charging
system. The product has been developed through the company’s own R & D
efforts. The alternator caters to the high power needs of modern vehicles and
heavy earth moving equipment. It offers long life and maintenance free
Operation.
Mamala Unit, Ernakulum District, Inception: 1968
The transformer Division of KEL at Mamala, Ernakulum, was established in
1968, with the technical assistance of BHEL to manufacture supreme quality transformer
for various State electricity Boards, Government Departments, Public and Private Sector
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Companies. This division, ISO9001 is certified by TUV, boasts of a long sustained list of
extremely satisfied clients, many of whom who have stood by KEL, for decades. Over
the years relying on the unmatched quality of KEL transformers, electricity boards across
India perfectly maintain a healthy power distribution supply system. The Transformer
Division has production and distribution of medium range power transformers up to
1600KVA. Manufacturing custom-build transformers, for specific requirements is yet
another specialty of KEL. This division undertakes design, fabrication and
commissioning of hydraulic control gates and hoists for power and irrigation projects,
cranes, pressure vessels and other industrial structure.
Olavakkod Unit, Palakkad District, Inception: 1977
Unit started in the year 1977 with technical know-how from UNELEC of
France. This unit manufactures Isolators/Changeovers, Switch fuses, Fuse units/Cutouts,
Distribution fuse boards/Panels and castings used for Industrial, Commercial and
domestic applications through their LT Switchgear Division.
Product Range
• Fuse Switches, Changeover switches, Porcelain Fuse Units.
• Distributions fuse Boards and industrial type switch boards, Distribution Boards.
Project Division:
KEL project wing headed by the GM attached to its corporate office undertakes
turnkey projects in design, fabrication, supply and erection of gates, hoists
and controlling equipments for power and irrigation projects and civil works including
heavy machinery erection.
Edarikkod Unit, Malapuram District, Inception: 1988
Unit was commissioned in 1988 for the manufacture of Brushless
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AN ORGANIZATION STUDY AT KEL
Alternator for Automobiles (BAA). But as per the instruction of the government the
execution of the BAA project was suspended as the government wanted to give top
priority for the implementation of the Kasargod project. The capital outlay originally
envisaged for BAA project was Rs.6.42crores, which was subsequently enhanced to
Rs.12.75 crores due to the cost overrun which is in turn, was consequent to the delay in
execution. Now this unit is used for the manufacturing of Power and
Distribution Transformers.
Marketing Division:
The corporate marketing Division piloted by the GM (Marketing) is
controlling the various service centers and Regional Offices in New Delhi, Bombay and
Madras. And sales and service centers in Kanpur, Calcutta, Bhopal, Hyderabad,
Bangalore, Coimbatore and Trivandrum.
Expansion Project:
While trying to consolidate its exciting units by means of
technological up gradation,KEL in a head on its way with future expansion projects
including brushless alternator for automobiles, Nickel, Cadmium Battery ,special purpose
motor project with technical collaboration from Austria.
3.4 The various products developed by KEL R&D wing are the following:
• 5 kVA,400 Hz alternator for Antarctica expedition for the defense department of
Govt. of India
• 20KW DC manual and self propelled type ground power units for ‘Vayudoot’ for
starting their Aircrafts.
• 30kVA rotary converter for radar application for helicopter starting for Indian
Navy.
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• 3KV generator for wind mill applications.
• 5KV alternator for with rectifier regulator unit for battery charging in locomotive
engines.
• 40kVA ground power unit for requirements of starting of fighter aircrafts like
‘MIRAGE’.
• 90 kVA ground power unit for Boeing and Air Bus aircrafts
• 20kVA alternator for powering mobile radar installations.
3.5 Over Seas Partnerships:
As a company in tune with modern technology, KEL have had associated with reputed
overseas manufactures who are experts in their respective fields.
• Inductor type brushless alternator for lighting and air conditioning of rail coaches --- EVR ,France
• HRC fuses --- UNELEC, France
• General purpose brushless a.c generators --- Moteures Leroy Somer, France
• Nickel-Cadmium battery project --- Honda, Japan
• Technical collaboration with ----T-Lin of Austria
3.6 Players in India
• Kerala Electrical and Allied Engineering Company
• H.M.T.D Chennai
• Stone India Calcutta
• Crompton Greaves Ltd Chennai
• Steasalite Ltd
• Press tech India
• Unitec
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3.7 KEL-KUNDARA UNIT
The Kundara unit of the company was established in the year 1946
in private sector for manufacture of low tension switches and was taken over by the Govt.
of Kerala in 1964.In the early 70’s the unit was diversified into the field of brush less
alternators for railway lighting. As a part of diversification program, new mechanical
equipments and facilities were added to the unit. KEL had set up a modern iron foundry
which manufactures spherical granite iron and gray iron castings of various grades at
Kundara unit.
The Kundara unit of KEL has manufacturing brushless alternators
which is acclaimed and accepted by the Railways as the most efficient and reliable one.
More than 25000 number of alternators manufactured in KEL are already in operation
with the Indian Railway alone.
3.7.1 Vision Statement of KEL
To be a globally recognized enterprise committed to enhancing
stakeholder value by providing world class engineering and power system solutions.
To achieve our vision by:
• Applying state-of-the-art technology, processes and innovative solutions.
• Building long term relationship with stakeholders in an environment of
fair business ethics and values.
• Creating value through sustainable and profitable growth.
• Leveraging productivity through highly motivated & empowered team.
3.7.2 Mission Statement of KEL
• Ensuring team work at all levels.
• Establishing and maintaining vendor evaluation and rating.
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• Establishing and maintaining quality system suitable for meeting customer
requirement.
• Continuous improvement through constant up gradation of technology, process
and skilled manpower.
3.7.3 Core Values
• Fairness, transparency, integrity.
• Trust and mutual respect.
• Passion for professional and operational excellence.
• Corporate and social responsibility.
3.7.4 Objectives
To educate and train our skilled manpower on a half yearly basis at the
rate of 8 hours training per employee to upgrade the skill level and to reduce the rate of
absenteeism to 3% from 5% .Which will be measured on a monthly basis.
3.7.5 Quality Policy
The Quality Policy of KEL, Kundara is to Achieve Customer Satisfaction
by providing the right product and services at the right time as per Customer’s
requirements .
This shall be achieved through
Ensuring team work at all levels.
Establishing and maintaining suppliers’ evaluation and rating.
Establishing and maintaining a quality system suitable for meeting customer
requirement.
Continual improvement through constant up gradation of technology / process and
skilled manpower.
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3.8 PRODUCT PROFILE
• Location : Kundara ,Kollam District
• Inception : 1964
• Technical knowhow : EVR of France
• ISO 9001 certified by RWTUV
• Statodyne Alternator Division:
• Used for : lighting & air conditioning of railway coaches
• Capacity : 3000 alternators per year
• More than 25000 alternators with Indian Railway alone.
• Foundry Division:
• Manufactures : Spheroidal Graphite iron & Grey Iron casting
• Capacity : 1500MT per annum
• Induction Furnace : 2x3T
• Fully mechanized molding lines with sophisticated testing
equipment to ensure quality castings.
Fig .3.1
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3.8.1 PRODUCT RANGE
Table No: 3.1
No Range Name Purpose
1 3KW,24V Brushless Alternator Train lighting (Third Class Coaches)
2 4.5KW,24V Brushless Alternator Train lighting (Second Class Coaches)
3 4.5KW,110V Brushless Alternator Train lighting (Second Class Coaches)
4 12KW,110V Brushless Alternator 2 Tier AC Coach(Meter Gauge)5 18KW,110V Brushless Alternator 2 Tier AC Coach(Broad Gauge)
6 25KW,130V Brushless Alternator Roof Mounted AC Coaches7 12KW Auxiliary Alternator Diesel Electric Multiple Unit
Coaches8 18.5 KW Auxiliary Alternator Diesel Electric Multiple Unit
Coaches9 2KW Diesel Generator (DG)Set Ground Power Unit
10 50kVA Diesel Generator Set Ground Power Unit11 20kVA Alternator DG Set for Defense Applications
12 5kVA Alternator DG Set for Defense Applications13 25KW Electronic Rectifier Unit Train Lighting (Ordinary
Coaches)14 4.5KW Electronic Rectifier Unit Train Lighting (Ordinary
Coaches)15 BL DC Fan Railway Application
USP
Induction Alternator
Brush less excitation without winding on the rotor. Both field and
armature
windings are embedded in stator slots, hence no limitation for
working speed and
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ideal for variable speed application like ---Train, Automobile,
Windmill etc…
Totally enclosed fan cooled version available for
Dusty/Humid/Corrosive
environments.
3.8.1 Top customers:
• Integral Coach Factory, Rail Coach Factory
• Indian Railway
• Tanzania Railway Corporation
• Rites
• Station Power Controls Ltd
• L&T
• CGL
• Paras Electricals Ltd
• AVISH AVIATION Equipment Pvt. Ltd
• Medha Servo System
• DIGHI , Pune
• Indian Defense, Air Force
• Bharat Heavy Electricals Ltd(BHEL)
• Bharat Earth Movers Ltd(BEML)
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Organizational structure
CHART NO:4.1
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GM/UNIT HEAD
HOD M P&A M AS&SHOD
MKTG
M MKTG HOD
MMD
M
MECH
M
TESTING
ELE
AM P&A
AM D&D
M(P)M(P)
REG
M(P)
REG
AM FYFOREMAN
CH
CH
SKILLED
USW
CH CH
SKILLED
USW
APO-1
STAFF
SI
SEC
GUARD
PEON
CH
AM PLNG
FOREMAN
STAFF
CH
SKILLED
SUPERVISOR
AM MKTG
STAFF
GSTORES
SKILLED
USW
AM
MMD
M MMD
STAFF
SKILLED
SKILLED
STAFF
JOSTAFF
AAO-2
USW
STAFF
AN ORGANIZATION STUDY AT KEL
5.1 DEPARTMENT PROFILE
5.1.1 Personnel & Administration Department
5.1.2 Finance Department
5.1.3 Marketing Department
(a)After Sales Department
5.1.4 Production Department
5.1.5 Planning Department
(a) Dispatching Department
5.1.6 Materials Management Department
5.1.7 Design and Development Department
5.1.8 Quality Assurance Department
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5.1 PERSONNEL DEPARTMENT&
ADMINISTRATIVE DEPARTMENT
The term personnel management has now been modified as Human
Resource Management. But in KEL, they still follow the old term Personnel
Management. The Personnel Management controls the personals in company. Personnel
management function has a great role in productivity and quality. A human performance
is the “product of his/her ability and motivation”, right personnel/HOD policies are
important for sustaining ability and motivation in the human element. The technical
functions of this department include recruitment, performance, deployment, wage
agreements, discipline, performance appraisal, termination as well as activities.
There are 8 unions representing the workmen and the staff. The labor
relation climate has long been peaceful and conductive to production.
5.1.1 Policy
To achieve competency of our skilled manpower through constant
training, education and experience in order to product quality.
5.1.2 Objective:
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To educate and train our skilled manpower on a half yearly basis at the
rate of 8 hours training per employees to upgrade the skill level and to reduce the rate of
absenteeism to 3% from 5% which will be measured on a monthly basis.
Department Structure
Chart No: 5.1.1
5.1.3 Duties of a Personnel Manager
Manpower planning.
Recruitment.
Selection.
Placement Procedures.
Training and development.
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General Manager
Manager
Asst .Personnel
Staff
AN ORGANIZATION STUDY AT KEL
Performance appraisal.
Transfer and Promotion.
Employee Welfare Administration.
Disciplinary action.
Wages and Salary Administration.
Leave Administration.
Trade Unions
Time Office Administration.
Security Office Administration.
Public Relations.
General Estate Keeping.
House Keeping Activities.
Typing Section.
MAN POWER PLANNING
Manpower planning is one of the important functions of personal and
administrative management. It means corrective utilization of man power. They
undertake the task of creating human capacities which ensures that fully contributes to
the total organizational performance. They also have the responsibility for the
determination of manpower recruitment of the organization both in the right number and
of the right kind.
RECRUITMENT
Mainly three types of recruitment are following in KEL. They are:
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1. Direct Recruitment:
On the basis of rules and regulations prevailing in the company, the
management can recruit the technical hands such as unskilled workers and
semiskilled workers. They are appointed as apprentice trainee. They are recruited
through employment exchanges. Sometimes security guards are also appointed
through direct recruitment.
2. Internal Recruitment:
In certain cases, company conducts an internal notification for higher posts. The
qualifications, experience, additional qualifications etc…required must be clearly
specified in the notification. The internal recruitment is through promotion, only
after considering the merits and performance of the employees.
3. External Recruitment:
In this type, recruitment is done through Kerala Public Service Commission
(KPSC).On the vacancies intimated by the management, KPSC advertises
through the media calling appropriate candidates. The test/ interview is conducted
by the KPSC and post them into the company.
SELECTION
Selection is mainly for the ex service men that is by an agency through application,
scrutiny test. The persons selected are based on interview for the placement of job.
GRIEVANCE HANDLING
Grievance is also handled by personal and administrative department. They collect the
grievance of the employees and informed to the top level managers and solved their
problems. There is a suggestion box inside the organization for the grievance of the
employees.
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LEAVE STRUCTURE.
Casual Leaves – 14 days
Sick leaves – 14 days. (For more than three consecutive days sick leave,a medical certificate should be produced.)
Privilege leave -30 days
TRAINING & DEVELOPMENT
It is the effective tool for employees’ development. Three types of training
are adopted in KEL.
1. Induction Training:
The fresh employees and the transferred employees from other units must
undergo this training. A training schedule is prepared by the personnel department
and directs the employees to the various sections or departments for the training.
2. External Training
This is given to the permanent employees such as Engineers,
Officers and other Executives conducted by External agencies or External
organizations.
3. Internal Training
This type of training is given to technical persons working in various
division/Sections. Apprentice training also given as a part of internal training.
Work rotation is another technique for internal training. Management gives
training for a period of one year for the fresh employees. After the successful
completion of training he is recruited on probation and after he is appointed in
regular service. This training is compulsory for the company.
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AN ORGANIZATION STUDY AT KEL
DISCIPLINARY ACTION
The personal and administrative department is responsible for disciplinary action
against violation of rules and regulations which are mentioned in the standing order.
Some Cases are
Willful in subordination.
Disobedience.
Fraud.
Theft
Dishonesty
Illegal Absence.
Sexual harassment
PROCESS
1. Case reporting to the GM.
2. Issue show case memo.
3. Warning or enquiry.
4. Inform to head office.
5. Approval for enquiry and posting of inquiry officers.
6. Meeting management witness and employee witness.
PUNISHMENT ACTIONS
Suspension
Increment Banning.
Dismissal.
Institute of Management in Kerala, Kundara 28
AN ORGANIZATION STUDY AT KEL
TRADE UNION AND LABOUR RELATIONS
Electrical and Allied Workers Union (U.T.U.C).
Electrical and Allied Industries Employee Union (I.N.T.U.C).
KEL Employees Organization (S.T.U).
KEL Employees Union (C.I.T.U).
WELFARE MEASURES
Loan Facility
Canteen
Recreation Club
Education Benefit
Death Assistance
Funeral Assistance
Retirement Assistance
Marriage Contribution
Provident Fund
ESI
Accident Benefits
Maternity Leave
Drinking Water
Latrine & Bathroom
ALLOWANCES
Institute of Management in Kerala, Kundara 29
AN ORGANIZATION STUDY AT KEL
Washing allowances
Night Shift allowances
Milk allowances
Food allowances
Uniform allowances
Insurance allowances
Risk allowances
Heat treatment allowance
Cycle allowance
WAGES & SALARY ADMINISTRATION
Wages:
Wages depends on the long term agreements exist for duration of four years.
Wages are fixed after bilateral discussion with labor unions and management. These
wages are enacted only after the approval from the management. There is no profit
sharing, but they get indirect benefits out of realized profits.
Salary:
Salary = Basic Pay + DA + HRA + Allowance DA is based on the cost of living
index at Kollam district. Department of Economics and Statistics fix the
index. Government fixes the DA for officers. Allowances include washing allowance,
risk allowance, heat treatment allowance and night shift allowance etc.In fact there are 7
unions exist in KEL. But of these 7 unions only 4 unions are affiliated unions.
KEL has got 4 affiliated unions:
Institute of Management in Kerala, Kundara 30
AN ORGANIZATION STUDY AT KEL
Electrical & Allied workers Union (UTUC).
Electrical & Allied Industries employee Union (INTUC).
KEL employees organization (STU).
KEL employees union (CITU).
TIME OFFICE ADMINISTRATION
Biometric punching system is being followed for all employees. Attendance
bonus is used for motivating employees. The scheme provides with 12days bonus salary
for employees with full attendance.
There are three shifts and a general shift
Table no.5.1.1
First Shift 12:00am to 8:00am
Second Shift 8:00am to 4:00pm
Third Shift 4:00pm to 12:00am
General Shift 8:00am to 4:30pm
TRANSFER & PROMOTION
TRANSFER
At the time of appointment every employee is given a declaration to the
management regarding, they are willing to work in all over India where ever the company
has units and regional offices. As par the manpower requirements, transfer the employees
to different units. In case when employee request to transfer as per his convenience, if the
Institute of Management in Kerala, Kundara 31
AN ORGANIZATION STUDY AT KEL
management found the reason is relevant they gives consent. But the employee is posted
as the junior most employee of that unit in the same category.
PROMOTION
It is based on the promotion policy agreement; it’s strictly based on the
seniority of service. If there is vacancy in higher post, then promote to the higher post
otherwise give the higher grade scale.
5.2 FINANCE DEPARTMENT
Finance department is headed by the Head of the Department
(finance) .The main responsibility of Head of the Department is to take financial
decisions, which includes investment decisions, financing decisions and dividend
decisions. The manager has to keep constant touch with the entire department and also
keep all the record of the transaction. At the end of every year he is responsible for
making the financial statements.
Financial statements are prepared for the purpose of presenting a periodical
review of report on progress by the management and deal with the status of investment in
the business and result achieved during the uses of funds. Financial statements reflect a
combination of recorded facts, accounting principles and personal judgment. In order to
understand the financial performance of the company is necessary to analyses the
Balance sheet, Profit and Loss account.
To maintain all books of accounts up-to-date as per the statutory
requirements and manage working capital, preparation of budget ensuring discipline in
the case of financial resources preparation and analysis of the book of account. The main
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AN ORGANIZATION STUDY AT KEL
books of account maintained in KEL are cash book, bank book, purchase register, journal
records, pay roll statements and Central excise record. The software used is Tally 9.0
5.2.1 FUNCTIONS
To ensure maximum effective operation and healthy relation with customers,
workers and financiers etc.
To maintain all books of account up to date as per the statutory requirement.
To manage working capital.
Preparation of budget ensuring discipline in the case of financial resource
Department Structure
Institute of Management in Kerala, Kundara 33
General Manager
Asst.manager
(HOD)
Asst. Accounts
Officer 2
Jr. Officer
Staff
AN ORGANIZATION STUDY AT KEL
Chart No: 5.2.1
5.2.2 Objectives:
To ensure maximum efficiency of operation and healthy relations with
suppliers, Workers, financiers etc.
To maintain all books of accounts up to date as per the statutory
requirements.
To manage working capital
Preparation of budget ensuring discipline in case of financial resources.
Preparation and analysis of books of accounts.
In KEL Financial statements are audited internally and externally. The
internal audit is done by corporate office while the external audit is done by government
officials. Also includes financial forecasting and planning, acquisition, safe keeping of
securities and other valuable documents like insurance policies etc.
The main responsibility of the financial department is to make.
Investment decisions.
Financing decisions.
Dividend decisions.
5.2.3 The main account books maintained in KEL are:
Cash Book.
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AN ORGANIZATION STUDY AT KEL
Bank Book.
Purchase Register.
Sales Register.
Journal Register.
Central Excise Register.
VAT Records.
The software used in accounting purpose is Tally 9.0
5.2.4 Significant Accounting Policies
1. Accounting Convention
The financial statement is prepared under historical cost convention on accrual
basis and in compliance with Companies ACT 1956.
2. Fixed Assets
Fixed assets are stated at cost less depreciation. Assets and liabilities are recorded with higher cost.
3. Depreciation
Depreciation of fixed assets has been provided as per rates indicated in line X1V of Companies ACT 1956 under written down value method.
4. Inventories
Finished goods are valued at cost on market price whichever is less.
Excise duty is also taken into consideration
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AN ORGANIZATION STUDY AT KEL
Scraps are valued at net realization value
Goods in transit are valued at cost.
5. Sales
Sales comprises of sales of goods and services including excise duty.
Price variation claims on sales effective are accounted for on accrual basis.
6. Consumption
Loose tools issued to shop floor are stated as consumed and return off as scrap.
Consumption of materials for production is computed on derived basis.
7. Liability on material on transit
The liability on account of bank charges and other expenses on material in transit on the date of closing is accounted on approval basis.
8. Research and Development
Capital expenditure on R&D is treated as an addition to fixed assets and revenue expenditure on R&D is charged to P&L account under appropriate heads in the year in which it is incurred.
9. Contingent Liability
Contingent Liability are not provided for, but disclosed in notes on accounts.
5.2.5 Source of Fund:
Main source of fund are from Government and from banks, Mainly 5 banks that
offer funds to KEL. They are:
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AN ORGANIZATION STUDY AT KEL
State Bank of India
State Bank of Travancore
State Cooperative Bank
Federal Bank
State Bank of Mysore
5.3 MARKETING DEPARTMENT
The main function of the marketing department in KEL is to establish and
maintain a quality system suitable for organization’s vision, commitments towards
products and services rendered to the customers.
The KEL’s main product is 4.5 KW and 25 KW alternators. The main
customers of KEL are Indian Railways, L&T, BHEL (Bharath Heavy Electrical Limited),
BEML (Bharath Earth Movers Limited) and Defense (Prithvi and Trishul Missiles). But
always main user is Indian Railways. As the target consumer is Indian Railway, KEL’s
marketing department has no need for marketing the product. So there are no markets
research and analysis activities done by marketing department.
KEL participate in open tender as and when railways invite tenders.
KEL’s service centers are located in all the metropolitan cities. These offices give all
support services to sale and marketing lean guarantee complete customer satisfaction. As
the number of customers is limited, there is having short channel of distribution.
5.3.1 Policy
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AN ORGANIZATION STUDY AT KEL
To provide customer satisfaction and confidence to the customers that
quality is being maintained and will be continuously sustained in the delivered product by
providing the right product at the right time.
5.3.2 Objective:
To meet customer needs both stated and implied in order to maximize the
order realization by 10% within one year.
To reduce sundry debtors by maximizing the collection.
Increasing the sales by minimum 10% by supplying the items in time.
5.3.3 Scope
The procedure covers all tenders enquiries, submission of tenders, acceptance and
amendments of orders execution, invoicing and collection of payment.
Departmental structure:
Institute of Management in Kerala, Kundara 38
General Manager
Asst .Manager
Foreman
Staff
AN ORGANIZATION STUDY AT KEL
Chart No: 5.3.1
(a) Marketing Department Functions:
Liaison with customer for receipt of tender enquiries.
Purchase of tender documents.
Evaluation and review – both technical and commercial.
Pricing of the product, Preparation of order, Submission of tender.
Tender opening, Negotiation, Follow up of order.
Receipt of order review and acceptance.
Order register
Amendments from customers.
Issue of sale order and follow up, Road permits.
Arranging of inspection.
Preparation of delivery Chelan.
Invoicing
Collection of payments.
Management information and records keeping.
RECEIVING THE TENDER:
Railway as they only customers of the KEL they have annual requirement.
For that they invite individual tenders. They evaluate the offer on the basis of the
past performance .Capacity, Technology, etc and award the tender to the best
bidder. It is the duty of the marketing department to receive the tender.
EXECUTION:
Intimation goes to the production and other concerned department from
marketing department. Planning department plan the production actives .Material
department purchase the raw materials, store these material and issue item. It is the
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AN ORGANIZATION STUDY AT KEL
duty of the material department to produce item accordingly to the order and in
time. When the production is over, production department will inform the
marketing department.
ARRANGE INSPECTION:
Marketing department arranges the inspection. They invite the inspection
authority .Railway have their owe inspection authority. These authority are RDSO
and RITES they come to KEL and test the product accordingly to there
specification
DISPATCH TO THE RESPECT CONSIGEES
If the inspection agency is satisfied with the quality of the product then it
dispatch to the respected customer.
INVOICES PREPRATION:
Invoice IS prepared by the marketing department. Invoices contain
number of finished goods to sent, rate, total price etc.
SENT TO PAYMENNT AUTHORTY
Marketing department will sent those invoices to the paying authority of
the Railways. Railway has a paying authority called FANCO.
COLLECTION OF PAYMENT
Marketing department collect the payment from the payment authority of the Railway. Collection of payment is handed over to the finance department.
(b) Marketing strategies followed by KEL
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AN ORGANIZATION STUDY AT KEL
Strict quality control
Prompt supplier
Trained sales personnel
Credit facility
Reasonable price
Penetrating new markets
Appropriate advertisement.
Pricing strategies
Pricing strategies that are used in KEL are
Cost plus pricing
Comparative pricing
Pricing is also influenced by last tender that accepted by the
Indian Railway.
(c) List of registers used in Marketing Dept:
Tender Register
Sales Order Register
Payment Register
(d) Market Share Analysis:
Table No: 5.3.1
COMPANY MARKET SHARE
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AN ORGANIZATION STUDY AT KEL
KEL 26%
HMTD, CHENNAI 8%
STONE INDIA, CALCUTTA 28%
PRESS TECH INDIA 8%
STEASALITE LTD 28%
UNILEC 0%
CROMPTON GREAVES LTD, CHENNAI 2%
Market share Analysis
26%
8%
28%
8%
28%
2%
Market share
KELHMTD,CHENNAISTONE INDIA,CALCUTTAPRESS TECH INDIASTEASALITEUNILECCROMPTON GREAVES LTD,CHENNAI
Chart No: 5.3.1
Competitors
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AN ORGANIZATION STUDY AT KEL
BHEL
HMTD Chennai
Stone India Ltd
Press Tech India
IC Electricals
Crompton Greaves Ltd, Chennai
P D Steels
KAPSON
UNILEC
(a) After sales department
Policy
To provide customer satisfaction and confidence to the customers that
quality is being maintained and will be continuously sustained in the delivered products
by providing the right product at the right time.
Objective
To improve upon customer satisfaction by reducing customer complaints, other
than product complaints by 50% within 6 months.
To meet customer’s need both started and implied in-order to maximize the order
realization by 10% within one year.
To increase customer satisfaction by 10% of the existing index by avoiding delay
in providing on-time services by 10% within one year.
After sales and service department actives
Mainly two actives
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AN ORGANIZATION STUDY AT KEL
1. Preventive action
a. Periodic action
b. Intimation of design changes
c. Training to customers
2. Servicing
a. Customer complaints
b. Warranty service & training
c. Maintaining tools , instrument and spares
d. Maintain calibration
5.4 PRODUCTION DEPARTMENT
The main function of the production department is the creation of a
product or service required satisfying customer needed wants and desire. Main problem
that KEL Kundara faces is that the freight charge of raw materials is high. KEL mainly
purchases raw materials from France, Germany and from some other states in India. This
will lead to the increase in the cost of production and also there will be an increase in the
selling price.
Structure of Production Department
Institute of Management in Kerala, Kundara 44
General Manager
Manager 3
Work Manager
AN ORGANIZATION STUDY AT KEL
Chart No: 5.4.1
5.4.1 Policy
Right product at right time will result the customer satisfaction through team work.
5.4.2 Objective
Right product : reducing the rework/rejection. In house failures reducing rework
/failures by 25% at the following stage.
a) Shaft ground
b) End shield / turned/drilled
c) High voltage test/ wound frames
d) Testing of alternator with rectifier regulator unit
Right time : achieving better on-time delivery by interesting the number of
satisfied customers by 85% within the next three months and 90% within one year
Team work : improving employee involvement and team work through generation
of two suggestions as per quarter and implementing a minimum of two
improvement projects per year.
5.4.3 Product Features:
Institute of Management in Kerala, Kundara 45
Asst Manager
Forman
Worker
AN ORGANIZATION STUDY AT KEL
The system consists of brushless induction type alternators and a
completely static regulator rectifier unit. The alternator is completely devised of any type
of moving cost on sliding contacts and this ensure a trouble free operation without
periodically any maintenance. The regulator rectifier unit makes use of silicon diodes,
transformers and magnetic amplifier. All the components used in the rectifier regulator
units are unlike transistors and the thyristorstailor made to the requirements of the
hazardous application to which they are put into rolling stock. As such the reliability of
the KEL generating system is high.
5.4.4 Production Process
1. Ensure availability of material and allocate the work.
2. Receipt of materials /tools.
3. Projecting requirement of measuring and testing equipments.
4. Production process.
5. Return of items to store due to non conformity during production process.
6. Review of N.C items found during process.
7. Offering for inspections.
8. Issue of F.G.T.N (Finished Goods Transfer Note)
9. Return of excess material.
10. Production monitoring.
11. Breakdown intimation.
5.4.5 Equipments used in Production:
Lathes
Vertical turret lathes
Milling machines
Hydraulic press
Drilling machine
Slotting machine
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AN ORGANIZATION STUDY AT KEL
Shapers
Bending machine
Welding machine
5.4.6 Different Sections of Production Department:
Fabrication shop
Old machine shop
New machine shop
Winding & assembling section
Foundry
Process Flow
Institute of Management in Kerala, Kundara 47
NEW MACHINE SHOP
ASSEMBLY & WINDING UNIT
OLD MACHINE SHOP FOUNDRY UNIT
REGULATOR SECTION
FABRICATION
AN ORGANIZATION STUDY AT KEL
Chart No: 5.4.2
Process flow Alternator
5.4.7 Production Process:
Production of alternators comprises of two main stages:
Component Manufacturing:
70% of the components used in the alternators are made in the house. These can
be classified into the following groups.
Pressing and rolled parts Turned parts Tapped and drilled parts Welded parts
Supplementary activities are as given below.
Painting Tool room Electrical and Mechanical maintenance
The main activities of these sections are explained below.
Institute of Management in Kerala, Kundara 48
FINISHED GOODS
PAINTING SHOP
TESTING
AN ORGANIZATION STUDY AT KEL
Press Shop:
Infrastructure available includes hydraulic pressure mechanical
presses, rolling machines, shearing machine and press brake. But many of the
presses and shearing machine are old and need progressive replacement.
Automatic press protection systems need to be installed to prevent accidents. The
workers are all qualified ITI holders in this section.
Machine Shop:
The main works that take place in this section are boring, drilling, facing,
centering, turning, milling, grinding and balancing. Two machine shops are there,
they are Old Machine Shop and New Machine Shop. Central lathes, Capstain
Lathes, Radial drilling machines, milling machines, grinding machines are being
used. The operators are all qualified ITI holders.
Fabrication Shop:
The stator frames, the regulator boxes and the terminal boxes are being
fabricated here. Welding machines are used in this section. Grinding work is also
done here.
Painting:
The regulator boxes and the terminal boxes are zinc plated after pre-
treatment. The stator and pulleys are painted with enamels after surface treatment.
The process is manual and conventional. For better consistency, semi/fully
automated painting system could be established.
Tool Room:
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AN ORGANIZATION STUDY AT KEL
The tool room functions solely on the skill of the die makers. The tools are
made using conventional methods of hand-marking and filing. Modernization has
been kept abeyance due to scarcity of finance. Making of new tools for replacing
worn out ones takes long time due to the conventional techniques of tool making.
Accuracy also varies from person to person. Hence modernization of tool room is
to be speeded up.
Assembly, Testing and Finishing:
The alternator section comprising assembly, testing and finishing is headed by the
Asst.Manager. The assembly, testing and finishing section are given below:
Assembly:
Assembly mainly involves the following operations,
1. Assembly of rotor and stator
2. Fixing bearing and end shields3. Fixing alternator pulleys. Assembly operations are carried out manually. Since there is no
pneumatic puller, the dismantling operations are not so easy.
Testing:
There are 3 test beds. There s provision for mounting the alternators near
the drive and subjected to all the routine tests as per the RDSO specifications.
Internal inspection is done for all the machines (100%). The RITES and RDSO
inspectors conduct type test and their inspection, the inspection affix seal on each
tested alternator. The test beds needs modernization. The computer aided testing
is to be provided so as the increase the output and consistency. More over
automatic error printout from the computer eliminates the manual recording of
Institute of Management in Kerala, Kundara 50
AN ORGANIZATION STUDY AT KEL
test data as well. The huge cost cannot be afforded during the present stage of the
company.
Finishing:
Finishing work on alternators comprises general checking, tightening the T.B
screws, cover fixing, sealing and packing in wooden cases. Pneumatic screw
drivers are better for consistent tightening of screws.
Finishing is the last stage in the manufacturing cycle, before physical dispatch to
the customer, the worker in this section should have a better orientation towards
quality and customer satisfaction.
Other important sections of Production Department:
o Regulator Section:
Functions are:
AC to DC conversion (Rectification)
To Charge Battery.
o Foundry Unit:
Foundry or casting is the process of producing metal/alloy
components parts of desired shape by pouring the molten metal/alloy into
a prepared mould and then allowing the metal/alloy to cool & solidify.
The solidified piece of metal/alloy is known as casting. The Foundry unit
in KEL was established in the year 1985. Silica sand is brought to KEL
from Cherthala for the processing of silica sand is 1500 degree Celsius
where Ordinary sand requires only 1000 Degree Celsius to melt. The silica
sand is dried and then only will used for processing.
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AN ORGANIZATION STUDY AT KEL
o Furnace:
The total capacity of the furnace is 31/2 ton. The main advantage is
that we can prepare any grade metal. This furnace is worked under
induction principle. The voltage required for the furnace is from 350volt to
1500volt.
5.5 PLANNING DEPARTMENT
Planning is one of the important functions of the management.
The main functions of the planning department is to plan and schedule for the production
and dispatch. This department includes both planning and dispatch sectors. The objective
of the planning department is to co-ordinate the manufacturing operations in line with the
marketing plan so as to achieve the production target in time.
Structure of Planning Department
General Manager
Asst Manager
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AN ORGANIZATION STUDY AT KEL
Chart No: 5.5.1
5.5.1 Policy
To establish and maintain a documented procedure for planning the
production availability of materials and schedule of dispatches for enabling the
organization to provide the right product and services at the right time every time as per
the customer requirements.
5.5.2 Objectives
To minimize the difference between planned and achieved production.
Monthly plan and monthly production schedule for the next month will be issued
on the last working day of every month.
5.5.3 Functions
Get information from marketing department about the orders received. The
information contains all details about the customer quality and quantity.
Analysis of orders and decide about when to start and how to start.
Information is then passed to production department.
Check whether materials are available in the store department if not then the
information is passed on to the materials department to purchase the materials.
5.5.4 Planning Process /Activity
1. Yearly Planning
2. Quarterly Planning
Institute of Management in Kerala, Kundara 53
Foreman GRI
Staff
AN ORGANIZATION STUDY AT KEL
3. Monthly Planning
4. Preparation of work order.
5. Issuing of work order.
6. Raising Purchase Return.
7. Monitoring Production.
8. Analysis of production short fall.
9. Maintenance of records.
PROCESS FLOW CHART OF PLANNING DEPARTMENT
Institute of Management in Kerala, Kundara 54
START
Monthly Production ScheduleMonthly plan
Preparation of work orders issue to various department
Raising Purchase Requisition for ‘A’ value items
Monitoring of Production&
Analysis of Short Fall
Request for Delivery
Period Extension to
AN ORGANIZATION STUDY AT KEL
YES
NO
CHART NO: 5.5.2
1. (a). Dispatching Department
In KEL dispatching activities are controlled by the planning department itself.
Objective
Eliminate wrong dispatches and reduce transit damages to 50% within one year.
Policy
Delivery of products in the right time.
Process/Activity
Checking of finished goods and storing (FG Store).
Checking and preservation (FG Store).
Packing of finished goods (F.G.C.F.G.)
Institute of Management in Kerala, Kundara 55
Short fall if
any?
Dispatch as per Schedule
Request for Delivery
Period Extension to
END
AN ORGANIZATION STUDY AT KEL
Intimation for preparation of D.C and excise gate passes.
Delivery of finished goods as per D.C
Collection of acknowledge D.C from consignee.
KEL has tie up with a number of transporters for their dispatching and
transporting activities. About 30 companies are constantly interacting with the firm.
Some of them are:
M/S Kerala Transport Co. Mukkada. Kundara
M/s Suraj Goods Transport Service. Kollam
M/s Carvan Goods Carriers Pvt ltd .kundara
Flow Chart of Finished Goods Store
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START
Checking Preserving&
Storing of Finished Goods
Packing of FG as per DC
Delivery of FG as per DC
Collecting of
PackingInstruction
s
AN ORGANIZATION STUDY AT KEL
Chart No: 5.5.3
5.6 MATERIALS MANAGEMENT DEPARTMENT
This department deals with the purchasing of raw materials for the
production. The main functions are
Purchasing.
Storage.
Inventory control.
Standardization.
Supplier Rating.
General Store.
Material Management means managing materials in an organization with
the main objective of reducing the cost and efficient handling of materials at all stages
Institute of Management in Kerala, Kundara 57
Collecting of
AN ORGANIZATION STUDY AT KEL
and sections in an undertaking. This department deals with material costs, supply
utilization and handling.
5.6.1 Policy
To establish and maintain the process for development for procurement of
right material and service at right time, from approved suppliers as our requirement and
those of our customers.
5.6.2 Objective
Procurement of required quality and the quantity of materials at the best price.
Maintaining continuity of supply to ensure production schedule at the minimum
investment.
Avoiding of duplication of materials leading to waste of materials
and equipments.
Creation of goodwill for the company through dealings with suppliers.
To achieve 100% on time delivery by suppliers
To develop alternative sources to the maximum extent possible.
Structure of Materials Department
Institute of Management in Kerala, Kundara 58Asst .Manager
Manager
Manager
HOD
General Manager
AN ORGANIZATION STUDY AT KEL
Chart No: 5..6.1
5.6.3 Functions
Procurement of requires quality and quantity of materials at the best price for
production as per design.
Maintaining continuity of supply to ensure production schedule at minimum investment i.e. inventory handling.
Avoidance of duplication of materials leading to wastage of materials and equipments.
Creation of goodwill for the company through dealing with the suppliers, ABC analysis is used in inventory handling of materials.
5.6.4 Sub Divisions of Materials Management Department
1. General Store
2. Purchasing.
3. Supplier Rating.
1. General Store
Objectives
Institute of Management in Kerala, Kundara 59
AN ORGANIZATION STUDY AT KEL
To establish and maintain a quality system procedure for receiving,
storing and issuing of materials.
Scope
This covers all materials used in production, installation and servicing of plant
and machinery.
Quality System Procedure
1. Receipt of material.
2. Quality verification.
3. Preparation of GRNS.
4. Offering for inspection.
5. Inspection status.
6. Rejection Intimation.
7. Segregation.
8. Issue of materials.
9. Issue of materials to sub contractors.
10. Stock Intimation.
2. Purchasing
Objective
To establish and maintain a quality procedure for purchase of goods and services
to ensure that all materials and services obtained from outside sources fully meet our
requirements and those of our customers.
Scope
Institute of Management in Kerala, Kundara 60
AN ORGANIZATION STUDY AT KEL
This covers all materials and services used in production, installation and
developments of technology and servicing of plant and machinery.
Quality System Procedure
1. Vetting of Purchase Return.
2. Registration of sub-suppliers, new suppliers.
3. Floating of enquiry.
4. Emergency purchase.
5. Comparison of quotation.
6. Purchase order preparation.
7. Placement of purchase orders.
8. Purchase order amendment.
9. Follow up of purchase order.
10. Sub-contracting jobs.
11. Advice in discrepancies.
12. Rejection intimation.
13. Rejection Return.
14. Acceptance with deviation.
15. Issue under positive recall.
16. Retention of quality records.
17. Settlement of payment.
3. Supplier Rating
Objective
To establish and maintain a system for supplier rating, ensure consistency and
reliability in quality and delivery of products.
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AN ORGANIZATION STUDY AT KEL
Scope
All suppliers supplying items that goes directly or indirectly into the final
product.
Quality System Procedure
1. Supplier Evaluation
2. Supplier Rating.
3. Final supplier’s assessment.
4. Supplier Re-assessment.
Supplier evaluation process
Considerations
Past experience in the related field.
Reputation of the supplier.
Experience with associated units.
Supplier capacity assessment and supplier evaluation.
Supplier rating
Weightages
Quality rating - 60 points
Delivery rating - 15 points
Service rating - 20 points
Organization rating - 5 points
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5.7 DESIGN AND DEVELOPMENT DEPARTMENT
5.7.1 Policy
To establish and maintaining a documented procedure for designing the
right product in the right time. This is achieved through continual improvement through
constant technology up gradation and team work at all levels so that customer satisfaction
can be achieved.
5.7.2 Objective
To design the alternators and its accessories as per design, plant on receipt
of the approved drawings or customer supplied drawings or customer’s supplied
drawings within the delivery period with zero design errors. So that field failures are
eliminated.
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Departmental structure:
Chart No: 5.7.1
5.7.3 Process for developing new product
1. Tender enquiry from marketing department.
2. Feasibility study.
3. Order and specification
4. Design Plan.
5. Design input collection.
6. Review of design input.
7. Design output preparation.
8. Review of design output.
9. Verification.
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General Manager
HOD
Asst .Manager
Staff
AN ORGANIZATION STUDY AT KEL
10. Issue of design report.
11. Prototyping.
12. Verification.
13. Validation of design.
14. Revalidation.
15. Design change control.
FLOW CHART OF DESIGN AND DEVELOPMENT
YES
NO
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Start
Tender Enquiry from Marketing Department
Feasibility Study
Order & Specification
Review Customer Feedback
Design plan
AN ORGANIZATION STUDY AT KEL
Chart No: 5.7.2
5.7.4 The design and development department activities are
1. Collection of input.
2. Design Calculation
3. Design review
4. Preparation of drawings
5. Preparation of Material list.
6. Preparation of materials specification.
7. Preparation of acceptance criteria.
8. Design review. (Output).
9. Modification of review.
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Collection & Review of Design Inputs
Preparation of Design output such as drawings TDS, BOM etc. . .
Review of designVerification
Planning Materials Production Quality Assurance
Prototype manufacturing Verification
Validation
Design Freezing
END
AN ORGANIZATION STUDY AT KEL
10. Issue of drawings, Technical Data Sheet, material list.
11. Prototype manufacturing.
12. Preparation of Quality Assurance Plan and Validation Plan.
13. Validation & Review of validation design.
14. Modification if required.
15. Offering of prototype for customer inspection.
5.8 QUALITY ASSURANCE DEPARTMENT
DEPARTMENT STRUCTURE
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Staff
General Manager
Manager 2
AN ORGANIZATION STUDY AT KEL
Chart No: 5.8.1
5.8.1 Policy
Quality policy of Quality Assurance Department is to ensure the quality of
materials/components to the concerned areas for further processing.
5.8.2 Objectives
Materials offered along with Goods Received Notes s will be inspected within ten
days from
the date of receipt of goods Received Note.
Reducing the defective material retuning from production to 50% within
One year.
5.8.3 QAD Functions:
Incoming material inspection and analyze each and every inputs received.
In process inspection
Final inspection
Quality System Procedure for Control of Inspection/Measure/ Test Equipment
QSP for Calibration of Jigs /Fixtures/ Gauges/ Templates
Decide on error declarations period
Quality testing is done at QAD (Quality Assurance Department). Quality
testing is done at 3stages. They are:
(a) Incoming Material Inspection:
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AN ORGANIZATION STUDY AT KEL
The test conducted in the QAD and they verify every incoming raw
material against there levant ISO specification. When the material fails to the
criteria, the whole lot of batch is rejected, however when it require the materials
urgently department will reject only the fault item. The activities include:
Acknowledgement Receipt of Goods received notes.
Verify GRN with drawing/P.O
Inspection of material and Record Data
Indicate status
Record non-conformity(QAD)
Return Goods received notes to the store
(b) In processing Materials Inspection:
In process inspection which is sometimes called stage inspection, aims at
detecting Nonconformity at the earlier stage of processing to avoid wasteful effort
on output that is going to be rejected. If the Non-conformity is detected at an early
stage, it may be possible to rectify the Non-confirming product and make adjustment
in the process, thus preventing further production of Non-confirming products. In
process Inspection assures the persons responsibility for next stage of manufacturing
process that they are receiving correct input materials.
This test is conducted by the QAD during the production. The
production department offers the materials at various hold points for verification.
Then QAD checks the products and maintains record of conformity. The activities
include:
Offering materials from production
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Indicating inspection and test status
Maintain record of non-conformity
Analysis of defective materials returned from production.
(c) Final test:
A final test for the reliability is carried out by KEL, on all alternators and
regulatorsas per specification given by RITS and Indian standard alternators will
perform. Its intendedfunction verified for a specified period under certain
experimental conditions. Test status for using suitable identification system
identifies the product by making tag, stamping etc. no product shall be
dispatched until activities specified in quality plan or documented procedure has
been completed.
5.8.4 Quality Manual
The quality management system established maintains and documented in the
quality manual. It is developed as a policy manual to describe the quality management
system followed in the organization. The quality manual includes:
Quality policy
Objectives
Organization structure
Responsibilities
Authorities
Scope
Reference to procedures and process maps.
Sequence and interaction of the processes.
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Policy of the company regarding each process or activity.
The quality manual is received and approved by the General Manager for correctness and
suitability to the organizational requirements.
5.8.5 QUALITY SYSTEM PROCEDURE FOR CONTROL OF DOCUMENT
Objective
To make available required documents at all centers of operations related to quality
systems, to follow and demonstrate conformity to the specified requirements
incorporating the latest revision.
Scope
All documents such as quality system manual, quality system procedures, quality plan
and quality assurance plan, acceptance criteria drawing, specification, work instructions
format, charts, material list and master list of document.
5.8.6 QUALITY SYSTEM PROCEDURE FOR CORRECTIVE ACTION
Objective
To establish and maintain a documented procedure for implementing corrective action to
eliminate the causes of existing non-conformities at all levels of quality system,
to prevent the recurrence of non-conformities.
Scope
All functional areas of organization wherever quality system is implemented.
Overall Responsibility
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Committee for continual improvement
5.8.7QUALITY SYSTEM PROCEDURE FOR PREVENTIVE ACTION
Objective
To establish and maintain a documented procedure for implementing preventive
action to eliminate the causes of potential non-conformities at all levels of quality system
to prevent the occurrence of non-conformities.
Scope
All functional areas of organization wherever quality system is implemented.
Overall Responsibility
Committee for continual improvement
SWOT ANALYSIS
SWOT analysis is the process of analyzing the various strengths,
weaknesses, opportunities and threats of an organization or firm. This analysis is useful
to make awareness of the organization’s strength that is where the resources are useful to
the firm to the maximum for the firm. The analyzing of the weaknesses of the firm helps
the firm to analyze the firm to identify the areas where they have to improve.
Opportunities analyzing will help the firm to analyze the areas where the firm can
propitiate their business or make a boom to their product market. The threat analysis will
be useful to the firm as they can be careful in those threat areas. Thus the SWOT analysis
is a useful strategic tool for analyzing the business.
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Chart No.6.1
1. Strengths
Good brand image.
Good customer relation.
ISO 9001:2000 certification.
After sales services at various metro cities.
Wide marketing network.
Efficient personnel administration that bridges the employer – employee
relation unconditionally.
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Intensive training and development program for the employer and
employees that helps them to adopt to the changes in the technology and
environment.
Fully equipped to manufacture the alternators from the initial stage of the
raw materials without depending on the external sources.
2. Weaknesses
No ERP system.
Lack of computerization and information technology application.
Paper works for the internal correspondence is higher.
The premises or structure of the firm is not worth to give a first
impression that has to be the best for an outsider.
Lack of transportation facility.
Lack of sufficient and Effective Sales Promotion Activities.
Being a public sector company, lot of Political influence may affect
the smooth running of Organization.
Raw materials are not freely available.
Still using the old machinery.
Lack of Multi skilled Labors.
3. Opportunities
Globalization.
Can develop more potential market.
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Largest Public Sector Company.
Development of Railways.
Increasing overseas market.
4. Threats
High competition from the competitors.
Increasing price of raw materials.
Depends only on major customer.(Indian Railways)
PORTER’S FIVE FORCE ANALYSIS
The model of pure competition implies that risk-adjusted rates of return
should be constant across firms and industries. However, numerous economic studie
s have affirmed that different industries can sustain different levels of profitability; part
of this difference is explained by industry structure.
Michael Porter provided a framework that models an industry as being
influenced by five forces. The strategic business manager seeking to develop an edge
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over rival firm can use this model to better understand the industry context in which the
firm operates.
According to Michel porter the nature and degree of competition in an industry depends
on the 5 forces. The points of force are represented as follows:-
Diagram of Porter's 5 Forces
Chart No.6.2
1. Rivalry among current competitor increased because of
Aggressive sales promotion and the advertisement.
Cheap credit facility.
Cash discount and Trade Discount.
Relative Price.
Modernization.
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AN ORGANIZATION STUDY AT KEL
Players have similar strategies.
Products are not much differentiated.
Low market growth rate.
Exit barriers are high.
2. Threat of substitutes
Diesel generation.
Arrival of electric trains.
The threat of substitutes is low by the factors like
Brand loyalty of customers.
Close customer relationship.
Switching cost for customers.
The relative price or performance of substitutes.
Current trends.
3. Bargaining power of suppliers
Availability of substitutes.
Large no of buyers.
The suppliers are fragment so this bargaining power is high.
The switching costs from one supplier to another are high.
Possible to suppliers integrating forward.
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4. Bargaining power of buyer
Price sensitive customers.
High competition.
Quality Assurance.
Customers bargaining power are high under the following circumstance.
Concentration of buyer
Undifferentiated product
Railways are the main buyer of the company. KEL exports its product. Therefore the company is having local customers and international customers.
5. Threat of new entrance
H.M.T.D Chennai
Stone India Calcutta
Crompton Greaves ltd Chennai
Steasalite ltd
Press tech India
Unitee
The threat of new entrance to the KEL is low due to,
Insufficient capital requirement for the new venture.
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The cost incurred for the product in its various stages may affect the entrance.
Economic of scale.
Product differentiat
FINDINGS
The major findings of the study are:-
1. The major customer of KEL Kundara is Indian Railways.
2. An outstanding product of the division is the Statodyne brushless alternators.
3. The company has a good brand image.
4. Their products are marketed through an All India Network.
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5. Marketing and after sales services offices are situated in all the metro cities.
6. The communication channel in KEL is very good.
7. No advertisement activities are performed.
8. Workers are recruited through employment exchange, Kerala PSC and direct recruitment.
9. KEL follows three shifts systems.
10. It is an ISO 9001:2000 company.
11. Kundara unit is on the path of Modernization
12. KEL implements good number of welfare measures to the employees.
13. Emphasizing to Product quality than profit.
14. KEL follows time rate system of wages.
15. Good Employee-Employer relation is maintained in the Organization.
SUGGESTIONS
1. Strict internal auditing along with creative suggestions and close monitory system
. can make continual improvement.
2. Online marketing will help the company to increase their sales.
3. In the era of electric trains, company has to diversify its product range in order to
exist in the market.
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4. Introduction of new concept would help the company to reduce the Production
and Maintenance cost.
5. Company should introduce modern management tools in the administration and
strategy formulation.
6. Company should revise the strategies by considering the long term market and
Economic conditions
7. Infra structure to be efficiently maintained and also properly arranged for
convenient working of the employees.
8. The management should conduct meeting with workers weekly or fortnightly to
know about the satisfaction with their working surroundings.
9. Multi skilled employees should be introduced to the organization for the effective
functioning.
CONCLUSION
KEL was established in 1947 in Kerala and is fully owned by state govt. of
Kerala. It is an ISO 9001:2000 certified company. It has been the major supplier of Brush
less alternators for the Indian Railways. It one of the biggest public sector companies in
Kerala. The organizational study in KEL, gave a brief idea about all functional areas of
management. Eight departments are functioning in KEL.All the departments are working
together for achieving their objective.KEL is one of the major public sector company in
the state. Major customer of KEL is Indian Railway. It is an ISO certified company.KEL
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AN ORGANIZATION STUDY AT KEL
adopt modern technology for production and their products are marketed throughout all
India network. Its workforce includes 1250 persons which include 250 qualified and
well-trained professional engineers; KEL is one of the biggest public sector companies in
the State of Kerala with three branches all over the state. KEL came into the field of the
Alternator production by 1970’s .The company is tuned with modern technology.
Products are marketed through all India network marketing and after sales service offices
are located in all metropolitan cities. The major customer of the company is Indian
railways. Being a public sector company KEL has its own limitations. But when we
analyses the organization, through the efficiency of work and the brand name they have
created among their customers as well as competitors their work was more than that of a
private sector company. This is one of the factors that make the organization in the lime
Employees strength of KEL is nearly 400.Their main product is Brushless Alternators,
which is used for lighting and air-conditioning the rail coaches.KEL provides wide range
of facilities to their workers. Even though the company faces some problems in recent
years, the company is now in a profitable path.
BIBLIOGRAPHY
BOOKS
Kothari C.R , Research Methodology, 2e: wishwa prakashan, New Delhi,1990
Kotler Philp, Marketing Management Prentice- Hall of India Pvt, Ltd.,2002
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AN ORGANIZATION STUDY AT KEL
JOURNALS
KEL Annual Report
Production Manual
WEBSITE
www.kel.co.in
APPENDIX
ABBREVIATION
1. KEL - Kerala Electrical and Allied Engineering Company Limited
2. USP - Unique Selling Proportion
3. DA - Dearness Allowance
4. DC - Direct Cost
5. HOD - Head of the department
6. VAT - Value Added Tax
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7. KPSC - Kerala public Service Communication
8. GRN - Goods Received Notes
9. R& D - Research and Development
10. P/L - Profit and Loss account
11. FGTN - Finished Goods Transfer Notes
12. PR - Purchase Return
13. MKTG - Marketing
14. AS&S - After Sales &Service
15. AM - Assistant Manager
16. CH - Charge Hand
17. SW - Skilled Worker
18. USW - Unskilled Workers
19. SI - Security Inspector
20. JO - Junior Officer
21. QAD - Quality Assurance Department
22. AAO - Assistant Account Officer
23. FY - Foundry
24. P&A - Personal & Administration
25. D&D - Design & Development
26. F&A - Finance &Accounts
BALANCE SHEET OF 2012-11, 2011-10 & 2010-09
PaticularsNote No
As at 31st March 2012(Amt)
As at 31st March 2011(Amt)
A. Equity & Liabilities1.Share holders fund
a) Share capitalb) Reseve & surplus
c) Money received against share warrants
2. Share application money pending
12
_
_
871,480770(1,030,503,021)
_
(1159,022,251)_
871,480770(967,674,141)
_
(96,193,371)_
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allotment3. Non-current liabilities
a) Long-term borrowingsb) Deferred tax liabilities
c) Other long-term liabilitiesd) Long-term provisions
4.Current Liabilitiesa) Short-term borrowing
b) Trade payablesc) Other current liabilitiesd) Short-term provisions
Total
B. Assets1. Non-current assets
a. Fixed assetsi. Tangible assets
ii. Intangible assetsiii. Capital work in progressiv. Intangible assets under
development
b. Non-current investmentc. Deferred tax asset
d. Long-term loans & advancese. Other non-current assets
3_45
6789
10
10A
11_12
13
90,288,844_
10,811,884109,852,026
210,952,754
43,281,823109,076,258374,358,9275,781,699
732,498,707
784,429,210
35,268,737_
35,067,444_
70336,181
55000_
19,367,748
648,271
90,407,200
80729,378_
12,748,519103,167,228
196,645,125
227,449,394171,264,967438,106,42435,161,307871,982,092
972,433,846
38,910,272_
35067444_
73,977,716
55000_
39,985,837
648,271
114,666,824
Schedule no
As on 31-3-2011(Rs)
As on 31-3-2010(Rs)
I. Source of funds1.Shareholders funda) Shareholders fund
b) Reserve and Surplus2.Loan Fund
a) Secured Loansb) Unsecured Loans
Total
II. Application of fund1.Fixed Assets
AB
CD
8714807701567828
158643943274889836
1306582377
7137807701567828
234886031314143151
1264377780
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AN ORGANIZATION STUDY AT KEL
a) Gross Blockb) Depreciation
c) Net blockd) Capital work in progress
2.Investment3.Current asset, loans and advances
a) Inventoriesb) Sundry debtors
c) Cash and Bank balanced) Loans and Advances
Less: Current liability and provisionsa) Liabilitiesb) Provisions
Net Current Assets
P|L account
Total
E
F
GH
I
120384768814744963891027235067444
73977716
55000
1952112336061956061756160481019443
899987886
491942446144737748
263307692
969241969
1306582377
2955413682403239335521743535067444
90284879
50000
1838740184103330341606942572248640
682525117
37009269892550142
219882277
954160624
12643377780
Schedule no
As on 31-3-2010(Rs)
As on 31-3-2009(Rs)
III. Source of funds1.Shareholders fundc) Shareholders fund
d) Reserve and Surplus2.Loan Fund
c) Secured Loansd) Unsecured Loans
Total
IV. Application of fund
AB
CD
7137807701567828
234886031314143151
1264377780
7137807701567828
218805765300457751
1234612120
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AN ORGANIZATION STUDY AT KEL
1.Fixed Assetse) Gross Blockf) Depreciation
g) Net blockh) Capital work in progress
2.Investment3.Current asset, loans and advances
e) Inventoriesf) Sundry debtors
g) Cash and Bank balanceh) Loans and Advances
Less: Current liability and provisionsc) Liabilitiesd) Provisions
Net Current Assets
P|L account
Total
E
F
GH
I
2955413682403239335521743535067444
90284879
50000
1838740184103330341606942572248640
682525117
37009269892550142
219882277
954160624
12643377780
266029893232780391332495026023791
902848879
50000
1973765543727124521391950448659362
632667872
34034865284669373
207649847
933424830
1234612120
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