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NAGESHA.G
BRINDAVAN COLLEGE
BRINDAVAN COLLEGE
Declaration
I NAGESHA.G, had carried out the internship project "ORGANISATIONAL STUDY", at HMT MACHINE TOOLS LIMITED Company and is a independent study under supervision and guidance of my internal guide Prof.MOHAMED SHAFI of MBA department of Brindavan college of Management Studies Bangalore and external guide Mr. SUDHAKAR of HMT MACHINE TOOLS Limited Company. Now submitted to Bangalore University for the partial fulfillment of University regulation course for the award of Master of Business Administration. I further declare that this report is based on the original study undertaken by
53
me and has not formed a basis for the award of any Degree of Bangalore University or other University.
Date: Place:
TABLES OF CONTENTS CONTENTS INDUSTRY PROFILE ~ 1.1 Historical Background ~ 1.2 Manufacturing Range -1.3 Current trends ~1.4 Export performance ~1.5 Industry structure -1.6 Machine tools 1 COMPANY PROFILE -2.1 Introduction to HMT -2.2 Introduction to machine tools LTD -2.3 Background and Inception -2.4 Objectives -2, 5 Nature of business carried -2.6 Corporate vision -2.7 Corporate mission -2.8 Corporate strength -2.9 Organizational structure -2.10 HMT Quality policies -2.11 Customs service -2.12 Infrastructure -2.13 Technology and R & D 2 PRODUCT PROFILE -3.1 Machine tools -3.2 Watches -3.3 Tractors -3.4 Pressure die casting and plastic injection 3 PAGE NO
CHAPTER NO
3.5 Printing machine 3.6 Precision machine ~3.7 Dairy machine 3.8 Reconditioning 4 FUNCTIONAL DEPARTMENTS 4.1.1 Human resource department - 4.1.2 Planning department 4.1.3 Finance department -4.1.4 Purchase department 4.1.5 Production department - 4.1.6 Sales department SWOT ANALYSIS OF THE COMPANY FINDINGS AND SUGGESTIONS OF THE ORGANIZATION CONCLUSSION
5 6 7
Industry profile
INDUSTRIAL PROFILE
An industrial which has undergone a radical shift in its paradigm thinking, the Indian machine tools industry is now recognized as a provider of cost- effective high quality lean manufacturing solutions. The industry resiliency supports all its users to enhance productivity as well as improve competitiveness, for the betterment of the customer. Being an integral sector, growth of the machine tool has an immense bearing on the entire economy, especially India's manufacturing industry and is even more crucial for development of the company's strategic segments such as defence, |railways, space & atomic energy. World over too, industrialized advanced countries have created niches on the back of a well, indigenous machines tools have the highest impact on capital output ratios. Machines tools consumption of Rs. 100crores truly support the advancement of the country's engineering sector, output of which to be worth over Rs. 150000crores.
1.1
HISTORICAL BACKGROUND
Machine tools were manufactured as early as 1890, but were poor in quality and lacked standardization. After 1930 machine tools of a reasonably good quality began to be produced in India principally by P N DATTA & COMPANY in Calcutta. Cooper engineering works at Satara & The Indian Machinery Company at Dasnagar near Calcutta. These enterprises, which were the pioneer of the machine tools making in India, Made mostly sliding, surfacing and screw cutting lathe of the head stock types. However all the enterprises suffered from the absence of the ready, Market for then &products, mainly because of competition from established Manufactured in England.
The Outbreak of the 2nd world war India became the main base of supply &production of the war materials for the British & the ally's army in the east. There was tool, although, import of machines tools continued on a reduced scale. Throughout 1936 & 1940 the situation became increasing more precarious. In 1941 the government of India passed the machine tools control over whose main object was to make an inventory of machine tools that could be obtained in India & Regulate & improve production so as to meet the needs of the ordinance factories & other war industries. The machines tools control laid the foundation of machine tool industry in India.
1.5
INDUSTRY STRUCTURE
Machine tool industry in India comprises about 450 manufactures with 150 units
in the organized sector. Ten major companies of the industry contribute almost 70% of production of India. And over three quarters of total machines total production in the country comes out of ISO certified companies. Many machines tool manufacturers have also obtained CE marketing Certification, in keeping with the requirements of the European markets. The industry has an installed capacity of over Rs. 10000 million & employees a workforce totaling 65,000 skilled and unskilled. Bangalore is considered as hub for the Indian machine industry. The city for instance house HMT Machines Tools LTD, a company that manufactures nearly 32% of the total industry's output. Machines tool industry in India is scattered all over the country. The hub of manufacturing activities however is concentrated in places like Bangalore, Jalandhar & Ludhiana in Punjab.
Company profile
HMT machine tool ltd (HMT - MBX) is a multi - unit, multi - location, multi technology Company manufacturing a wide variety of 'STATE - OF-THE-ART machine tools. HMT machine tools ltd has its location at 5 location, with each unit specialized in a 'particular family of machines. The sales and services network is spread across the length and breadth of the country. All the manufacturing units of HMT machine tools are ISO 9001 certified. HMT factory which is located in Bangalore it covers area of 103 acres, colony area 278 acres, Industry area 22 acres. Totally it occupies 403 acres. HMT is giving benefits other salary to their employees like, medical benefits, canteen facility, conveyance allowance, education facility etc.
Hindustan machine tools are a public limited company started in 1955 & first output is given in 1955. HMT ltd was incorporated as HMT LTD on 07/03/1953(has branched into 16 factories, 24 divisions and 29,000 employees in 10 different states. Jawaharlal Nehru inaugurated HMT & remarked it, as "HMT is gift to country & jewel of country"
2.4 OBJECTIVES:
To build mother machines. To produce needs of country like agriculture, transportation & defence.
To encourage the modernization of Indian industry through supply of engineering goods and services of world class excellence. To maintain technological leadership through continuous efforts to update production technology & manufacturing methods. To globalize operations by developing a mix of international markets and business. To ensure a satisfactory return on capital employed to meet growth needs & aspirations of our stakeholders, to present an active, pleasant & productive working environment.
To improve & sustain quality of work life for employees of country. To develop & retain human skills & talents necessary for corporate growth & performance excellence in all functions.
To achieve sustainable competitive advantage through value edge and technological leadership in products & services of company.
products has incorporated "HMT MACHINE TOOLS LIMITED" as its fully owned subsidiary on 9th august 1999. "HMT MACHINE TOOLS LIMITED" (HMT-MTL) is a> multi unit, multi location, Multi technology Company manufacturing units at five locations with each unit specialized in a particular family of machines. The sales & services network is spread across the length and breadth of the country. As leading manufacturer of machine tools in India HMT-MTL provides the best of products in terms of technology, productivity and cost effectiveness Comprehensiveness customer support services including application engineering, customer and after sales services. All the manufacture units of HMT-MTL are ISO 9001 certified.
2.6 CORPORATE VISION To be leading Global Engineering CONGLOMERATE focused on CUSTOMER DELIGHT in our fields of endeavour.
2.7 CORPORATE MISSION To established as one of the world's premier company in the engineering field having strong international competitiveness. To achieve market leadership in India through ensuring country satisfaction for supplying internationally competitive products & services.
HMT Office
Corporate Office; Bellary Road-Bangalore, Karnataka.
Regional office: Hyderabad, Jammu, Bangalore. Manufacturing Unit; Bangalore. Kalamssary, Ajmer, Pinjur, Hyderabad.
ORGANIZATIONAL STRUCTURE
Today, HMT comprises six subsidiaries under the ambit of a Holding Company, which also manages the Tractors Business directly. In India HMT is built on a strong foundation of technical know how acquired from world leaders in machine tools such as OERLIKON, GILDMEISTER, LIEBHERR, FRITZWERNER, PEGARD & SIEMENS. HMT'S broad range of machine tools covers General Purpose Machines, Special Purpose Machines CNC Machines to meet the application needs of every engineering industry. HMT'S units have ISO 9001 certification confirms to national standards for quality. HMT is the backbone of Indian engineering industry supplying varieties of machine to suit the needs of various industries. By acquiring state of art technology from time to time, HMT started manufacturing watches, Tractors, Die casting, plastic moldings and Food processing machinery. The new addition to HMT is HMT INTERNATIONAL, which is providing services across the globe.
2.11
CUSTOMER SERVICE
Wide marketing network manned by qualified & trained sales & service engineers
Service outlet at customer doorsteps in major industrial locations. Critical spare parts available at Field Offices.
training for machine tools. Manufacturing Units supplement customer support for tooled-up and high technology machine tools. Customer Component manufacture to suit customers' needs.
2.12 INFRASTRUCTURE
CNC Machines for Metal Cutting & Metal Forming. CNC Coordinate Measuring Machines.
Heat Treatment Facilities. Precision Measuring & Inspection Facilities. Facilities for calibration of Measuring & Testing equipments.
following products and provides various services: Machine tools. Watches. Tractors. Printing Machinery. Pressures die casting and Plastic injection molding machine. Precision Ball Screw. Dairy Machinery Reconditioning Services.
PRODUCT PROFILE
Lathe machine (turning machines) Drilling and boring machines Shaping machines Grinding machines Radial drilling machines
Heavy duty lathes Gear cutting machines Multi spindle and single automatic lathes.
CNC turning center. CNC slant bed turning center. CNC turn mill center. CNC twin spindle chucker. CNC vertical drilling and boring machine. CNC special purpose machine. CNC cylindrical grinding machine. CNC internal face grinding machine. CNC gear hobbling machine.
The above mentioned machines tools are manufactured in two or three different sizes according to the need of customers.
3.2 Watches
The first watch factory was setup in Bangalore in early 1960's. HMT then produced barely 15000 watches, but now the watch production around 7 millions with 2 factories in Bangalore, one each in Srinagar, Tumkur and Ranibagh. The watch range models include hand wound mechanical watches to top - lien quartz and analog and digital watches. HMT has so far sold over 75 million. The following are the various models manufactured by H.M.T Ladies watches. Gents watches. Hand wound and automatic watches. Pocket watches. Quartz watches. Analog alarm watches. Digital alarm watches. Electro luminescent watche
3.3Tractors
The agricultural sector in India felt the need for modern farming method. This promoted HMT to start the manufacture of tractors at Pinjore. As with other major diversification of HMT, bulk of the equipment for the manufacture of tractors was produced by HMT itself - a natural result considering HMT'S excellent capabilities in machine tools manufacturing. Reputed as one of the top tractor manufacturer in India, HMT has a sustained high production level and market acceptance. It is alone of the brand leaders in the country today. HMT manufactures of 25, 35, 45, 59, 57 HP capacities.
3.8 Reconditioning
HMT'S reconditioning expertise offers a comprehend sieve package for reconditioning of old and run down machines providing new lease of life to old machines about to be scraped. HMT'S superiors technical know how and immense reservoir of machine tool manufacturing engineering and maintaining experience make a HMT'S reconditioning absolute and total.
FUNCTIONAL DEPARTMENTS
Scope
The recruitment of professional trainees in engineering and other professional areas like finance, marketing, personnel etc.,induction level of executives that is PS 3 for centrally pooled requirement of units. Recruitment of senior executive at level of corporate cadre like PS 7 as per need of unit.
TITLE OF THE STUDY: "A study on human resource development and recruitment procedure" at HMT MBX, Bangalore
ESTABLISH MENT
INDUSTRIAL RELATION
WELFARE
Mr. Chmnpakarnm Mr. Smlhakar. B Mr. Hegde, Mrs. Ranjini Mr. Raviiulra Mr. Babii.Mr. Reddy
Establishment Section
Establishment section of HMT MBX involved with the activities like recruitment, selection, promotion, and performance appraisal record of day-to-day activities as well as manpower adjustments. The selection is basically involved with establishment activities
Not less than 50% of vacancies projected and approved in manpower operational Campus recruitment for post of executives in PS 3 for engineering graduate or post
graduate in technical areas or postgraduate diploma holder from recognized institution only. 5.
6.
Mode of selection by group discussion and personal interview by above committee. All India advertisement will be released every year, inviting application from
candidates' possess degree in engineering with minimum marks of 60% who will be eligible for written test.
7.
The result of written test candidate in the ratio 1:6 will be called for interview and Selected candidate will undergo induction training for period of a year. For selection of senior executive at level of corporate cadre will be taken up by
group discussion. 8.
9.
corporate personal directorate once in 4 months in April August and December in calendar year. 10.Recruitment was done for last time in 1992 & now days HMT is planning to recruit fresh blood.
Induction Policy
After selection of qualified candidate they undergo management trainee induction program for a period of one year. In one year 3 months are at MDI and remaining months at respective units. Purpose of induction program is to acclimatize them into company's working system and culture.
First month- Classroom training to give brief knowledge of the Company. Second month- in plant training at HMT to understand shop floor situations. Third month- rotation through R&D, CSB, HMB, CMC, SWCD and head office of different groups.
Fourth-sixth month- Rotation between sections of units. Seventh- twelve month- on job training in particular section. The unit chief
decides on which section the trainee has to be placed. During nine months trainee has a mentor to guide him and after completion of training period he will be given a functional designation and placed on probation period for a year. After this stage trainee will be confirmed on his job.
department Training shall be planned, implemented & reviewed There shall also be general orientation awareness & knowledge based training program including induction program to the trainees in a new areas & freshly recruited personnel. Training program for personnel working areas of special purpose Selection of trainees:
Head of all function shall identify training needs &inform to HRD along with the list of their department, such nominated employees will be informed to attend the training program.
Selection of training institute HMT is in touch with some of the leading training institutions & this institution will be asked to conduct the training program at suitable data. Types of Training Provided by HMT (MBX) Apprenticeship training: Training is for period of 3years. Those who apply for apprentice should have passed S.S.L.C on the date of report. The report says that there are 91 trainees are paid a stipend of 8207- to 10907-.
Graduate training:
Training is given for graduates such as B.A, B.COM, and B.E in mechanical & others. The period of graduate s training is for a year and they get a stipend of 19707- PM.
Sandwich training:
Diploma students are eligible for taking sandwich training. It is for one year. Students are from various colleges. They are given 3 months basic training & they have their classes. After completing basic training they will be send to different department for 15days or 1 month and they get stipend of 11407-
J ob knowledge
2. Managerial ability factor Planning & organization Problem analysis & decision making Interpersonal skills Self motivation Commitment Responsiveness to change/ innovation Developing subordinates Management of human resources
Positive discipline Performance Appraisal Rating TOTAL SCORE 201 & ABOVE 151-200 121-15O BELOW 120 APPRAISAL RATING
To develop workforce with multi skill employees who match the future needs of organization.
Transfer is a normally part of exposure and growth in any multiunit company. All employees of HMT are liable for transfer from one place to another. The objective is to fulfill the company need for a total executive in a multiunit, multiproduct. Welfare Department It plays a vital role in HMT. HMT being a PSU will have to raise their standards with respect to safety health and welfare of its employees, the welfare activities of HMT can broadly classified as follows.
I. Welfare measures inside the workplace. II. Welfare measures outside the workplace 1. Welfare Measure Inside The Work Place Working conditions:
Cleanliness, neighborhood, safety. House keeping, maintaining of lawns, passages and doors. Providing safety equipments such as helmets, goggles and first-aid equipments. Safety training programs for supervisors and workers to avoid accident. All machineries are examined periodically to ensure their safe
working. Six safety committees constitute to discuss safety related problem and to take corrective measures for prevention of accidents. Employees are provided with uniforms every year. Company is incurring around 14-15 lakhs p.a for this purpose. B. HMT provides number of amenities to its employees in addition to meeting the statutory obligations under various labor organizations: Canteen- Canteen is managed by welfare department; it is incurring 96 lakhs p.a to provide hygienic food to its employees. Transport- Company has a fleet of 65 buses besides Vans and Cars to provide transportation facilities to its employees. Township-A self-contained township with modern facilities has been provided for the benefit of employees. There are around 1676 houses of various types of allotment to employees and allotment is based on seniority and grade eligibility.
Medical-A 200-bed hospital with all modern facilities is established in the township to take care of medical needs of employees residing in township and surrounding areas.
However, if employees are not covered under ESI (Employees State Insurance Corporation) the company will provide medical facilities. As to say, if the salary is Rs. 10000 or less, the employees will get ESI benefits. And if the salary is above Rs. 10000 they will get company's medical facilities.
Medical benefits: Around 1.61% from employee's salary and 4.75% from company will be deducted and transferred to ESI.
Leave: 90 days medical leave per year is provided to each employee. Maternity leave: 84 days leave (6 weeks before delivery and 6 weeks after (Delivery) will be provided to women employees.
Wealth: Benefits like PF, ESI, and Wealth Relief Found will be provided to each employee, 12% will be deducted from employer and employee's salary, 8.33% towards PF, 3.66% towards Pension.
Compensation for Employment (Injury not covered under the Workmen's compensation act) In view of amendment to workmen's compensation Act, by amendment act of 22 of 1984 which regulates compensation for employment injury in respect of employees not covered under ESI Act and workmen compensation Act is here by withdrawn with immediate effect consequently, the provision of amended workmen's Act are made applicable to employees who are now not covered under ESI Act & workmen's compensation Act.
PUNISHMENT:
Normally when employee is proven to be guilty for his/her job, punishment will be given. Employees/Management will also be given chance to submit their evidence before the officer to prove their statement. The officer may be external or internal person. Neither pay nor work till termination/dismissal.
EMPOWERMENT:
It is giving full authority to perform a specific task to the employee or group of employees. Normally it is not practiced in HMT.
RETRENCHMENT:
It is permanent removal of employee from the organization when there is no production or any economical instability. It is not practiced in HMT as it is a public sector and it is considered as a social obligation.
LEGAL ASPECTS:
It comes into picture when any dispute occurs within employees. Then it is carried to labor commission court or consultation officers for negotiation or may be directed to civil court. If they are not satisfied they can file grievance to tribunal office.
Industrial Relation
In HMT (MBX), Industrial relations deal with either the relationship between the state and employers and workers in an organizational themselves. This helps to resolve from any kind of disputes like: misunderstanding, difference of opinions, (or) conflict that arises between an employer and his workmen. Therefore a high level of understanding and positive relationship between them, can alone lead to the achievement of organizations objectives. Hence industrial relation plays an important role.
Methods of Planning
Planning of material; Under this the planning department plans about the relative materials, which are required to be used in production. It also checks the availability of equipments. Planning of process; Under this the planning department plans the
sequence of operations to be performed for production in time very easily and in a structured pattern to be followed for smooth flow of operations without excess consumption. Planning of tools: In this process the planning department takes the decisions regarding the tools, which will be used for production, and tools will also be produced internally.
Planning of machineries: This is the process of planning where they plan about the type of machines required and optimum allocation of machines for the smooth flow of operations, without any interruption. Estimation To set performance target Machines loading and scheduling To set up standards and to study machine utilization and labor performance
Provides information in helping the management in techniques like value engineering and programmed evaluation review technique.
Estimation of time:
A)
It represents the time, which incurred to produce a product. This is done by the workstudy etc. By this planning department can know the amount of time required for the production of a particular component. B) Estimation of cost:
It consists of direct material cost, direct labor cost, expenses of overhead, and overhead as per the percentage of prime cost or production cost. In addition to the above cost elements, the product cost includes the cost of the following special items: i.e. development cost, engineering cost, special tool cost, pattern cost etc.
Various Departments under Planning: Design department. Engineering department. Process production department. Inspection. Assembly line. Trials and testing. Delivery to customer
Functions of Finance Departments: The various functions on Finance departments are: Planning of funds. Acquisition of funds. Allocation of funds. Investment of funds. Dividend decision. Recording of the transaction. Preparing of financial statements. Evaluation of financial performance.
Evaluation of Financial Performance: The financial performance evaluated by comparing budgeted statement and actual statement by using comparative BS, ratio analysis. Various Sections under Finance department:
INWARD BILL SECTION (IBS) OUTWARD BILL SECTION (DBS) WAGE SECTION .
The materials purchased are classified into various groups: Group 1 - Stores and Spares. Group 2 - Purchase of raw materials. Group 3 - Capital items. Group 4 - Export machinery. Group 5 - Foreign purchases. Group 6 - Miscellaneous expenditure/payment towards freight. Group 7 - Electrical parts.
Wages Section: Wage section is the section, which deals with the employee's benefits and other activities with regard to company services towards the employees. It is the section, which helps to keep a better relation between union and management. It deals with any grade and handles the task of basic pay, DA, HRA etc. There, ace three punching times: a. In punch. b. Lunch punch.
This section deals mainly with the attendance record, salary payments and incentives payments. There are two types of incentives and they are:
Direct areas incentives for workers grade Indirect areas incentives for officers grade Salary includes basic wages, DA, retaining allowances and cash value of food
concession, admissible if any. The salary is considered on the basis of past service, pension able service, widow pension and withdrawals benefit, as written in constitution.
CASH SECTION:
Cash section is one of the important sections in finance department. This department handles all cash dealings. It generates funds for the company and utilizing the funds through proper investment.
Cash section deals with:
Payment made by cash and cheque. Receipts and payments of cash. The activities through UCO bank, local UCO branch, Punjab national bank. Preparation of petty cash book.
Cash dealings:
1. 2.
To ensure continuous search for alternate source supply. To act as information center for material. To ensure investment made on inventory is at optimum level.
Purchasing procedure:
Following is the procedure involved in the purchase of materials: 1. Indent.
2. Material purchase requisite. 3. Circulation of enquiries. 3. 4. Repairs of offers. Comparative statement.
7. 8. 9.
10. Placement of order. 11. Confirmation of order. 12. 13. 14. 15. Follow up. Receipt at stores. Preparation of material inward slip. Inward inspection.
D.G.M
A.G.M
MANAGER
DEPUTY MANAGER FOREMAN SUPERVISORS JUNIOR SUPERVISORS WORK GRADE EMPLOYEES HTC Division: HTC division means High Technical Center. As most of operations were done through computer numerically controlled machines, so it is very well known as the high technical center. There are 50 employees working under this division. This division consists of two types of machines, i.e. 1. 2. Vertical machine Horizontal machine
Vertical machines function vertically, i.e. all kinds of drilling, milling, shaping, etc is done through in vertical direction. In HMT there are 3 vertical machining centers are available in HMT division. These vertical machining centers are produced by HMT for in house manufacturing. Horizontal machines are the machines, which are doing the operation horizontally. There are 8 vertical machining centers are available in HMT. There is one imported horizontal machine also available, which is imported from England and known as
KTM machines.
TOOLROOM:
Tool room is a store house of all kind of tools, which are used during the milling, grinding, spinning, turning etc, during production. The tools are normally fitted to the machines so that it can be able to give a required shape and size to product.
ROUND DIVISION:
Rounds are the section where the machining of components with round shape is being done. It may be of 10 to 700 die meters. There are 35 employees working under rounds division. Basically this section produces the round shaped components.
NON-ROUND DIVISION:
Non-Round Division is just the opposite of the round division as round division involved in production of round shape products, as same like that non- rounds division involved in production of round shape products. There are 16 employees working under the non-round division.
GEAR DIVISION:
/
Gear division produces the components, which were used for house production of 31 machines working together, and to handle all these types of function there are 22 employees working.
DIE CASTING DIVISION:
HMT'S Die casting machines carters to wide range of applications. From simple components to high precision industrial components, these machines take care of most dye casting needs. HMT offers a range of nine models with locking forces ranging from 80 to 1100 tones to cover a wide range of pressure dye casting of aluminum and zinc components built to high standards, these machines are subject to stringent performance testing using advanced testing devices to ensure productivity and reliability,
SPINDLE DIVISION:
Spindle division involved with the production of different types of spindles. In this division there are 19 workmen and 4 staffs were heading this unit. There are different kind of machineries involved such as, turning, milling mills, keyway milling, thread milling, drilling, cylindrical grinding, internal grinding, spine grinding, centre grinding, CNC turning etc.
ASSEMBLY DIVISION:
Assembly selection involved with the assembly of different parts and components, so that it can build a complete machine. In this section the machine tool parts were being assembled together to give a complete shape to product or machine. In this division there are almost 100 employees working.
HMT's Ball screw division is. the first to indigenize production of precision ball screws. This unit was started on 1989 with collaboration with Zeiss, Germany. Ball screws are used in machine tools to convert rotary motion to linear motion and vice versa. Ball screw is a machine tool component for translating rotary motion to linear movement used for present day CMC machine tools.
FACTORS FOR SELECTION:
> > > > > > > > > > >
Degree of accuracy required Services load conditions Desired service life Stiffness Permissible clearance or desired preload Critical speed Bucking load Machine tools Industrial robots Nuclear application and weapon system Transport and space system To produce above components there are different kinds of machine are
APPLICATIONS:
available which are used in this division are keyway milling, gear cutting, radial drilling, CMC thread milling, straightening machine, internal grinding, surface grinding, vertical drilling, heat treatment machines, cylindrical grinding machines, thread grinding machine, CMC milling machine etc.
FOUNDRY:
Foundry is the place where they put the raw materials or scrap into the Furnace and according to the frame size to produce the components. There may be of big or small size. These components are normally of heavy parts. There will be 1400 degree Celsius, it is the largest foundry in south Asia and it has the capacity to molt 5.5 tons, and silicon sand brought from the Godavari river basin from AP. Cooling period 36 hours in 20 degree Celsius. The wage grade people are working in this division. In foundry the first procedure is to make the frame of a product by which they can produce the required component. After the production of the component they cut it on to different sizes and then send it to the shop floor for further operation INSPECTION: Inspection is one of the important activities, which is done at the time of production of a particular component and at the final production of a machine. The inspection is done after each and every process of a product, so that no error can arise in later period.
Things used for inspection purpose: Micrometer Micromat Extension depth gauge Verinier Pitch micrometer
Tessa
Bevel protractor Plug gauges Vermoer caliper Dial test indicator
MAINTENANCE DEPARTMENT:
Maintenance section is very important as for as plant is concerned. The maintenance is varied from machines to machines because all machines have different features and different functional qualities. Process of maintenance: Putting the machine into operation Refreshing the axis Manual operations
Job operations
Traverse in increments Traversing to machine home position Maintenance of CMC is done by considering all the factors such as general, voltage stabilizers, CMC systems, switches, electrical cabinet, drives, AC servo motors, F/B devices etc. These services are done every quarterly, monthly or yearly. The preventive maintenance may be of daily, 200 hours, 500 hours, 1000 hours, 2000 hours, 4000 hours, 800 hours it is also done for electrical also. Safety precautions are on general and housekeeping, operation and services and maintenance.
Manager (1)
Supervisor (2)
Clerk
Engineering/Sales Execution Sections shall be responsible in their respective areas. Heads of Sales shall be responsible for the overall activities. Each individual
employee shall be responsible with the scope of resources available to him to/ implement and maintain Quality Systems and Quality Policy requirements. During the absence of Head of Sales, the Unit Chief decides as to who shall be in-- charge of these functions.
Sales Engineering:
Sales engineering prepares the Annual operation plan (AOP) for Sales based on the Marketing Forecast/ Past Trend. Sales Engineering plans and controls the activities such as submission of offer to customer and converts them into orders.
Sales Execution:
Sales Execution activities start with receipt of order. On receipts of order, they coordinate to build Machines / Procure /Manufacture and ensure delivery of the machine to customer. It has direct interaction with Design in case of special machine to customer.
The Purchase Order on receipt will be scrutinized with respect to offer, checklist and price list for General Purpose Machines. For any deviation / discrepancies noticed, it is taken up with marketing / customer and resolved mutually. The allotment order will be issued to the Head of concerned Assembly (Mechanical & Electrical), Inspection, Material Engineering, planning and progress. For Tooled up machines / Special purpose machines, the applicable machine layout, tool layout, Fixture layout, etc. shall be sent for customer approval / reference as per contract. The approved layouts shall be available in designs. After the contract is technically / commercially clear, Order Acceptance is released to customer.
5.2 Weakness:
Delay in implementing new systems.
Surplus manpower in some divisions. It is facing financial crisis and has been incurring losses since 1993. No internal control. Management is not given more powers to take timely decision. Wide range of machines in the organization has left to non-concentration. Wide gap in communication. The employees do not know the annual target of HMT. Immediate planning and execution is not carried out.
5.3 Opportunities:
Bulk requirement of machine tools like speed/automated presses, forging likes etc for defence production. Modernization of railways and plants. Renovation and upgrading of Machine tools. Increased export requirement for HMT's range of metal firming tools in countries like Africa and high technology machines by advanced countries like USA. HMT can deliver its products very faster to the customer by speeding up the production process. Boom In the infrastructure to benefit HMT entry into earth moving machines or higher HP tractors.
5.4 Threats:
The company has to face severe competition from both international as well as domestic market. Competitors offering high technology machines through collaboration up gradation of existing products and resorting of flexible prices. *:* HMT is lagging behind in current trend technology as compared to MNC players. Increasing competition with entry of new manufacturing countries China the prominence of Taiwan and republic of Korea.
Rise of 'Regional' distributors selling on 'Stock and Sale' basis, on behalf of foreign Manufacturers.
CHAPTER 6
FINDINGS AND SUGGESTIONS OF THE ORGANISATION FINDINGS:
The growing competition and technological developments in this sector are having inevitable effects on the Indian machine tool industry as a whole. The HMT machine tool limited is facing typical problems in the emerging globalization scenario as under: POSITIVE ASPECTS 1. 2. Manufacturers sell different designs of machine -variety is too large. HMT machine tool has a regular system for determining unserviceable or
damaged stores, raw materials and finished goods. 3. Materials are classified as 'A', 'B' and 'c' class items. The units have maintained proper records showing full particulars including quantitative details ailed situations affixed as sets. 5. The unit has maintained up to date records and submitted to respective authorities. 6. Inventory has been physically verified during 1 he year by the management. 7. Majority of respondents perceived HMT as a global player and market leader In developing countries. 8. The major kind of agent used by the company is training and orientation program 9. Exports are high.
NEGATIVE ASPECTS
1. The company has not been utilizing whole installed and licensed capacity of its machines effectively which has in turned resulted in low production. 2. Interruption of trade union is more in the work of management. 3. Lack of utilization of infrastructure. 4. The technology is not advanced. This is one of the reasons for low productivity. Thus production process is costly and time consuming and overhead costs are high. 5. Government is not industrializing at fast pace. 6. Absence of center of excellence for Research and Development. 7. Idle time is more; there is no proper time management in HMT. 8. Motivation of employees is less. 9. Less concentration on domestic market. 10. Lack of training including the concept of 58. 11. No recruitment and selection in corporate office. 12. After 1993, salaries are not revised.