sheet metal fabrication industry

ORGANIZATIONAL STUDY ON SRI LAKSHMINARAYANA ENGINEERING INDUSTRIES

ORGANIZATIONAL STUDY

SRI LAKSHMI NARAYANA ENGINEERING INDUSTRIES

Submitted in partial fulfillment for the award of the degree of

Master of Business Administration

Of

Mahatma Gandhi University

By

GINO GEORGE

(Reg.No………..)

Under the Guidance of

MR. KPC NAIR

Sree Narayana Guru Institute of Science & Technology

North Paravur (2009-11)

1


CONTENTS

1. INTRODUCTION

2. INDUSTRY PROFILE

3. COMPANY PROFILE

4. OBJECTIVES AND METHODOLOGY

5. ORGANIZATIONAL CHART AND DEPARTMENTATION

6. MANUFACTURING PROCESS

7. SWOT ANALYSIS

8. FINDING AND SUGGESTIONS

9. CONCLUSION

10. REFERENCE

11. BIBLIOGRAPHY

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CHAPTER -1

INTRODUCTION

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INTRODUCTION

Fabrication, when used as an industrial term, applies to the building of machines, structures and

other equipment, by cutting, shaping and assembling components made from raw materials.

Small businesses that specialize in metal are called fab shop.

Fabrication comprises or overlaps with various metalworking specialties:

Fabrication shops and machine shops have overlapping capabilities, but fabrication shops

generally concentrate on the metal preparation aspects (such as sawing tubing to length or

bending sheet metal or plate), welding, and assembly, whereas machine shops are more

concerned with the machining of parts on machine tools. Firms that encompass both are

also common.

Blacksmithing has always involved fabrication, although it was not always called by that

name.

The products produced by welders, which are often referred to as weldments, are an

example of fabrication.

Boilermakers originally specialized in boilers, leading to their trade's name, but the term

as used today has a broader meaning.

Similarly, millwrights originally specialized in setting up grain mills and saw mills, but

today they may be called upon for a broad range of fabrication work.

Ironworkers, also known as steel erectors, also engage in fabrication. Often the

fabrications for structural work begin as prefabricated segments in a fab shop, then are

moved to the site by truck, rail, or barge, and finally are installed by erectors.

Metal fabrication

Metal fabrication is a value added process that involves the construction of machines and

structures from various raw materials. A fab shop will bid on a job, usually based on the

engineering drawings, and if awarded the contract will build the product.

Fabrication shops are employed by contractors, OEM's and VAR's. Typical projects

include; loose parts, structural frames for buildings and heavy equipment, and hand

railings and stairs for buildings.

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Engineering

The fabricator may employ or contract out steel detailers to prepare shop drawings, if not

provided by the customer, which the fabricating shop will use for manufacturing.

Manufacturing engineers will program CNC machines as needed.

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CHAPTER -2

INDUSTRY PROFILE

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INDUSTRIAL PROFILE

Metalworking is the process of working with metals to create individual parts, assemblies, or

large scale structures. The term covers a wide range of work from large ships and bridges to

precise engine parts and delicate jewellery. It therefore includes a correspondingly wide range of

skills, processes, and tools.

Metalworking is a science, art, hobby, industry and trade. Its historical roots span cultures,

civilizations, and millennia. Metalworking has evolved from the discovery of smelting various

ores, producing malleable and ductile metal useful for tools and adornments. Modern

metalworking processes, though diverse and specialized, can be categorized as forming, cutting

or joining processes. Today's machine shop includes a number of machine tools capable of

creating a precise, useful work piece.

Prehistory

Metalworking predates history. No one knows with any certainty where or when metalworking

began. The earliest technologies were impermanent to say the least and were unlikely to leave

any evidence for long. The advance that brought metal into focus was the connection of fire and

metals. Who accomplished this is as unknown as the when and where, but the Egyptians are

thought to have been one of the first civilizations to work gold.

Not all metal required fire to obtain it or work it. Isaac Asimov speculated that gold was the "first

metal. His reasoning is that gold by its chemistry is found in nature as nuggets of pure gold. In

other words, gold, as rare as it is, is always found in nature as the metal that it is. There are a few

other metals that sometimes occur natively, and as a result of meteors. Almost all other metals

are found in ores, a mineral bearing rock, that requires heat or some other process to liberate the

metal. Another feature of gold is that it is workable as it is found, meaning that no technology

beyond eyes to find a nugget and a hammer and an anvil to work the metal is needed. Stone

hammer and stone anvil will suffice for technology. This is the result of gold's properties of

malleability and ductility. The earliest tools were stone, bone, wood, and sinew. They sufficed to

work gold.

7

http://en.wikipedia.org/wiki/Machine_tool

http://en.wikipedia.org/wiki/Machine_shop

http://en.wikipedia.org/wiki/Ductile

http://en.wikipedia.org/wiki/Malleable

http://en.wikipedia.org/wiki/Ore

http://en.wikipedia.org/wiki/Smelting

http://en.wikipedia.org/wiki/Tool

http://en.wikipedia.org/wiki/Jewellery

http://en.wikipedia.org/wiki/Engine

http://en.wikipedia.org/wiki/Bridge

http://en.wikipedia.org/wiki/Ship

http://en.wikipedia.org/wiki/Metal


At some unknown point the connection between heat and the liberation of metals from rock

became clear, rocks rich in copper, tin, and lead came into demand. These ores were mined

wherever they were recognized. Remnants of such ancient mines have been found all over what

is today the Middle East. Metalworking was being carried out by the South Asian inhabitants of

Mehrgarh between 7000–3300 BCE. The end of the beginning of metalworking occurs sometime

around 6000 BCE when copper smelting became common in the Middle East.

History

By the historical periods of the Pharaohs in Egypt, the Vedic Kings in India, the Tribes of Israel,

and the Mayan Civilization in North America, among other ancient populations, precious metals

began to have value attached to them. In some cases rules for ownership, distribution, and trade

were created, enforced, and agreed upon by the respective peoples. By the above periods

metalworkers were very skilled at creating objects of adornment, religious artifacts, and trade

instruments of precious metals (non-ferrous), as well as weaponry usually of ferrous metals

and/or alloys. These skills were finely honed and well executed. The techniques were practiced

by artisans, blacksmiths, atharvavedic practitioners, alchemists, and other categories of

metalworkers around the globe. For example, the ancient technique of granulation is found

around the world in numerous ancient cultures before the historic record shows people traveled

seas or overland to far regions of the earth to share this process that still being used by metal

smiths today.

As time progressed metal objects became more common, and ever more complex. The need to

further acquire and work metals grew in importance. Skills related to extracting metal ores from

the earth began to evolve, and metal smiths became more knowledgeable. Meta lsmiths became

important members of society. Fates and economies of entire civilizations were greatly affected

by the availability of metals and metal smiths. The metalworker depends on the extraction of

precious metals to make jewellery, build more efficient electronics, and for industrial and

technological applications from construction to shipping containers to rail, and air transport.

Without metals, goods and services would cease to move around the globe on the scale we know

today.

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More individuals than ever before are learning metalworking as a creative outlet in the forms of

jewellery making, hobby restoration of aircraft and cars, blacksmithing, tinsmithing, tinkering,

and in other art and craft pursuits. Trade schools continue to teach welding in all of its forms, and

there is a proliferation of schools of Lapidary and Jewelers arts and sciences at this- the

beginning of the 21st Century AD.

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CHAPTER - 3

COMPANY PROFILE

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Company Profile

Established in 1990, “Sri Lakshmi Narayana Engineering Industries” is functioning in our own

premises at Narasimmanaikenpalayam for the past 15 years. G. DORAISWAMY is the CEO of

the company. We are a sheet metal fabrication company with good client base that includes

leading players like Indian Railways, Lakshmi Machine Works, Eureka Forbes and True Air

System to mention a few. The company specialize in performing high accuracy jobs and some of

our products include CNC machine covers and parts, outer chasing for water purifiers, paddy

thrasher in agricultural segment blowers and dryers for humidification plants and the like. Our

latest foray has been into the fields of hospital equipments and kitchen equipments where we are

making good strides. The company expertise in particular includes 15 years of experience in the

fabrication of electric panel’s board both for PCC, MCC and M.V.PANELS, SSB, DB

The company machinery infrastructure includes all facilities for fabrications are also

available at our premises. Our ultimate impetus is on quality and values and in our quest to

become global players in our field we continuously aspire to provide value-added products and

services to the society. Innovation in a sustained and determined manner and integrity are our

key goals.

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CHAPTER-4

OBJECTIVES & METHODOLOGIES

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OBJECTIVE OF THE STUDY

• To study about general aspect of SRI LAKSHMI NARAYANA ENGINEERING

COMPANY

• To explore the organization structure of the company

• To understand different departments in the organization and their functioning.

• To do a SWOT analysis with the available information

Methodology

Primary data

Direct interview with the managers, other employees and workers.

By observing the departmental works.

Secondary data

From office records

From internet

Limitation of the study

The time period of this study is very short

The local language of labours made some communication barrier

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CHAPTER -5

ORGANISTIONAL CHART

&

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DEPARTMENTATION

ORGANISATIONAL CHART

15

CEO

TECHNICAL MANAGER

Purchase/ Stores

Marketing Prod/Maint Quality Assurance

Accounts

Operators/Fitters Inspectors

Assistants


RESPONSIBILITY AND AUTHORITY

CEO

A) Reports to the Board of Directors

B) Responsible for:

Overall management of the company

Laying down quality policy and objectives

Carrying our management reviews

Approval of product & process, Design & quality.

Ensuring the compliance to the quality management system of the company

Review and approval of quality management system documents

Finance management

Approval for purchase of raw materials, consumables and spares

Review and authorizing all agreement / contract (customer / suppliers)

Overall responsibility for new products and projects

Defining responsibility and authority of functions who are expected to take the

independent decision

Providing resources as identified including training

Appointment of management representative

Review the performance of the quality management system in line with ISO 9001 / 2000

STD requirement

Review of orders received from customers

Review of nonconforming products as a member of review meeting

Approval of corrective actions taken against customer complaints and purchased products

including productions operations

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Coordination and spear heading the continuous improvement activities of the

organization

Receive and record customer complaints in the register

Maintaining the data related to delivery schedule adherence to customers

Outsourcing Operations (Productions) as required

Identification of training needs of functions reporting to him

Has the authority to stop production

TECHNICAL MANAGER

A) Reports to Chief Executive Officer

B) Responsible for:

Overall activities of the day to day production operations

Planning and review of production against plan

Process design and development


Preparation of work instruction for production activities

Initiation of corrective action with regard to in process / final stages of production

Maintaining customer satisfaction and taking suitable corrective action

Implementing the corrective actions for the customer complaints in coordination with

CEO

New Product Development

Initiating the corrective action against the customer complaint in coordination with CEO

Proposal of corrective action and verification of effectiveness of

corrective actions

Monitoring customer satisfaction and taking suitable corrective actions

Ensure safe working practice

Drawing control in related to distribution and revision and over all maintenance

Control of customer supplied products / documents

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Has the authority to stop production, to correct the quality problems.

PURCHASE STORE IN CHARGE

A) Reports to CEO

B) Responsible for:

Preparation of purchase order / Arranging for purchase of Raw Materials, spares and

consumables

Supplier evaluation and maintenance of approved suppliers list follow up with suppliers

Maintenance of record in relation to purchase of products

Maintenance of minimum stock level

Maintenance of FIFCO system for Self Life Item

Stock register and material identification

Preservation of materials identification

Preservation of materials stores

MARKETING IN CHARGE

A) Reports to CEO

B) Responsible for:

to material Inward and Inspection Receipts of enquires / Orders from the customers and enter in the register Receives and record customer complaints in the register Maintaining records related to customer related processes Tracking of customer satisfaction and on time deliveries

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SUPERVISOR-PRODUCTION

A) Reports to technical manager

B) Responsible for:

Production , quality as per planning

Man, Materials, Methods, Machineries Management

Monitoring House Keeping

Ensure safe working practice

Maintenance of records related to production & quality


Has the authority to stop production, to correct the quality problems

MANAGEMENT REPRESENTATIVE

A) Reports to CEO

B) Responsible for:

Planning, establishing and implementing quality Management system in consultation with CEO

Organizing internal quality audits Organizing management Reviews meeting and taking follow up actions Initiate preventive actions with regard to repeated system non conformities Liaison with certifying agencies and arranging for external audits Ensuring internal communication in regard to effectiveness of quality management

system

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MAN POWER

There are 165 employees

72 Skilled technicians

17 Engineers

12 Administrative staff members

CLIENTS

Kerlosker

Poduval sons

Indian Railways

Lakshmi Machine Works

Eureka Forbes

True Air System

PRODUCTS

CNC machine covers

Outer chasing for water purifiers

Paddy thrasher

Hospital equipments

Kitchen equipments

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INSPECTION PROCESS

QUALITY CONTROL

Process input Mode of output Process Measures

1.Quality plan/Work Instruction

2.Drawings/Specifications

3.Incoming Raw material

specification

4. Measuring devices

5. Inspection skill

6. In formations/feedback from the

customer with regard to quality of

the product.

7. Inspection status

1. Inspection report

2. Non conformance

report

3. Corrective action

report

4. Test certificate

1. Number of customer

complaints

Related to quality of the

product

2. Customer rejection

percentage

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INCOMING STAGE:

A. On action on receipt of raw materials from suppliers/processed products from the service

providers are inspected as per incoming/process/product wise quality

B. The raw materials/production operations are accepted based on the test

certificates/inspection reports wherever required as applicable received from the

suppliers/service providers.

C. The quality supplied and accepted criteria is ensured against P.O/job order as applicable

and the same is updated in the material inward inspection report/service provider’s

register

D. The consumable are checked for the quality and specification (Visual through labels or

stickers etc.) as per purchase order/purchase orders register and accepted. The result are

updated in MIIR

The non-conformance identified during this inspection, are handled as in continual

improvement process

IN PROCESS AND FINAL STAGE

A. In process and final inspection are carried out as per the process and final inspection

quality plan. The inspection results are recorded in inspection reports.

B. Final inspection/Testing are done on the finished 100% Qty of the product as per the final

inspection quality plan

C. Final inspection/Testing results are recorded in the Final /stage inspection report.

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D. If result are not meeting accepted criteria/tolerance during in process /final stage ,then

non-conforming product control process is implemented as per the process module-

continual improvement process

E. Inspection status is identified on the components through tag/board/respective

location/paint mark identification.

F. Inspection skill is measured through skill matrix and necessary action is taken as per the

process module.

G. Proper instrument with valid calibrated are selected for the inspection. Instrument are

selected such that its least count is 10% of the size under measurement.

SUPERVISOR-QUALITY CONTROLA) Reports to technical manager

B) Responsible for:

Overall quality control and assurance

Maintenance of records related to incoming materials, in process materials and final stage

productions inspection reports including dimensional inspection

Calibration of inspection and testing equipment / instruments


Has the authority to stop production, to correct the quality problems

ACCOUNTS

A) Reports to CEO

B) Responsible for:

Overall responsible for accounts related activities includes sales tax, excrise & banking

Maintaining commercial records and invoice

Coordinating with auditors for carrying out annual audit

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RESPONSIBLITIES OF OTHER PERSONNELSConcerned sections in charges define and communicate the responsibilities of personnel working in their respective areas.

QUALITY ASSURANCE

The management of SRI LAKSHMI NARAYANA ENGINEERING INDUSTRIES is fully

committed to the development and implementation of modern quality management system and

continually improving its effectiveness. Towards these requirements, the company has oriented

all its systems and procedures inline international quality management standards and practices

The quality manual of SRI LAKSHMI NARAYANA ENGINEERING INDUSTRIES is

issued on 31.08.06, which incorporates company’s quality policy and the basic procedures.

The company has decided to obtain ISO 9001/2000 certificate to fulfill the requirements of its

discerning customers, who are constantly upgrading their own requirements and making

increasing demands on their supply chain to enable better competitiveness.

The quality management system is oriented to achieve, maintain and improve overall

organization performance, capability and also to identify and meet the needs and expectations of

the company’s customers, employees, suppliers and owners.

The quality management system procedures in the quality manual are supplemented with further

supporting work instructions, check sheet and together they form a comprehensive documented

quality management system, designed to result in better customer satisfaction, a basic

requirements of the company’s quality policy

The Chief Executive Officer/MD, Technical Manager/section in charge is committed to

the development and implementation of the quality management system and continually

improves its effectiveness by

A) Communicating within the organization, the importance of meeting the

customer as well as statutory and regulatory requirements

b) Establishing the quality policy

c) Ensuring that quality objectives are established

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D) Conducting management reviews

E) Ensuring the availability of resource

The Chief Executive Officer is authorized to approve the quality management system

procedures incorporated in this manual and subsequent amendment to them.

The Management representative is authorized to approve other work instructions, check

sheet and formats o the quality management system to maintain uniformity within the company.

It is mandatory on the part of all employees of SRI LAKSHMI NARAYANA

ENGINEERING INDUSTRIES, to faithfully implement the quality management system and

work towards continuous improvement based on regular analysis of current performance data

and keeping in view the increasing expectations of the customers.

CHAPTER-6

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MANUFACTURING PROCESS

MECHINARY LIST

SL NO M/C NAME MAKE CAPACITY QTY

1 SHEARING TEE 4MM*2500MM 12 BENDING TEE 3MM*2500MM 13 CNC

BENDINGJFY 4MM*3100MM 1

4 CNCPUNCH

JFY 6MM*2500*1250MM 1

WITH 32 STATION5 POWER

PRESSSME 30 TONS 1

6 NIBBING AMC 6MM 17 WELDING

L&T MIG 300A 2SUPREME TIG 300A 1BHARAT ARC 250A 5MALIK SPOT 15KVA4+4MM 1

26


CUTTING

27


PUNCHING (SHEARING)

28


BENDING

29


NIBBING

30


WELDING

31


32


CUTTING

-Ordinary cutting machine

33


FINISHING

-For Finishing sander machine is used

34


POWER PRESS PUNCHING MACHINE

\ PROCESS STEPS

35


PROCESS MAP

BASIC PROCESSES FOR PRODUCT REALISATION

36

BENDING

PUNCHING

BENDING

WELDING

FINISHING

DESPATCHING


PROCESS FOR QUALITY MANAGEMENT SYSTEM

37

RECEIVING CUSTOMER ENQIURIES AND EXAMINING FEASIBILITY OF MANUFACTURE BEFORE COMMITTING TO CUSTOMER

PLANNING FOR DESIGN/DEVELOPMENT, PRODUCTION AND TOOLING

PROCUREMENT AND STOCK OF RAW MATERIALS

INSPECTION OF INCOMMING MATERIALS

DEVELOPMENT OF INITIAL SAMPLES

DESIGN AND DEVELOPMENT OF PROCESS/QUALITY PLAN

CUSTOMER APPROVAL OF SAMPLES

PROCESS CONTROL AND REGULAR PRODUCTION

IN-PROCESS AND FINAL INSPECTION

DELIVERY TO CUSTOMER AFTER SALES SERVICE

CUSTOMER FEED BACK/COMPLANTS/INVEMEGATION AND CAPA

DEVELOP QUALITY POLICY AND OVERALL OBJECTIVES AND COMMUNICATE


PROCESS FOR MEASURMENT

38

DEVELOP QUALITY MANAGEMENT PROCEDURES/WORK INSTRUCTIONS, CHECKS SHEETS AND IDENTIFY QUALITY RECORDS

PROVIDE NECESSARY RESOURCES INCLUDING TRAINING

IMPLEMENTING QUALIYY MANAGEMENT SYSTEM

MONITOR EFFECTIVE IMPLEMENTATION

FEED BACK TO MANAGEMENT FOR ASSESSING SYSTEM EFFECTIVENESS AND FUTHER IMPROVEMENT

PROCESS CONTROL MEASURMENT


CONTINUAL IMPROVEMENT OF THE QUALITY

CONTINUAL IMPROVEMENT OF THE QUALITY MANAGEMENT SYSTEM

39

ANALYSIS OF RESULTS OF MEASURMENT AND CONTINUOUS IMPROVEMENT

PRODUCT CONTROL MEASURMENTS

CONTROL OF MEASURING SYSTEM

CUSTOMER SATIFICATION MEASURMENT

QUALITY MANAGEMENT SYSTEM MEASURMENT THROUGH INTERNAL AUDIT

CONTINUAL IMPROVEMENT OF THE QUALITY MANAGEMENT SYSTEM


INPUT OUTPUT

PURCHASE AND STORE PROCESS

PROCESS MANAGEMENT PROCEDURE ACTIVITY

40

MGNT. RESPONSIBILITY

PRODUCT REALISATION

RESOURCE MANAGEMENT MEASUREMENT, ANALYSIS, IMPROVEMENT

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The purchase in-charge maintains the list of materials list of suppliers and list of services

providers

SELECTION OF SUPPLIERS (PURCHASE PROCESS)

All the existing suppliers/service provider as on 31.08.06 are brought into the list of approved

suppliers and the list of service providers based on the past experience with respect to quality and

delivery.

If there is a need for any new suppliers/service providers, purchase in-charge source the

information about the potential suppliers/service providers through market information. Purchase

in-charge sends the assessment questionnaire for supplier registration to them, and their details

are collected. CEO review the information provided by the suppliers/service providers and

decides about their approval. If approved, their names are included into the list of

suppliers/service providers.

A new/unapproved suppliers/service provides is included in the list of approved suppliers based

on the following conditions.

a) Quality feedback received from the production/Q.C for at least 3 trail supplies.

b) Filled supplier registration from approved by CEO

PLANNING AND PROCRING OF MATERIALS (PURCHASING

DATA)

The Raw material and the production related consumables are purchased based on monthly

orders/schedule or during day to day work orders and subsequent stoke verification.

If production in charge found stock Qty is less, raises the material requisition to stores and stores

in turns raises indent to purchase in charge for the procurement of the materials.

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Purchase orders are raises against the stores indent/purchase requisition memos to the approved

suppliers on a yearly/ monthly/daily basis as applicable and required. If there is any change in

the contract within the financial year, amendment of purchase order is raised to the suppliers.

Further if purchases are made through letter or orally, the same is monitored through purchase

order register

Emergency purchase is done from the suppliers other approved suppliers on ane time basis if

approved by the CEO.

PLANNING OF SERVICES

The list of service providers contains the name of the service providers and their scope of supply

is maintained by purchase/prod in charge.

The production in charge/CEO orders the service to those in the list on a need basis. The

communication about the services requirements is communicated through

drawing/sketches/work instructions.

The material is send to the service providers through the delivery channel and sends and returned

details are recorded in the service provider register

RECIEIPT OF MATERIAL (VERIFICATION OF PURCHASED

PRODUCT)

The material received from the suppliers/service providers are inspected and stored in the

material storage area.

The raw material/consumables received are checked for the quality against the advised quality

and updated in the MIIR. If there is any excess/shortage the supplier is informed suitably. The

accepted material is stored in their respective storage location and the stock ledger for raw

materials and consumables are updated for the receipt of corresponding quality.

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The material received from service provider like machined casting is updated in service

providers register. The machined castings are accepted based on the service provider inspection

report or Q.C/inspector carries out the inspection as per the requirement and the inspection is

recorded in the inspection report. If any deviations occur, is informed to the service provider

suitably and CEO/Q.C in charge is responsible for making decision based on the severity of the

deviations either to rework or accept conditionally. The accepted materials are stored in their

respective storage location and the records are updated.

ISSUE OF MATERIAL

The material in storage is under the control of stores in charge. The material required for

production is issued against the material requisition by production. The material are updated in

the stock ledger the store in charge

The CEO/production in charge review the stock status of the material periodically to ensure the

availability the material for production against the minimum stock level maintained at stores.

Shelf life item are issued as per FIFO system by maintaining the shelf life item list in stores

EVALUATION OF SUPPLIERS/SERVICE PROVIDERS

The performance of the suppliers/service providers are monitored and rated based on the quality

of the supplies and delivery performance.

The supplier/service providers rating is carried out on half yearly basic. The rating is done on

two aspects namely quality (60%) and delivery (40%) weight age and rating in recorded in

suppliers / service provider rating from

FOR PRODUCT QUALITY

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A) For purchase products Total Quality Accepted

X 60

Total Quality Supplied

Qty. Rejected X 60 Qty. Reworked

B) For Productions operations: 60- +

Tot. Qty Supplied Tot. Qty supplied

For Delivery Adherence

Qty. Supplied on time

A) For purchase products: X40

Ordered Quality

B) For productions operations: 40- Sum of fraction of delayed Qty. Supplied X

No. of days of delay

PRODUCTION PROCESS

44


Process inputs Mode of Output Process Measures

1.Customer order

2.Work order/Daily plan

3.Customer Drawings

4.Quality plan/Work Instructions

5.Trained human resource

6.Machines

7.Raw materials and consumables

8.Safty precautions

9.Feed back received from QC,IA,MRA

and customer complaints

10.Product nonconformities

11.Product identification method

1.Production

Process

2.Products

1.Adherence to

planning

PROCESS MANAGEMENT PROCEDURE ACTIVITY

45


1. The schedule/orders from the customers are received by the CEO. After consolidating the

schedule, CEO reviews the availability of the capacity along with technical manager/concerned

section in charge received from the customers marketing in charge raises the work order to

production in charge

2. Based on the work order received from marketing, production plan is arrived by the

production in charge in the work order rear side itself.

3. Based on the weekly plan, the raw material/consumables planning is carried out by the CEO

interacting with the production in charge and the material requisition is raised to stores about

procurement. Stores in charge after verifying the stock raised the indent to purchase in charge for

procurement

4. If any additional schedules are received from the customers CEO along with technical

manager section in charges in consultation with CEO amend the monthly/Weekly planning. The

raw material/consumable planning are also reviewed for additional and if necessary,

requirements are informed to purchase in-charge

5. In case of no-availability of the required from the capacity CEO decide about the action to be

carried out, including the action of the service providers.

6. CEO instructs the production departments highlighting technical and quality requirements.

7. The production is carried out under controlled condition based on the customer

drawings/requirements. The work instructions/process flow charts/activity charts, quality plan-

product wise as applicable, are available in the work spot skill to carry out production process

are identified through skill matrix once in a year and the appropriate records are maintained by

the section in charges.

8. Production details are recorded in daily production logbook maintained by the concerned

section in charges.

9. The in process inspection is carried out as per the quality plan-product wise it is section in

charge’s responsibility to ensure that operators follow the work instructions. It is ensured that

inspection/testing is carried out all stages as per work instructions/quality plan-product wise.

46


10. Process parameters and product characteristics are monitored as per work instruction or as

per customer requirement/quality plan-product wise.

11. In case of any out sourcing productions operations is required it is done through the service

providers. The performance of service providers is evaluated and monitored by rating once in 6

months by CEO/Q.A in charges

12. The products after completion of all processes are offered for pre-delivery/final inspection as

per the quality plan-products wise are available at work spot.

13. Based on work order/production plan whenever products are already for dispatch, they are

dispatched either in loose condition or packed as per customer requirements and the relevant

documents are sent along with products. Test certificates and inspection reports are verified by

quality control before dispatch.

14. Section in charge in consultation with CEO, decides the corrective action to be taken, in case

of any problems related to production and dispatch.

IDENTIFICATION AND TRACEABILITY

INCOMMING STAGE:

a. Raw materials/consumable are stored in bags/containers/loosely at identified areas or

through tag/labeling as applicable

b. Raw materials like rough casting are stored in casting stores identified with name boards

or as suitable.

IN PROCESS STAGE

47


Product at various stages of production process is identified with its status displayed on the

board’s viz. under process, for inspection, for fitting, for painting, for dispatch as applicable.

ACTIVITY

FINAL STAGE

Manufactured products are identified by manufacture’s name board detailing the product

name, manufacturing date, specification, etc. As required by the customers

TRACEABLITY

Manufacturing details including the name of the manufacturer date of manufacturing,

working capacity and other specifications as applicable and as required by the customers are

affixed on the product.

CUSTOMER PROPERTY:

CUSTOMER PRODUCTS

No customer products either supplied or involved in manufacturing process. If at all in future,

the customer products will be maintained for its suitability to use.

CUSTOMER DOCUMENTS

The documents supplied by the customers such as drawings, specification are maintained in

the relevant file. Section in charge maintains list of customers supplied as /internal drawing.

The control of documents, issue of documents, revision of document are carried out as per

the documentation process.

PRESERAVATION OF PRODUCTS

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a. The products are preserved in such a way as to no damage is done to the product in any

form.

b. After the completion for each stage of process, the products are stored in the respective

identified area with status.

c. Shelf life and FIFO is not applicable for the products as its quality is not deteriorated due

to storage.

d. If required by the customer by contractually, products are provided with rust preventive

oil or paint coating or as required by customer on preservation of products

e. Based on production plan, whenever the products are ready for dispatch, they are packed

as per contractual requirements/customer requirements to avoid transit damage.

f. Products are packed as per the contractual requirements/customer requirements either in

wooden cases or in carton boxes or wooden creates or as suitable to avoid any damages.

When the quality is not affected during transport, products are also dispatched in loose

conducting the number of products taken.

WORK ENVIRONMENT

The following factors are managed to achieve conformity of product

1. Proper Housekeeping

2. Identification of products

3. Proper illumination

4. Proper Air Circulation

5. Proper safety equipment is available.

Feedback received from internal audit, Management review and customers are reviewed to

improve the process performance

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SERVICING

Complaints received after warranty period are taken as servicing calls are entered in

service register by making in charge

Most servicing is done at customer premises, and on special request by the customer

is done at customer end

Q.A Executive test the motor received for service as per the quality plan and detect

the problem and forward to production executive for necessary action.

Production executive attend the problems and make the motor functionally o.k.

Q.A Executive re-inspects the motor and gives clearance to dispatch to the customers.

If any service is due to operating mistakes, the concerned customers are properly

trained for correct operating procedure.

All the details of the service activities and any spares replaced are recorded in service

register and the service report is send to the customer along with test report.

EQUIPMENT MAINTAINANCE PROCESS

Process inputs Mode of output Process measures

1.Preventive

Maintenance plan

2.Equipment

3.Spares

1.List of machinery

2.Preventive maintenance record

3.Machine History Card

1.Machine down time

1.Measuring

instruments/gauge

1.List of measuring instruments

2.Calibration history cards and

reports

1.No of occasions instrument

found having error

exceeding acceptable error

limit

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PROCESS MANAGEMENT PROCEDURE

ACTIVITY

INFRASTRUCTURE

The Management of SLN identifies, provides and maintains the facilities it needs to achieve the

conformity of product, which includes,

Buildings, Workspace and associated facilities,

Equipment, hardware and software,

Supporting services(Such as transport, Communication etc)

Equipment used for manufacturing activities is listed in list of machineries measuring

instruments are listed in the list of measuring instruments

MAINTENANCE OF MACHINERY

Preventive maintenance of machinery is carried out as per the preventive maintenance plan and

the result/observations while checking are recorded in the preventive maintenance record

Preventive parameter are reviewed at least once in 3 months during the MRM meeting. On the

basis of repeated break down occurred and the plan is revised if necessary. Problems/break down

and the corrective action taken is recorded in the machine history card

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CALIBRATION OF MEASURING/TEST INSTRUMENT

A. All the measuring instruments or any other devices used to measure are listed in the list of

measuring instruments

B. The acceptable error limit is fixed based on the measurement tolerances of the dimensions

measured using the instrument. The calibration frequency is fixed based on the usage of the

instrument. If required in the future, based on the calibration results the Q.C review the

frequency suitably.

C. It is ensured that the master instrument used by the calibration agency have been calibrated

against national/international measurement standard by receiving a calibration report of master

instrument used.

D. After receipts of calibration report, the results are reviewed against the accepted error limit

fixed in the list of measuring devices. The calibrated details are recorded in the calibrated history

card.

E. If the result of calibrated is not acceptable, inspection result taken before the calibration is

assessed for the past 6 months from the date of calibrated against customer complaints/product

acceptance/quality rating report from the customer. Results of assessment including documents

verified are recorded in the calibrated history card.

F. calibrated status is identified through a sticker, which contains instrument code No, date of

calibrated and calibrated due.

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CHAPTER-7

SWOTS ANALYSIS

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SWOTS ANALYSIS

Sri Lakshmi Narayana Engineering Industries - SWOT Analysis company profile is the essential

source for top-level company data and information. Sri Lakshmi Narayana Engineering

Industries - SWOT Analysis examines the company’s key business structure and operations,

history and products, and provides summary analysis of its key revenue lines and strategy

Sri Lakshmi Narayana Engineering Industries is a steel manufacturer and recycler in

the coimbator. The company manufactures hot-rolled steel (angles, rounds, flats, channels, sheet,

wide-flange beams, pilings, billets, blooms, beam blanks, and plate), cold-rolled steel, steel joists

and joist girders, steel deck, cold finished steel, steel fasteners, metal building systems and light

gauge steel framing.

Reasons to Purchase

- Support sales activities by understanding your customers’ businesses better

- Qualify prospective partners and suppliers

- Keep fully up to date on your competitors’ business structure, strategy and prospects

- Obtain the most up to date company information available

STRENGTH

High reputation

Well qualified and technically skilled manpower

Company has very long period of experience

Good employee management relationship

Product Quality

Company reputation

WEAKNESS

Workers are not able to adopt new technologies

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Lack of Export.

OPPORTUNITIES

Uses of machines are increasing

New technologies are developing

Increasing demand of steel day by day

Increasing demand of steel day by day

THREATS

Heavy competition

Increasing in the price of raw materials

Adopting old techniques of manufacturing

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CHAPTER-8

FINDING AND SUGGESTIONS

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FINDINGS

1. The company have structured organization

2. Absenteeism of the company comparatively large.

3. There is a heavy competition from other companies

4. Increase in the price of the raw materials is one of the main thread

5. They have a effective team work

6. They have a full team of experts

SUGGESTIONS

Welfare activities of the worker should have to be improved.

Company should ensure participative management.

Promotion and adverting activities should be improved

Scope for expansion

Company focuses on modernization & up gradation

CHAPTER-9

57


CONCLUSION

58


CONCLUSION

Our machinery infrastructure includes all facilities for fabrications are also available at our

premises. Our ultimate impetus is on quality and values and in our quest to become global

players in our field we continuously aspire to provide value-added products and services to

the society. Innovation in a sustained and determined manner and integrity are our key

goals

CHAPTER-10

59


REFERENCE

60


REFERENCE

GOOGLE

WIKIPEDIA

COMPANY WEBSITE

MANUALS, BOOKLERS

CHAPTER-11

61


BIBLOGRAPHY

BIBLOGRAPHY

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- Company manuals

- Direct interview with managers

- Internet

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sheet metal fabrication industry

Documents