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, (EPD)
BHEL EPD belongs to heavy electrical equipment / machinery industry. Thus, we shall have a glimpse of heavy electrical machinery industry in India.
markets and higher bargaining power as a result of combined technological strengths through technology transfer from global majors. However, the industry is still highly fragmented with more than 50 per cent of the manufacturers with a turnover of less than Rs. 500 million. This is because there are many companies in the unorganized sector that manufacture transformers, switchgears, and other products in the lower technology fields. In the organized sector the domestic manufacturers mainly consist of Public Sector Units (PSUs).
Contestant
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Manufacturer
Company description
ABB
Has 14 manufacturing facilities and more than 6 500 employees. ABB Group is leveraging its India operations for projects, products, services, engineering, and R&D. India is a hub for the South Asia region.
Control systems, highvoltage products and systems, transformers, cables and accessories and generators.
Crompton Greaves
Started its India operations in 1937. One of Indias largest private sector companies. It is a diverse company engaged in designing, manufacturing and marketing technologically
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Established more than 40 years ago, it is the largest company in the industry. Its range of 180 products caters to power generation and transmission, transportation, telecom, and renewable energy industries.
Kirloskar Electric
Established in 1946 it is one of Indias leading manufacturers of electrical machinery and power equipment. Is capable of manufacturing a range of custom made products.
Motors, generators, switchgears, transformers, and other electrical products like DC machines.
It is one of the largest private sector companies in the business. It manufactures custom designed and engineered electrical machinery and systems.
Switchgear, control and automation systems and meters, turbine casings etc
Alstom
Employs more than 3 300 people in India and has 4 manufacturing facilities. Alstom India has full capabilities in engineering, manufacturing, project management and supply of power generation equipment.
Havells
One of the fastest growing indigenous electrical and power distribution equipment manufacturing companies.
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Thermax
An Indian company having 5 manufacturing facilities and has been in the business of manufacturing electrical equipment for more than 3 decades. Its products are sold in more than 40 countries worldwide.
Contribution of the heavy electrical machinery industry to the India economy: economy:
More than 95 per cent of the electrical machinery successfully installed in operation in India has been produced, installed and commissioned by the Indian electrical machinery industry itself. Most of the products required for the industrial, commercial, and domestic sectors are manufactured by the Indian heavy electrical machinery industry. India has developed strong capabilities in manufacturing top-end and high technology products like transformers, turbines and generators that are at par with international standards. The industry had a volatile time during the period 1997 1998 to 20012002, but has been showing positive trends since electrical machinery segment has exhibited a strong growth. 20022003. The heavy
ORIGIN OF BHEL BHEL was established in 1956 at Bhopal and came into existence in November 1964. At first, nearly 41 years ago at Bhopal, a plant was setup, and that was the genius of heavy electricals equipment industry in India. BHEL is today the largest Engineering and manufacturing Enterprise of its kind in India with well recognized track record performance. Right from 1971-72 this organization is making profit. Garden City College, Bangalore
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Heavy Electrical equipment Plant - Haridwar - Uttar Pradesh January 1967. As there was need for an integrated approach to the development of power equipment manufacture in India and also with the view to optimally utilize the resource, Heavy Electricals (India) Ltd. Bhopal was merged into BHEL in 1974. Presently BHEL manufactures about 180 varieties of products under 30 major product groups. It has built up an available reputation for high quality and reliability of its equipment. In BHEL 67.72% of shares are held by the Government of India and 28-32% is held by Financial Institutions, mutual funds, insurance company, foreign institutional investors and employees. BHEL is paying dividend since 1976-77. BHEL has been a profit making company right since its incorporation and has been making significant contribution to the Governments funds by way of dividend on the equity, taxes and duties etc. BHEL has also received Excellent rating for 9 years consecutively in achieving Memorandum of Undertaking targets with Government of India and has been conferred the priceless status of a Navaratna Company. Another major contribution of BHEL to the nation is by the way of its involvement in the social development work such as adoption of backward villages, buildings and running of schools, medical centers providing self employment facilities for widows, handicapped persons etc.
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Advanced Research and Development facilities for ceramic products, processes and applications at, Bangalore Ceramic Technological Institute, Bangalore (CTI).
BHELs NETWORK:
The wide network of BHEL with Corporate head quarters at New Delhi and consists of 14 manufacturing plants all over the India, 9 service centers, power sector, 4 regional centers in addition to over 150 project sites spread all over India and also provides prompt and effective services to the customers which has attained ISO 9000 certification, BHEL is now an embassy upon Total Quality Management. With the opening up of power sector to the private investment BHEL is likely to face an intense competition from other leading power sector organizations. However, in the past BHEL demonstrated the capability to successfully face international competition introduced by multilateral agencies for funding of power projects in India.
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WITH THE COMPANY IS ACCREDITED WITH FOLLOWING INTERNATIONALLY ACCLAIMED STANDARDS: ISO 9001 COMPANY
Quality policy
ISO 14001
Environmental policy
OHSAS 18001
Occupation health and safety policy
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Customer segment
SEBs, Power Grid, EPC contractors BHEL, ABB, AREVA
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Among all the functional areas of management, production is considered to be crucial in any industrial organization. The production department undertakes the process of converting the raw materials and other inputs into finished products. The manufacturing of goods requires a predetermined plan so that available recourses of the company are used to optimum level and wastage is reduced to the greater extent.
BHEL-EPD unit being the power intensive unit consuming 8.5 million units/annum is the leading manufacturer of High Tension Electro porcelain Insulators in the country and it has also pioneered on the manufacturing and supply of Indigenous wear resistant high alumina ceramic lining material for Power, Steel and Cement industries and also wide range of Industrial ceramics.
For the production to take place smoothly and effectively the whole process involved in the production operation is divided into various sections. Each section is managed by one deputy manager followed by senior executives, executives, engineers, supervisors, shift in charge, assistances, trainees & artisans.
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a) The process of production for insulator is called Stiff mud process. The cake which is formed after filter press is given to pug mills & blanks are formed. These blanks are thrown & jiggering is carried over. The shaped material goes for finishing operation. Then it goes for visual & oil inspection and then for glazing, sanding and gets fired in the kilns. This finishing of the product is called Green / Dry finishing because the rejected material from here can go for recycling. The insulators, which are manufactured, are disc, post, hollow and solid core insulators. These insulators range from 70 KN to 420KN.
b) For ceramic lining tiles production the cake which is got from filter press is dried and production roduction, granulated. The granulated cakes are mixed with organic binders and are compacted in a hydraulic press into the required shape of the tile. Then it is fired in kilns.
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b) Kiln used for firing ceramic lining tiles is a Modern Micro-processor controlled kiln.
i.
Hydraulic Pressure test: In this test, a huge amount of pressure will be executed over the fixed insulators (disc) at an order of 180 +/- 20 kg/cm for insulators ranging from 70KN to 210 KN and of order 200 +/- 20 kg/cm for 320 KN disc insulators.
ii.
Thermal test: The insulators, which are successful in the hydraulic pressure test, are subjected to thermal testing. In this testing the insulators are dipped in hot water at 90 Celsius. Then within 60 seconds it has to be removed from the hot water and has to be placed in the cold water which is having a temperature around 20 Celsius. This test is done to see its withstanding capacity for fluctuation in temperature. If the insulator fails to withstand the sudden fluctuation in temperature, small cracks will appear.
iii.
Mallet test: In this testing, the insulators, which have undergone thermal testing, are beaten using a nylon hammer of 1.5kgs on the top and sides of the insulators. If there is any small crack, it will be revealed and thus are rejected.
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iv.
Electrical test: Insulators are subjected to routine electrical testing at 70 kV to 80kV for 4 minutes, 1 minute for high frequency power test and 3 minutes for high voltage power test. If any insulator fails in the test or it punctures and it is thus rejected.
b)
For ceramic lining tiles there are no tests conducted but visual inspection of the tiles are done tiles, to check its shape and to see whether the tiles are complying to the geometrical requirements.
6. Assembly Section:
a) For insulator insulator: These tests are done before assembling. Then the units go for assembling where special, crock, cap, pin are placed using cement & is fed to steam dryer for initial setting & then finally goes into hot water for 3 days & 1 day to steam. This final product again goes for electric resting at 150kV & the successful insulators are sent for dispatch after packing.
b) For ceramic lining tiles tiles: Here, depending upon the nature of application, the fired and tested tiles are fixed to the metal base by either using silicon cement or metal studs and thus they are dispatched after proper packing is done.
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The production in BHEL-EPD runs 365 days, and it is a continuous process. Here raw materials are tested before manufacturing the insulators so that raw materials obtained satisfies their requirements. All these materials are used in different quantities for different type of insulators that are manufactured.
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Crushing plant is used to crush these raw materials into powder form and also it is used to powder the rejected ones for recycling.
2. Weightment:
Different raw materials from the storage bins are collected and weighed
according to the percentage composition given by the ceramic lab section and according to the ball mill capacity to be charged. Then the weighing card is attached to the lot.
3. Ball Milling: Weighed raw materials including clay are mixed with sufficient water i.e. 50% of raw material & 50% of water and grinded in ball mills for duration of 20 to 24 hours. Its a continuous process round the clock. The material obtained in the ball milling process is called Slip or the Ceramic Slurry.
4. Screening: Here the slurry is transferred to the tank from the ball mill to remove the unwanted materials like threads of the plastic bags in which the raw materials were stored, wooden pieces, etc., through electromagnetic separation. This tank is called discharge tank.
5. Slip Agitating: After screening, the ceramic slurry is transferred to another specially built tank called Top Tanks. From this tank it is passed through two vibratory screens which will be rotating continuously to avoid accumulation of raw materials at the bottom and on top. Then the mixture is fed to Ferro filter for removing the iron particles. Finally the fresh slip is collected in the fresh tank or storage tank.
6. Filter Pressing: Filter pressing is dewatering process. In this process 80% of the water is removed from the slip so as to convert the slip into cake form using nylon clothes. In this process high pressure is applied by compressing them from both sides.
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8. Throwing: This process is done only for disc and post insulators. The blanks formed from pug mills need to be shaped in a tomb form to give the shape to disc insulators. This process is called as Throwing.
9. Jiggering: This process is done only for disc insulators. Here the blanks are given a shape using an automatic jiggering machine which produces 100 units per hour.
10. Drying: The disc insulators and hallow insulators are to be dried after giving their respective final shape to see that the moisture content is below 1%. Otherwise it will burst out in firing operation. The different drying steps are as follows: Chain Dryer: These driers are used for drying the disc insulators. After this process the insulators will be having less than 18% of moisture in it. Blank Dryers: For hallow insulators and solid core insulators the blank produced by pug mills are directly fed to these blank driers. For making the hollow insulators and solid core insulators the hardness of blanks is very much necessary. Therefore blanks are dried to see that the moisture content is less than 17%.
11. Turning: Turning is a process used to make hallow insulators and solid core insulators with Turning: the help of turning machine. In turning machine there is wheel in which the dried blank is kept
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12. Oil Inspection : After the disc insulators are dried from chain dryer, they go for finishing Inspection: operation. Those processes give a perfect shape for the product and then the visual and oil inspection is carried out for the quality of the product.
13. Tunnel Driers : The disc insulators after inspection; and hallow insulator and solid core Driers: insulators after turning, goes into tunnel driers for further drying. In this process the moisture is removed through steam. After the drying is over each product will have less than 1% of moisture in it. This model of drying is called drying chamber.
14. Glazing: After the model drying is over all types of insulators goes for glazing. Glazing is a process to give the required color to the insulators like red, brown, black and white. Glazing is done to give a coating of 0.3mm to 0.5mm of thickness. Glazing results in improved mechanical and electrical stability characteristics.
15. Sanding: The tip of the disc insulators is sanded using glue for mounting of the metallic cap and for inserting the metallic pin inside the insulators. For sanding, the fired insulators which are rejected are powered and used as sandy materials.
16. Firing: The insulators are subjected to firing operation in kilns where temperature is gradually increased, maintained and gradually decreased to avoid cracks in the insulators. The maximum temperature is up to 1300C. Garden City College, Bangalore
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17. Testing: After firing the insulators goes for testing. The various types of tests are Hydraulic Testing: pressure test, Thermal test, Mallet test and Electrical test.
18. Assembling: The insulators, which have undergone all the tests and are successful, are sent to assembling section. The insulators are then mounted with metallic cap on the top, which is inserted inside the insulator using electrets, a type of cement used to assemble these metallic parts.
19. Curing: After assembling, the insulator goes for curing operation. The different kinds of curing Curing: are steam curing, hot water curing & air curing.
Test: 20. Final Electrical Test : After curing, the insulators are set for final electrical test. If insulators
fail in this test, it bursts out and thus they are rejected.
21. Packing: The insulators, which are successful in the tests, are sent for packing section. The Packing: cking insulators are well packed in crates to avoid damages during transportation and to ease smooth handling. Thus, the time taken for all this activities crushing to packing is 31days.
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Lining. CERALIN is the abbreviation for Ceramic Lining Ceralin is an abrasion and erosion resistant high alumina ceramic lining material, which is the result of an extensive R&D programme initiated by EPD of BHEL. Ceralin reduces the down time and increases the overall efficiency of the system or metal in which it is being used. It also has an added advantage of withstanding very high temperature of up to 300 degree centigrade. Ceralin is produced in the form of tiles, depending upon the shape, geometry and the functional requirements. The shapes of tiles manufactured in EPD are : Curved plain tiles. Curved weld on tiles. Flat plain tiles. Flat weld on tiles.
Depending on the nature of application the tiles are fixed to the base metal either using silicon cement or by welding metal studs.
The Process
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Manager
Books & budget Indirect taxes Pay Roll
Manager
Cost Cash Material purchase Work proposal concurrence
Manager
Sales accounts
Manager
Bills Payable
3 Accounts Officer
3 Accounts Officer
2 Assistants
3 Assistants
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BOOKS SECTION This section keeps the records of all the matters of finance department and all theother records that each section keeps with it. They record all the ledgers and vouchers of monthly, quarterly and yearly accounts. They also maintain records of the inter-unit transactions i.e. the transfers that takes place between this unit and BHELs other units. They keep the records of the entire audit that is done internally as well as the record of the entire statutory and government audit. BUDGET SECTION This section also deals with the budgeting of the company. The funds are allocated by the corporate office for each BHEL unit. After receiving this budget they prepare their own budget of each department with the respective heads and then allocate the funds to each department for their Garden City College, Bangalore
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This section is concerned with the payment of all revenue bills. A revenue bill includes payment made to suppliers, payment to government agencies like KPTCL, BWSSB, BSNL and RTO. In case of purchasing the materials, the actual process starts once the order is placed and the material is received by stores and it is sent to quality section. Wherein inspection department will certify and then clear the stores receipt vouchers. The cleared stores receipt will then come to material
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4. Cash Section:
The main function is to account the cash and bank balance. Other than this function the actual payment of money is done through this section. The employees salary, contract laborers wages, suppliers amount and receipt of customers payment all are done through this section.
reimbursement, conveyance reimbursement, tour advance settlement, air fare settlement, payment of medical expenses of retired employees, provident fund and gratuity, etc,. Hence for this purpose, this section maintains Master Records which consists details of each and every employee regarding their date of joining, leave taken, payment of salary, loan taken, allowances given, etc., which are monitored and updated every month. This section ensures a pleasant atmosphere by ensuring accurate payment to the employees in order maintain industrial harmony and employee satisfaction. Apart from these activities, the department is also concerned with recording and maintaining the attendance, leave taken and over time work done by each and every employee. Here the department records time in and out of employee through the medium of automatic time recorders provided at the vantage points within the factory.
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INTERNAL AUDIT
It acts as a watch dog of the various functions by continuously observing and evaluating the records, both financial as well as others. This section mainly functions as a service to the management. The main activity of internal audit is to physically verify the assets mentioned in the records. This investigation helps in identifying losses, pilferage on inventory and controlling them.
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2. Statutory Audit :
It is done by the Chartered Accountants who are also called as Company Auditors. They are not full time employees but are appointed by the Company Law Board and are changed every 3 years.
3. Government Audit :
It is done by the resident at the Office of the Member Audit Board and Ex-office of the Director of Commercial audit. All BHEL units of the southern region are covered by the Director of Commercial Audit, BHEL Hyderabad.
For any organization to carry out its sales activity effectively and more efficiently it requires a good Marketing Department. Most of the activities of marketing in BHEL-EPD are carried out by BHEL-CBU (Ceramic Business Unit). In the field of ceramic components BHEL has a good stand in the country and its sales are very high. BHEL-EPD works only on orders. The concept of producing and looking for customers is not there. That means BHEL is a customer oriented organization. This brings a great deal of responsibility and stress for the functioning of the marketing department. Marketing Department in BHEL-EPD always looks forward for opportunities which generally come to them in the form of tenders and enquiries.
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In all cases where the contractor experience delay on either one or more than one of the above accounts, the contractor should intimate the purchaser the cause of the delay and the period lost during such occurrences. The deliveries specified in the offer will automatically be extended by the period thus lost. Delivery shall be made in one or several consignments and each dispatch would constitute a sale. 10. Payment terms : There are four modes of payments: 100% advance payments in case of private party. Through letter of credit in case of private and government party.
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I.
PRODUCT :
Product Width
Disc insulator HDVC 500kv 800kv HVAC *Fog & Antifog *Aero foil *ANSI *Normal 132kv 220kv Steel sector Cement 220kv 400kv sector 400kv Railway traction 66kv 132kv Pulverized pipes 220kv 33kv 66kv Pulverized mills 132kv Hallow insulator Solid insulator CERALIN Composite insulator
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Product depth
II.
PRICE :
Pricing Strategies:
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BHELDifferent types of prices applicable to BHEL- EPD: Ex- works FOR ( Free On Rail ) - Destination / Store FOR ( Free On Rail ) - Bangalore FOB ( Free On Board ) CIF ( Cost Insurance Freight ) CFR ( Cost + Freight ) DAF ( Delivered At Frontier ) DDP ( Delivered Duty Paid ) DDU (Delivered Duty Unpaid )
III.
PROMOTION:
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IV.
1. 2. 3. 4. 5. 6. 7. 8.
Power sector marketing group Industrial sector marketing Regional Operational Division (ROD) International Operations Divisions Oil sector rigs and maintenance Ceramic Business Unit Transmission Business Group Spares and Services Business Group
1. 2. 3. 4. 5. 6. 7. 8.
Aditya Birla WS Sharavana Modern Insulators IEC Chinese manufacturers Sediver France NGK - Japan.
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Efficient manpower is the greatest asset to an organization. The company has to keep the employees happy for its smooth functioning. For this purpose, an organization should have a department solely dedicated to manage the Human Resources and also to integrate all HR policies and programmes with the frame work of the companys strategies. In BHEL- EPD, there is an efficient Human Resources Department which effectively utilizes the human resources to assist the company in achieving a competitive advantage in the business arena.
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Senior Manager
Establishment
HRDC Security & Fire Intelligence
Deputy Manager
Recruitment Performance Appraisal HRIS MRIS Business Excellence Communication & Public Relations Contract labour
Medical Superintendent
Factory Medical Centre Township Dispensary
General Physicians
Kannada Cell
Executives Nurses
Rajbhasha Adikari
Translator
Attenders
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The chart above not only gives the information about hierarchical structure of the HR Department but it also gives information on the various sections that come under HR Department. As per that, the details pertaining to each of the various sections in HR Department are as follows:-
I.
ESTABLISHMENT:
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BHELSecurity Measures taken at BHEL- EPD for securing Properties of the company:
For preventing physical loss of the properties of the organization from outsiders, the company has 4 well secured gates. They are as follows: 1. Main Gate 2. Rear Gate For all types of visitors. For materials movement.
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ID Card Color
1. White 2. Green
Designation/Grade
Chairman, Director & MD AGM & above (E7 to E9) Dont have to produce ID card Should swipe the card for walking-in and walking-out of the factory.
_ ,, _ _ ,, _
Should swipe the card for attendance and should obtain a gate pass to walk-out of the factory premises.
Fire:
In BHEL-EPD, protection against fire is given on the basis of the classes of fire. The company has divided fire into 5 different classes. They are:1. A class fire : general fire Garden City College, Bangalore
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3. Intelligence Section:
Intelligence section under HR department is part of Vigilance Department. o It performs the following functions: Routine and surprise checks Scrutiny of personal files Suggestions and feedback Training programmes Inter-face meetings List of officers of doubtful integrity Complaints, investigation and penalty Informal counseling Liaison with CBI & COD
o It monitors the following: Out of turn allotments and sanctions Systems / procedures Employees in sensitive area ; job rotation Records / document tracking system
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II.
INDUSTRIAL RELATIONS
Industrial relations refers to the relationship between the management and the employee or among employees and their organizations that characterize and grow out of employment. In any industry Trade Unions are present to maintain such industrial relations. Trade Unions are a voluntary organization of worker or employees formed protect and promote their interest through collective actions. BHEL-EPD has only one union which is managed internally within the organization. The Industrial relations have been maintained peacefully in BHEL. The union consists of educated employees who prefer to settle issues within the factory. The organization also follows the methodology of involving the employees in decision making i.e. Management by Objective. .
III.
WELFARE
1. Canteen
Food which is the basic necessity of human being is being served in the company over the years at subsidized rates of about Rs 5 per day and it also serves nutritious and hygienic food. And a special feature is that, each and every employee has to swipe his/her I.D. card in a magnetic machine so that it is a way to identify the time of entry and exit to the canteen. The canteen also provides Tea/Coffee at least twice a day to the employees.
2.
ESI
The company provides ESI facility to the employees with the basic objective of offering Social Insurance to workers in respect of three contingencies - * Sickness * Employment injury & * Child birth
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3. Medical Centre
A Medical Center with an ambulance service is attached to BHEL industrial complex. The medical centre in the company campus provides, First aid to the injured employees at the time work. Regular health check-ups for the employees. Medical treatment for current employees and also for retired employees who are suffering from minor illness and diseases. This medical centre does not treat chronic illness, diseases or major health problems of the employees. The company has tie up with famous hospitals in the city for that purpose and the medical bill is paid by the company.
IV.
RECRUITMENT
Garden City College, Bangalore
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There has been no recruitment since 1994. Earlier to that, they followed the procedure of written test, followed by a personal interview for recruiting the employees.
Source of Recruitment:
From employment exchange From open market through advertisement in the press By considering departmental candidates possessing the specified require From reputed engineering/ management through college campus interview.
V.
SELECTION
In BHEL, selection of applicants is done through the central recruitment committee. The committee constitutes of corporate personnel departments in consultation with the respective division.
VI.
PERFORMANCE APPRAISAL
The Performance Appraisal and Performance management in BHEL-EPD is done through a web enabled performance management system. It is called as e- MAP i.e. electronic - MOVING i.e. PERFORMANCE. AHEAD through PERFORMANCE Performance evaluation and thereby performance appraisal at BHEL is done internally by the immediate concerned officer. The employees are given points based on the performance. The employees are evaluated on the basis of points.
Till 1999, BHEL-EPD appraised the performance through Annual Confidential Reports but later eMAP was introduced with the help of SAP.
Administrative control and convenience. Quick on-line access to remote locations and quick retrieval of records. Reduce paper records and storage problem. Allows for an interactive process of target setting and objective appraisal. Helps improve employee competencies through continuous feed back. Currently it is operating at over 70 locations across the country covering around 10000 executives + sites abroad.
Modules of MAP
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2. Mid year review: In the month of the October, the performances of employees are reviewed
before the final review.
3. Final review: Final review of performances of all the employees are done in the month of April. 4. Normalization: The actual end result is compared with the pre-set performance benchmarks
and necessary corrective measures are taken if there are any deviations.
KRA
1. ************ Marks 1 2 3 4 5
Levels
Stretch
Difficulty level of the job (Ranges from 0.33 to 1)
Action plan
***********
STRETCH MARKS * ST RETCH = TOTAL MARKS head. But the MAP cycle and policies are done by HR department.
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Employees are marked on a total marks of 100. Each functional departments performance is assessed by the respective departmental
Communication is the essence of social behavior. In everyday living, the mere presence of another person encourages communication. It is a universal human propensity and, as some state. In the organization point of view communication plays vital role for the smooth functioning of the concern. Communication flows between individuals, department, unit and corporate; and company and outer world. It creates connectivity, knowledge sharing and industrial and public relation. The sections main objective is to interact, communicate, share information and maintain good relations with the people. This department maintains and promotes the companys Goodwill in the business world.
are: The Functions of this department are: Press Releases about Company Achievements Media Coverage- Radio, Television Conceptualization and release of Advertisements Participating in International Exhibitions Publishing of House journals (for private circulation) Corporate Films Brochures of Product Profile Maintenance of the Transit House for employees/ customers/ VIPs Providing Holiday Homes to the employees at tourist places Entertainment for Customer like clubs Arrange for guests Lunches/Dinners at reputed Hotels which provide credit facility Photography on rate contract Accessories like diaries. Calendar, greeting cards are provided to employees and customers. Providing Corporate Mementoes and gifts.
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o Classification of employees:
The employees shall generally be classified as under: 1. Regular employee is an employee who has been engaged in a vacancy on the regular establishment of the company and who has satisfactorily completed his probationary period of service and employment in regular service has been confirmed in writing. 2. Temporary employee is an employee who has been engaged on a temporary basis for work, which is essentially of a temporary nature and likely to be completed within a stipulated period. 3. Casual employee is an employee whose employment is of an occasional or casual nature. 4. Probationer is an employee who is provisionally employed with a view of being considered for appointment on the regular establishment of the company. 5. Trainee is a learner who is paid stipend or placed a grade as may be decide by the management, during the period of apprenticeship
o Pay structure:
The employees are divided in two different grades which are: E1 to E9-executives S1 to S8-supervisors A1 to A12-workers B1 to B11-Administrators
Employees in BHEL are paid according to the 6th pay commission of the Central Government.
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These are the regular items in the pay cheque but there are some extra benefits like
Entertainment allowances-for E4 and above Over time allowances and night shift allowances for workers Special incentives-cash awards for acquiring higher qualification, sponsorship for higher studies
and family planning incentives.
Plant performance bonus-same for everybody. Bonus-this is given out of profits. Availability of ESOP for the employees.
City/class of cities
Mumbai and Delhi Other A class cities B1 and B2 class cities C class/unclassified cities
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Payment of HRA at the above rates would be subject to the provision that the employee will have to bear a 10% of their pay towards their house rent. Employees who live in houses owned by themselves, they will be paid HRA at the above rates, depending on the ratable values assessed by the Municipal Authority of the area where the house is situated.
5. Free uniforms accommodation 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Free electricity Kit allowances to employees deputed abroad Vehicle allowance Welding allowance to high pressure welders Transport subsidy Convenience allowance to blind and physically handicapped employees Washing allowance Educational assistance Re-imbursement of tuition fees Subsidiary to apprentices or trainees Traveling allowance.
o Promotions:
Promotions in BHEL are usually based on merit cum seniority. This ensures that no employee is deprived of promotion. They are all given equality of opportunity in growth and career prospects.
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o Transfers:
Employee shall be liable to be transferred at the discretion of the management from one work or development section of station to another, provided that in doing. So the management shall keep in view the suitability of the employees for the particular management work and also the pay grade and the seniority of the employees concerned is projected.
o Hours of work:
Every employee of the company shall be requires working 48 hours a week.
o Overtime:
The management reserves the right to require any employee to work overtime including work on weekly holidays in accordance with the instructions issued from time to time and the employee is also liable to be recalled for duty at anytime for such overtime, adequate compensation by way of compensatory of overtime payment will be allowed off at the discretion of the management.
o VRS scheme:
The Company in order to reduce its employee strength due to global competition and removal of the security veil by the government, it introduces VRS scheme for every four years.
o Retirement:
The retirement age of the employees is 60 years. They receive pension after retirement. They receive the provident fund in one lump sum on retirement after deducting any loans taken by them. They also get the benefits of medical reimbursement for the retired employee and the spouse throughout their lifetime.
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Since the introduction of IT sector to the world, IT has become a key part in the day to day functioning of organizations. Systems Department in BHEL-EPD provides service to production and other departments which in turn helps in network infrastructure, mail transaction and virtual private networks to connect other units and provides on-the-job training to employees. The company implemented SAP in the year 2004. SAP stands for Systems Applications and Products in Data Processing. Since then the units functions have gradually changed from traditional way of working to the usage of the systems. The implementation of SAP by using given resources in various levels and in different departments has made the functioning smooth, since IT maintains the systems round the clock.
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Senior Engineer / IT
Provide IT services to EPD office users Manage IT infrastructure Develop and maintain business applications Procurement, deployment & maintenance of IT Hardware and Software To plan, coordinate and implement software applications
FOR SERVICES PROVIDED BY IT DEPARTMENT FOR THE UNIT I. Server Administration & Operations Process
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II.
1.
2.
List of vendors who have supplied the equipments and services and are responsible for its upkeep, are maintained by IT Services staff.
For
Users log their Complaints and Requests with complaint coordinator numbers at the IT Department.
5.
The Complaint helpdesk coordinator checks the complaints and ensures communication to the
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equipment is taken out for repairs, Returnable Gate Pass is issued for the equipments taken out from EPD premises 8. Equipment is brought back after repair and IT Services group ensures the returned equipment by verifying with the issued Gate pass. 9. On resolution of complaint, the vendor representative informs the complaint coordinator. 10. Any complaint requiring further action or follow-up with vendor is taken up with vendor office.
III.
1. IT Services group receives computer hardware and software requirements from various EPD
Users and also has its own requirements for the operations. 2. Based on the rate contract issued by the CIT procurement group the requirements approval is taken from the competent authorities and the same is sent to CIT for Further Procurement. 3. The indent is generated for items not in the CIT rate contract or the items for emergency requirement and after necessary approval sent to MM / Purchase for procurement. The item after procurement and delivery is installed at user location.
IV.
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V.
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VII.
Users may register themselves for Internet or Email services by applying through Internet Registration Form and E mail Registration Form (AA:EPD:IT:ERF) which are also available on Intranet Site. Once the users are registered, they are intimated and can start availing the services. For providing the Internet services the corresponding approval has to be taken from the HOD of the respective user and HOD of IT department. The final authority for the approval of internet services will be Head of the Unit.
VIII.
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b) Mark the details on the tape/ cartridge with respect to the date of backup and details of the data. c) Send the backup tape / cartridge to a different seismic zone (IP-Jagdishpur) through a courier. d) Record the details of the courier onto a Disaster Notebook giving details of the date sent and the courier number. e) On receiving the tape / cartridge back, enter the details of the received courier details in the Disaster Notebook.
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SWOT analysis is a strategic planning method used to evaluate the Strengths, W eaknesses, Opportunities, and Threats involved in a project or in a business venture. It involves specifying the objective of the business venture or project and identifying the internal and external factors that are favorable and unfavorable to achieve that objective. A scan of the internal and external environment is an important part of the strategic planning process. Environmental factors internal to the firm usually can be classified as strengths (S) or S weaknesses (W), and those external to the firm can be classified as opportunities (O) or threats (T). W O T Such an analysis of the strategic environment is referred to as a SWOT analysis analysis.
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STRENGTHS:
1. The greatest strength of BHEL is its highly skilled, committed and motivated employees 2. Every employee is given an equal opportunity to develop himself and grow in his career. 3. Brand name of BHEL is known internationally without much promotional efforts. 4. BHEL-EPD has achieved TQM in quality and is aiming to achieve SIX SIGMA. 5. It has a separate Ceramic Research Institute with expert man power and lab for pilot production. 6. BHEL-EPD has an In House Engineering Department. 7. All the activities of the Company are directed towards Customer Satisfaction. 8. BHEL-EPD enjoys a market share of about 95% in CERALIN i.e. ceramic liners. 9. Leading status in CERALIN and impetus for new product introduction in existing market. 10. Business group of the Company helps in establishing a easy market entry.
WEAKNESS:
1. Ratios of skilled to unskilled workforce are low and hence difficult for deployment. 2. Over depleting of skill force due to retirement. 3. Expensive man power for Ceramic business product. 4. Manually oriented product lines. 5. Cost does not commensurate with returns for certain varieties of insulators because of long manufacturing process. It takes 31days to produce the product when compared to 27 days period in the competitors firms.
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THREATS:
a) Merger of world renowned Japanese manufacturer NGK with Indian firm (Jayashree Insulators) to produce high quality products in competition. b) Threat of low price Chinese insulators market entry in India. c) Profit margin threat due to stiff competition from the national players like Jayashree Insulators, WS Industries, Sharavana Insulators and electrical and international players restrict market share.
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The findings in different functional departments of BHEL-EPD are as follows: PRODUCTION DEPARTMENT: 1. The process production of production in BHEL-EPD is process production where the cycle time involved in manufacturing insulators is long which increases the cost of production. 2. Masks for Artisans are not provided in all the sections of the shop floor but it is provided only for the Artisans at the Glazing section which actually does give full protection from the dust and smell. FINANCE DEPARTMENT: 1. The method of obtaining costs for various departments, in that various sections and for each unit is very precisely done without any ambiguity. 2. The whole of Finance Departments activities are carried out and integrated with the help of SAP. MARKETING DEPARTMENT: 1. Sales promotional activities are minimum because they manufacture their products based on the orders mostly placed by the government department. 2. The market share of BHEL-EPD in CERALIN (Ceramic Liners) is more than 95% percent in India. INFORMATION TECHNOLOGY DEPARTMENT:
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HUMAN RESOURCES DEPARTMENT: 1. The company has maintained a well motivated & dedicated workforce. 2. The method of appraising the performance of employees through the e- MAP is very unique. 3. It encourages the students to take projects as a part of their Corporate Social Responsibility, so that they can get a practical knowledge of the companys different function areas. 4. Excellent canteen facility with hygienic food is provided to its employees at Re.1. 5. The Salaha Scheme introduced in BHEL with the initiative of the HR department has been successful in tapping the employees potential.
OTHER FINDINGS: 1. There is no proper storage facility for finished goods. They are packed and stacked on pathways.
2. Water recycling plant has been set up in the plant to promote water conservation or natural
resource. 3. The quality circles of BHEL EPD has won many awards. They have achieved TQM. They are keen to improve their benchmark and are working hard to acquire SIX SIGMA.
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1. Can implement Computer Integrated manufacturing system. 2. Job rotation should be done frequently to workers especially in the shop floor, so that they are released from boredom of work, and which also motivates them to acquire additional skills. 3. To design modernized facility layout so that the cycle time is reduced and thus the cost of production. 4. Workers should be provided with good quality masks in all the sections of the production department and they should be insisted to wear them compulsorily. The casual labourers also should be given all the safety equipments as is given to company employees. 5. The work force in IT department should be increased to reduce the burden bestowed on few employees. 6. Signboards should be provided within the factory premises to facilitate easy identification of the department. 7. Proper storage facility for finished products should be provided to avod stacking along the pathways.
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I would like to conclude that EPD is one of the growing units of BHEL. BHEL-EPD is doing well in the present market and possesses highest market share compared to its competitors. The employees are provided with very good facilities and have very good working environment and work culture which in turn helps Company achieve a newer heights every year. It has achieved customer satisfaction by manufacturing customer needed products of good quality. The Company is trying increase the profits by setting up new targets and implementing the new projects. They have also planned to go for semi-automation which will ease the conditions for workers without effecting their present job. The unit is also intensively working hard to achieve SIX SIGMA. The problem areas are identified and are solved by dedicated team work. It has been accredited with eco-friendly certifications. The unit has very good safety and security provisions. The organization is decentralized at certain conditions which encourage freedom to work, employee participation in the development of the organization. The unit consists of well established departments which work in coordination. It has in-house R&D which is doing research on Ceramics and on Grinding Media. BHEL which is one among the NAVARATNA Companies. Earlier I had a perception that BHEL being a Government Company may not be working like other private companies and also may not
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Books:
1. BHEL magazines (monthly and fortnightly) 2. Personal manuals of various departments. 3. Particulars of organization, functions and duties. 4. Norms set by company for the discharge of its functions. 5. Rules, Regulations, Instructions, Manuals and Records held by company or under its control or used by its employees for discharging its functions. 6. Details in respect of Information, available to or held by the company, reduced in an electronic form.
7. Obtained information, during the working hours of a library or reading room.
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Websites:
www.bhelceramics.com www.bhel.com www.teknikfortagen.se
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