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1. INDUSTY PROFILE
1.1 ORIGIN, GROWTH AND DEVELOPMENT OF THE INDUSTRY
Since the product of BHEL-EPD is the porcelain insulator, it is necessary to see the origin of the porcelain and then the origin of the ceramic insulators and non ceramic insulators. The ceramic or porcelain insulators were introduced in 1830s. Porcelain saw very minimal use for either telephone or telegraph after the development of thread less glass insulators. Glass tended to be cheaper than quality porcelain, and was deemed as it was thought that clear glass would discourage insects from building nests under the insulators reducing their effectiveness. This all would change with the proliferation of electricity.
1.1.1 Development of ceramic insulators:
Today, after more than 100 years of electric power transmission, wet process porcelain insulators are still the most widely used form of electrical insulation. Their development stems from the pin-type insulators that were in use on communication lines. In the first designs for power transmission, the commissioning of the communication pin-type insulators was increased to prevent electrical puncture and the diameter of the shed was made larger for increased leakage distance.
1.1.2 Development of Non ceramic insulators:
In the late 1950s, the development of line insulators with reduced weight and improved electrical and mechanical characteristics, relative to conventional ceramic string insulators, was considered a prerequisite to 1000kV transmission line. Although interest in 1000kV transmission gradually faded, interest in the light weight insulator continued so much so that the first non ceramic insulator was introduced by General Electric in 1959. However, that early Gepol insulator, despite its promise, experienced severe tracking and erosion failures that were related to the epoxy sheds.
The few types of insulators that are being manufactured in India are:
Disc Insulators: Disc insulators are mainly used for transmission and distribution. These insulators used in the form of string by connecting (coupling) number of insulators one into another. The strings can either be in vertical position The number of (suspension string) or in horizontal position (tension string).
insulators to be used for various strings depends upon the kV rating of the system. Pin Insulators: Pin insulators are used for over head power lines insulation (transmission and distribution lines) from 1.1kV to 33kV. Pin insulators are of rigid type and mounted on the cross arm of the pole. The conductor is rigidly fixed on to neck (or to the top grove) of the insulator by means of tie wire. The insulator are first fitted with rigid pins by means of thread and then mounted on to the cross arm. The thread dimensions of pin insulator are internationally standardized for the purpose of interchangeability. inside the porcelain part. Post Insulators: Post insulators are of rigid type and used in supporting bus bars, isolator assemblies and other energized equipments in a substation. Hollow Insulators: Hollow insulators are used in apparatus. Whenever an Pin insulator of 1.1kV range employ porcelain threads and 11kV to 33kV pin insulator employ zinc thimbles which are assembled
energized conductor has to enter through a wall of a transformer tank, a bushing housed in a hollow porcelain sleeve is used. Whenever a coupling capacitor on the winding of a potential transformer or a current transformer is to be housed in a weather casing, a hollow porcelain sleeve is used. Whenever an insulated oil tan of a circuit breaker is to be covered a hollow porcelain sleeve used. Solid Core Insulator: Solid core insulators are of various types-Stay arm
insulators, bracket insulators, 9-tonne insulator, Post (pedestal) insulators, Sectioning insulators, Operating insulators, Pantomounting insulators, Roof line insulators-solid core insulators for railways. 3
2. COMPANY PROFILE
2.1 Origin of the Organization:
BHEL came into existence in November 1964. At first, a plant was setup at Bhopal and that was the genius of heavy electrical equipment in India. BHEL is today the largest engineering and manufacturing enterprise of its kind in India with a record of accomplishment performance. Right from 1971-72 this organization is making profit. In BHEL 67.72% of shares is held by the Government of India and 32-28% is held by financial institutions, foreign institutional investors and employee. BHEL is paying dividend since 1976-77. Heavy Electrical (India) Ltd was setup in Bhopal in August 1956 with a view to reach self-sufficiency in industrial products and power equipment vital for the industrialization of the country. To meet the total demand of heavy electrical equipment, BHEL came into being in November 1964.
BHARAT HEAVY ELECTRICALS LIMITED (BHEL) is the largest engineering and manufacturing in the field of heavy electrical in India and one of the leading power plant equipment manufactures in the world. BHEL has presence in core sector like power, industry, transportation, oil and gas, telecommunications, defense and nonconventional energy sources from concept to commissioning. BHEL has 14 manufacturing plants and 150 project sites countrywide and abroad. Its products and systems have been exported to over 52 countries worldwide. Set up primarily to create self sufficiency in the field of power generation, the first plant of what is today known as BHEL was established in 1956 at Bhopal and was genesis of the heavy electrical equipment industry in India with a well recognized track record of performance, making profit continuously since 1971-72.
It achieved a sales target of Rs. 6,471 corers with a profit of Rs.1, 022 corers in 199798. BHEL an ISO 9001-2000 accreditation is now embarking upon Total Quality Management for its operation.
BHEL has continuously paid dividends to the government. BHEL also received Excellent rating for 9 years consecutively. Government of India and has conferred the 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, free medical camps, providing employment facilities for widows, handicapped persons etc.
2.3 The company is accredited with following internationally acclaimed standards: 2.3.1 Quality Policy of BHEL
In its quest to be World-class, BHEL pursues Continual Improvement in the Quality of its Products, Services and Performance leading to Total Customer Satisfaction and Business Growth through dedication, commitment and team work of all employees.
2.3.2 Environment Policy
In its endeavor to adopt and implement the environment policy enunciated as follows, To strive to be and environmental friendly company in its Activities, Products and services through: Compliance with applicable Environmental Legislation\Regulation Continual improvement in Environmental Management Systems to protect our natural environmental and control pollution.
BHEL is committed to provide safe and healthy working environment to all employees as an integral part of business performance through: Setting objectives and targets to eliminate/ control/ minimize risks due to occupational and safety hazards Appropriate structural training of employees on occupational health and safety aspects Periodic review of occupational and safety hazards management system to ensure its continuing suitability, adequacy and effectiveness Communication of occupational and safety hazards policy to all employees and interested parties. Compliance to applicable Legislation and Regulations
HPEP, BHOPAL: Hydro set, Nuclear Turbines, Thermal sets (110 MW). Marine Turbines (12 MW), AC Motors and Irate electric motors, Power transformers (above 220 kV), Traction machines and controls for traction and Industrial appliances, Diesel generating sets, Switch gear, Capacitors, Industrial turbines. TP, Jhansi: power transformers (less then 220 kV), freight low transformers, ESP Transformers, AC Locos, Diesel Electric shutters, etc.
HPEP, HYDERABAD: Thermal set (above 200 up to 500 MW), gas nuclear Generators (235 MW), Hydro sets, industrial machines, control panels, light trainer aircraft, gas turbines, defense equipment. CEEP, HARDWAR: Casting and forging for thermal/hydro sets, motors, defense, etc. Special facilities like 900 t press forging, electric arc furnaces for melting steel etc. HPBP, TRICHY: Utility and industrial boilers, valves, nuclear steam generators, well SSTP, TRICHY: Seamless steel tubes. EDN, BANGALORE: Variable speed devices, programmable logic and digital Controller, power devices, meters, photo voltaic / solar panels, EPABX, HVDC systems, process simulators etc. EPD, BANGALORE: Disc, Slid core, Bushing, Pin and Post Insulators, Ceramics liners, Wear resistant ceramic and Honey comb. IP, JAGDISHPUR: Disc Insulators, Ceramics Liners. JVC, GOINDWAL: Industrial valves. CEP, RUDRAPUR: Wind mills, solar water heaters and Solid lanterns. ESD, BANGALORE: Telecom products and simulators.
2.5 CUSTOMER PROFILE 2.5.1 for Disc Insulators Karnataka Power Transmission Corporation Tamilnadu State Electricity Board Maharashtra State Electricity Board Punjab State Electricity Board Andhra Pradesh State Electricity Board Rajasthan State Electricity Board Uttar Pradesh State Electricity Board Kerala State Electricity Board Meghalaya State Electricity Board
Delhi Electricity Board Domodar Valley Corporation Bhakara management independent power production.
2.5.2 for Solid Core Insulators Indian railways and Countries like: Sri Lanka, Nepal, Japan, Bhutan, Australia, New Zealand, Malaysia, Thailand, Turkey, Iran etc. 2.5.3 For Hollow Insulators ABB, Siemens, Sister units, Switch gear manufactures and Electrical equipment manufactures 2.6 Ownership Pattern:
Equity is held by the Government of India and 32.28% is held by financial institutions and employees of Bharat Heavy Electricals Ltd., Today Bharat Heavy Electricals Ltd., Manufactures 180 varieties of products under 30 major production groups. It has built an enviable reputation for high quality and reliability of its equipment.
BHEL (EPD) which is one among the Navarathnas is best owed with so much of awards and achievements since from inception. There are various awards which the company was nominated not only with in the country but also from foreign nations which will add feathers to it name & fame.
The following are the awards which are mentioned below as follows:
programmes.
Management
and
the
workers
in
accident
prevention
National Safety Award-1990 National Safety Award-1991 National Safety Award-1993 National Safety Award-1994 National Safety Award-1995 National Safety Award-1996 National Safety Award-1997
National Safety Award-1998 National Safety Award-1999 National Safety Award-2000 National Safety Award-2004
2.8 Vision:
Solutions through Quality Products, Systems and Services in the fields of Energy, Industry, Transportation, Infrastructure and other Potential areas.
2.10 Values:
Meeting commitments made to external and internal customers. Faster learning, creativity and speed of response Respect of dignity and potential of individuals Loyalty and pride in the company Team playing Zeal to excel with integrity and fairness in all matters
2.11.1 Business Mission: To maintain a leading position as suppliers of quality equipment, system and services in the field of conversion, transmission, utilization and conservation of energy for application in the areas of electric power, transportation, oil gas exploration and industries. Utilize companies capabilities and resources to expand business into allied areas and other priority sectors of the economy like defense, communication and electronics.
2.11.2 Growth: To ensure a steady growth in business so as to fulfill national expectations from BHEL and expand international operations.
2.11.3 Profitability: To provide a reasonable and adequate return on capital employed, primarily through improvements in operational efficiency, capacity utilization and productivity and generate adequate internal resources to finance the companys growth. 2.11.4 Customer Focus: To build a high level of customer confidence by providing increased value for his money through international standards of product quality, performance and superior customer services. 2.11.5 People Orientation: To enable each employee to achieve his potential, improve his capabilities, perceive his role and responsibilities and participate and contribute positively to the growth and success of the company, to invest on human resources continuously and to be available to their needs. 2.15.6 Technology: To achieve technological excellence in operation by development of indigenous technologies and efficient absorption and adaptation of imported technologies to suit business needs priorities, and provides a competitive advantage to the company.
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3. PRODUCT PROFILE
BHEL-EPD Indias leading manufacture of High Tension porcelain Insulators, a
class by themselves acknowledge by internationally reputed laboratories of CESI (Italy), KEMA (Holland), Dolton (UK), and IISc (Indian). BHEL disc insulators are known for their reliability more than 10 million insulators are in service in India and abroad.
3.1 Product range of BHEL-EPD includes:
High Tension porcelain Insulators for transmission and distribution lines from 11Kv to 800Kv with a wide range of 70kN to 300kN in standard, semi-fog, fog, anti-fog varieties.
Hollow Insulators for Power Transformers, Instrument transformers, Electrostatic Precipitators, Circuit Breakers of Conventional and Gas Insulated Types. Post Insulators for support for bus bars, switches and isolators from 11kv to 220kv. Wear-resistant High Alumina Ceramic Lining Material for power, steel, cement and mining industries, as well as a wide range of industrial ceramics. Catalytic converter for two and four wheeler vehicles.
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3.1.2 HOLLOW INSULATORS Application: In power transformers, instrument transformers electrostatic precipitators,
3.1.3 CAP AND PIN TYPE POST INSULATORS Application: As bus supports in substations for switches and isolators from 11 to 220kV.
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CANTILEVER STRENGTH from 920 kg for 11 Kv up to 400 kg for 220 Kv CREEPAGE DISTANCE from 330 mm for 11 Kv up to 6150 mm for 220 Kv APPLICATIONS AS BUS SUPPORTS IN SUB STATIONS FOR SWITCHES & ISOLATORS FROM 11 Kv to 220
3.1.4 DISC INSULATORS Application: Transmission lines for 11 KN to 800 kn. [AC&DC] and substation
RATINGS 70 KN to 300 KN e ms CREEPAGE DISTANCE 280MM TO 540 MM COUPLING DESIGNATION 16mm, 20mm, 24mm APPLICATION in TRANSMISSION LINE FROM 11 Kv to 800 Kv BOTHE A C AND D C
A hybrid insulator consists of a porcelain core fitted with weather resistant polymeric shed. This design offers better performance under pollution is light in weight can withstand flames/ arcs offers resistance to chemicals and UV radiation and in vandal proof.
HYBRID INSULATOR CONSISTS OF A PORCELAIN CORE FITTED WITH WEATHER RESISTANT POLYMERIC SHEDS. THE DESIGN OFFERS BETTER PERFORMANCE UNDER POLLUTION. LIGHT IN WEIGHT
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5. ORGANISATIONAL STRUCTURE
In BHEL-EPD activities are grouped into different functional units. Each major function of the enterprise is grouped into different department. This can also be studied as a separate function. Departmentation based on functions is a simple form of organizing the activities. Specialization of department promotes the excellence in performance. It leads to improve planning and control of key functions and ensure economy.
The various departments in BHEL-EPD are:Production Finance Human resource & Human resource Development Center Communication and Public relations Marketing Commercial
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Information Technology Management Services Material Management Quality Safety/HSE Engineering Security and Vigilance Works Engineering/ project /IE
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INSULATOR OPERATIONS
MATERIAL MANAGEMENT
PROJECT & CATELYTIC CATELYTIC CONVERTER HRM COMMN. & PUBLIC RELATION FINANCE DEPT
KILN & SOLID CORE INSULATOR CERAMIC LAB & DEVELOPMENT HOLLOW & SOLID CORE INSULATOR ASSEMBLY & TESTING
WEX
MS & EDP
QUALITY DEPT.
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6. PRODUCTION DEPARTMENT
Production department in any industry performs the functions of converting raw materials into finished products. The manufacturing of goods requires a predetermined plan so that available recourses of company are used to optimum level and more wastage is reduced to the greater extent. BHEL-EPD is today a leading manufacturer of high tension electro porcelain insulators with an experience of over 70 decades. EPDs product range includes disc insulators, post insulators, solid core insulators and hallow insulators in insulators category. Apart from these they manufacture ceralin tiles like curved plain tiles, curved weld on tiles, flat plain tiles, and flat weld on tiles.
6.1 MANUFACTURING PROCESS:
The raw materials required for manufacturing the insulators are: Quartz, Feldspar,
Bangepur Clay, Bikaneer Clay, Than Clay, Ellur Clay, Neyveli Clay, Ball Clay, Chaybasa Clay, Japan ball Clay, Kundra Clay, Festite and China Clay. The production in the BHEL runs 365 days, and it is a continuous process. Here raw
materials are tested before manufacturing the insulators so that raw materials obtained from places satisfies their requirements.
6.1.1 Crushing Plant:
Above said materials other than clay are available in the stone
form.Crushing plant is used to crush these raw materials into powder form and also it is used to powder the rejected ones for recycling.
6.1.2 Weightment: The raw materials are required to be mixed in different composition.
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6.1.3 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 a duration of 20 to 24 hours. Its a continuous process round the clock. The materials obtained in the ball milling process are called Slip or the Ceramic Slurry. 6.1.4 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 are stored, wooden pieces through electromagnetic separation. This tank is called discharge tank. 6.1.5 Slip Agitating: After screening, the ceramic slurry is transferred to another Specially built bank 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 after 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. 6.1.6 Filter Pressing: It is dewatering process. In this process 80% of the water is removed from the slip so as to convert 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. (250N/m2 or Pascal) 6.1.7 Pugging: It is a de-airing operation under vacuum. The cakes are filled into pug mills to remove air bubbles present in the cakes. In the pug mill homogenous mixing of cakes taken place. The product which comes out after pugging process is called as blanks. Blanks are extruded from the pug mills in the Cylindrical form of different sizes for different type of insulators. In this process the moisture content is reduced to the 22%. 6.1.8 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. 6.1.9 Jiggering: This process is done only for disc insulators. Here the blanks are given a shape using an automatic jiggering machine. 6.1.10 Drying: The different drying steps are as follows
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6.1.10.1 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.
6.1.10.2 Blank Dryers: For hallow insulators and solid core insulators the blank produced by
pug mills are directly fed to these black 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%. 6.1.11 Turning: Turning is a process to make hallow insulators and solid core using turning machine. In turning machine there is wheel in which the rod gives the spiral shape to the blank. 6.1.12 Oil Inspection: After the disc insulators are dried from chain dryer, they go for finishing 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. 6.1.13 Tunnel Driers: The disc insulators after inspection and allow insulator and solid core 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. insulators
vertically and is made to rotate. When it rotates, the other part of the machine having a metal
6.1.14 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.
Advantages of Glazing are:
Good looking
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6.1.15 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.
6.1.16 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. 6.1.17 Testing: After firing the insulators goes for testing. The various types of tests are Hydraulic pressure test, Thermal test, Mallet test and Electrical test.
6.1.18 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.
6.1.19 Curing: After assembling, the insulator goes for curing operation. The
different kinds of curing are steam curing, hot water curing & air
curing.
6.1.20 Final Electrical Test: After curing, the insulators are set for final electrical
test. If insulators fail in this test, it burns out and thus they are rejected.
6.1.21 Packing: The insulators, which are successful in the tests, are sent for
packing section. The insulators are well packed in crates to avoid damages during transportation and ease smooth handling. Thus, the time taken for all this activities crushing to packing is 31days.
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For the production to take place smoothly and effectively the whole insulator operation
is divided into various sections. Each section is managed by one deputy manager & consists of senior executives, executives, engineers, supervisors, shift in charge, assistances, trainees & artisans. Since production is a very important activity in any organisation, the process of
production should be smooth. To manage this process there are several section in existence. They are:6.2.1 Ceramics Lab:
Laboratory is meant for quality checking and help in product development. The
monitoring of quality of newly arrived raw materials and the materials which are inproduction process is done in this lab. There is a predefined systematic procedure & also the work instruction to study the actual quality of the material.
It is a preproduction section. Before the actual production starts. The raw materials
have to undergo a certain specific process. Here in slip house the raw materials are obtained from the Material Management
Department. These raw materials are mixed into certain composition according to the customer need then these are fed to Ball Mills. The ceramic slurry got from the Ball Mills is fed to the vibrator screens to check for the correct accumulation throughout the material and also to remove the solid particles. Then the material will be having too less impurities and then goes for filter press to extract water by pressing that ceramic body with high pressure.
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Here the actual insulators production takes place. The insulators, which are
manufactured, are disc, post & pin, hollow and solid core insulators. The process of production 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. To carry out this process smoothly & systematically there are 90 employees for disc
insulator manufacturing. There are 2 Deputy General Manager, Senior Engineer, Engineer, Supervisors and Artisans. For the jiggering process there is an automatic jiggering machine, which can produce 200 insulators per hour. The capacity of the plant for disc insulators production is 1300 units per shifts.
Kilns are used for firing the insulators to increase the resistant capacity of the product. There are 3 types of kilns and their capacities are:
Oil Tunnel Kilns Shuttle Kilns Rectangular Kilns
For disc & post insulators tunnel kiln are used. For hollow insulators & solid core
insulators they use shuttle kilns and also the rectangular kilns. Oil tunnel kilns can fire 2500 units of disc insulators per day. The process that takes place in oil tunnel kilns is oxidation, reducing, neutralization & cooling. The temperature at which the insulators are fixed is 1250 to 1280 degree Celsius.
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There are several tests to be carried out to check for the quality of the product. These Hydraulic Pressure test: In this 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. 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. 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. 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 it fails in the test or it punctures and thus rejected.
tests include:
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 disc insulators are sent for dispatch after packing. To do all these works there are artisans separately for assembling & testing, above them is Senior Engineer & above them is Senior Manager.
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Filter Pressing Pug Mill Throwing & Jiggering Drying Oil Inspection
Tunnel Dryer Glazing & Sanding Kiln (Firing) Routine Test Assembling Final Test (Electrical) Packing & Dispatching
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7. SAFETY DEPARTMENT
Precaution from accidents and taking suitable precautionary measures is the main activity of this department; EPD has separate section called HSE section. It takes in to account all the precautionary measures.
7.1 Safety Policy: The following are the safety policies adopted by BHEL-EPD unit:
Compliance with applicable Legislation and Regulations. Continual improvement in the safety management systems performance. Enhancement of safety awareness amongst employees, customers and suppliers by proactive communication and training. Periodical review of safety management systems ensuring its continuity, suitability, adequacy and effectiveness. Communication of this policy to all employees and interested parties. Co-ordination with concerned government agencies/regulatory bodies engaged in safety activities.
7.2 Functions:
Accident preventions. To provide Personal Protective Equipments (PPEs), like safety shoes to protect from piercing metals, contact from acids, electric shock etc., welding shields, safety belts etc. to employees and crash helmets are provided to those employees and crash helmets are provided to those employees who are working in kilns section to protect from head injuries. Safety Education. This unit has board exhibiting details regarding the production processes and safety measures to be taken by each and every sections of the production department to enable the employees to function smoothly. 25
Material should be lifted with the leg muscles, keeping the back straight and knees bent. When handling long objects, hold front end high and the rear end low. Take the help of crane, hoist or other mechanical device when heavy material is to be handled. Check for potholes and unevenness in floors when using pallet carts & wheelbarrows. Do not over pile material such that it obstructs the visibility of the person handling. When using wheelbarrow load should be placed well forward, so as to make it easier to lift and push. Concentrate on the job you are handling.
Fire prevention and protection: Leakage of Oil should be stopped. Housekeeping & cleaning in the work area to be maintained. Electrical safety precautions should be implemented to prevent electric shock. Fencing / Guarding of rotating parts of the machineries to be ensured. Any other Safety Measures relevant to the Jobsite to be ensured. Job specific PPE & safety devices to be provided. Reverse horn to be provided for all vehicles used within the premises Close supervision should be provided from day one. Trained First Aiders with first aid station should be ensured. Contingency plan for all the catastrophes should be prepared. Emergency preparedness and response plan should be prepared and implemented. Job safety analysis to be prepared for critical activities. Flashers and red reflective tapes to be provided on Driven piles.
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To continually evolve new bench marks, resources, practices for ensuring effective
Attract, retain, develop, and remain effective and motivate human resource with
the required skills and competencies to meet organizational needs in tune with changing business profiles and technological requirements. Maintain good industrial relations with high level of employee for better
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developing and implementing new schemes for performance related pay, rewards and benefits in line with comparable organizations and employees aspiration.
continuous learning that enable the joint optimization of organizational goals and individual potential. Making the human resource functions more effective and customer oriented
using Information Technology enabled systems. Bring in cost effectiveness in all human resources related operations and
become self sustaining in long run. To propagate, support and implement the principles of Global Compact to
United Nations.
8.3 GENERAL TERM AND CONDITIONS OF SERVICE:
The following general terms and conditions of service apply to all the employees,
besides other rules and regulations that may be framed and notified by the Classifications of employees. The employees shall generally be classified as under Regular Temporary Casual Probationer, Apprentice/ Trainee under BHEL schemes.
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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. 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. Casual employee is an employee whose employment is of an occasional or casual nature.
Probationer is an employee who is provisionally employed with a view of being Trainee is a learner who is paid stipend or placed a grade as may be decide by the
considered for appointment on the regular establishment of the company. management, during the period of apprenticeship BHEL provide many awards and incentives like:Cash awards for acquiring higher/additional qualification
Leaves Encashment Earned Leave.(EEL) Leave Travel Concession.(LTC). Group Saving Linked Insurance Scheme. The BHEL Group Saving Linked Insurance Scheme with effect from April 1987 provides an insurance cover for all employees and promotes savings to provide financial assistance to the employee/beneficiaries at the time of retirement or insurance cover in the event of death while in service.
8.5 PAY STRUCTURE: In BHEL, the employee/workers are paid on the following basis:-
Salary
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Dearness Allowances.(DA) House Rent Allowances.(HRA) City Compensation Allowances.(CCA) Reimbursement of Medical Expenses Traveling and Daily Allowances Rule.(TA)
Appointments to only post in the company shall be subject to the satisfactory verification of character and antecede
8.7 SENIORITY
It shall be determined by the merit order assigned by the selection board. The seniority of the person whose services are obtained on deputation and who is substantially absorbed in the service of the company without break shall be determined with reference to the date of his joining and the existing post initially on depuration.
8.8 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.
8.9 HOURS OF WORK
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, the work
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done, adequate compensation by way of compensatory of overtime payment will be allowed of at the discretion of the management.
8.11 Promotion Policy and Rules:
As part of the performance appraisal BHEL recognize the work of the employees and motivates them to work better and better. They want to see that assigned work is being completed in an efficient and effective manner. Therefore BHEL identifies and promotes them to next level, so this is done as a part of performance appraisal. The objectives of promotion is To provide all employees with broad Equality of opportunity in growth and career prospect. To ensure fair, equitability, consistency and uniformity in the matters of promotion of employees in all the Units Division of the company. To sustain the high morale of the employees by informing them about the promotion opportunity existing in the organization.
Expect as may be specifically provided in the contract of service or in the standing orders, the management may at any time discharge an employee from services by giving notice. Similarly, the employee will be required to give the same notice in the event of his intention to leave the service of the company. The services of an employee may also be terminated by the company on the following grounds, among others: On abolition of the post On being declared unfit for further service on medical ground. Conviction by a court of law for criminal offence amounting to moral turpitude. Employee engaging himself in other employment without the written
permission of the management or if he is found to have been working else where during the period of leave or off duty. Absence by an employee on grounds of sickness for a continuous period of more than 18 months if suffering from tuberculosis, leprosy, mental or malignant 31
disease or fracture of lower/upper extremity and six month or more if suffering from any other disorder on the basis of the opinion of the medical board. 8.12.1 Temporary employees
On expiry of stipulated period of appointment: - No notice on either side.
If no period of appointment is stipulated or the appointment is required to be terminated before the expiry of the stipulated period for which there should be a provision in the letter of appointment then one month on either side.
8.12.2 Probationers i.e., those appointment on probation one month on either side
in the case of executives and 14 days notice on either side for other categories.
8.12.3 Apprentices/Trainees As per the provisional of the bond.
It is the process of searching for prospective applicants and simulating them to apply for the job in an organization.
8.13.1 Procedure for Recruitment:
BHEL has developed a standard form of procedure for recruiting the applicants Requisition form to employment exchange Call letter for selection Call letter for trade/ technician Apprentices Offer of training for trade/ technical apprentices Offer for temporary employment Offer of appointment Offer of appointment for supervisors Acceptance form Joining Report
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Confirmation order for completion of probation From employment exchange From open market through advertisement in the press By considering departmental candidates possessing the specified From reputed engineering/ management through college campus
committee. The committee constitutes of corporate personnel departments in consultation with the respective division.
8.13.4 Recruitment Policy:
Reservation was made available for physically challenged ex-servicemen, schedule caste/tribes and other minorities.
8.14 Welfare:
Welfare includes anything done for the intellectual, physical, moral, economic betterment of the workers. It is normally done by the organization, over and above what is laid down by the law of what is normally expected.
In BHEL, lot of importance is given to the welfare of the employees. Welfare facilities provided to the employees are:
Uniforms and masks were given to employees and apprentice/trainees Special incentives for family planning scheme Overtime facilities The most important resource of BHEL is its employees. They are provided with safe work condition, detailed training in technical aspects of their jobs and also 33
imparted knowledge in areas like first-aid, fire fighting etc. A medical center with an ambulance service is attached to BHEL industrial complex and all workers are covered under BHEL 8.14.1 Group Insurance Policy: The company also organized a number of programs in team building, organizational development, productivity techniques and company information through a well- equipped HRD center. Employees are provided with housing facilities just outside the factory, a learning center and a canteen which serves nutritious and hygienic food. Employees are kept informed about various activities through a monthly house journal. Payment of HRA at the above rates would be subject to the provision that the
employee will have to bear the 10% of their pay towards their house rent. Employees who live in houses owned by themselves 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. The other allowances include City compensatory allowances Non practical allowances to medical Late night snacks allowances for night shift employees
Messing allowances Free uniforms accommodation 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 34
8.14.2 Canteen
Re-imbursement of tuition fees Subsidiary to apprentices or trainees Traveling allowance Daily allowance
company over the years at a subsidized rates say about Rs 3 per day and it also serves nutritious and hygienic food. And a special feature is that each and every employee has to wipe 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 concern. This canteen also provides Tea/Coffee at least twice a day.
8.14.3 Trade Union
Unions are a voluntary organization of worker or employees formed protect and promote their interest through collective actions. In BHEL we can also find Trade Unions, which take care of employee whenever issues are made against the employee. But the trade union in BHEL includes many educated workers so that the issues are settled within the factory. Top management and trade union leaders come together and try to settle problem within the factory premises.
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The pivotal role of HRD lies in helping management and employees alike in identifying and narrowing the above gap through appropriate training. This constitutes the core of contemporary HRD practice. So HRD is the process by which people are assisted in a continuous and planned manner to develop their job competence, personality and other capabilities. It is the total all round development of the people, so that they can contribute their best to the organization.
HRD in the organization context is a process by which the employees of the organization are helped continuously and planned way to: Acquire or sharpen the skills required to perform their present and expected future roles effectively. Develop the general capabilities to discover and explore their own potential for their own organizational developments. Develop an organizational culture that encourages team work, mutual trust and freedom to express ones feeling and opinion so as to contribute to professional well being to employees and organization. BHEL considers its work force to be an asset of the company. It takes care of human relationship in the organization.
Identify the needs of employees. Based on the need, training and development programme is undertaken. Training budget is approved by the HOD The required employees will undergo training.
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9.2 Objectives:
To conduct applied research on various aspects of ceramic materials Upgrade technology from laboratory to pilot plant scale prior to commercial production Provide consultancy engineering services Establish facilities for characterization and testing of ceramic materials
knowledge of all those managing, performing and verifying the quality of services. To impart resources into company programs for all the developmental programs. To consolidate into company programs for the training needs identified from all the departments/section.
9.3.4 Development Programmes:
outside.
Executive, Supervisors and Artisans. The company for this purpose invites faculty from
work, uninterested in the work, etc. for this purpose, the company encourages suggestions, group work etc., and hence motivate the employees.
9.3.6 Project Training and Visits:
provides training not only for the students, but the company also gets benefited through their research work carried out as their curriculum.
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in an organization effectively and efficiently. It is possibly managements most powerful tool in controlling performance and productivity of human resources in the organization. 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. For example: 10 points poor performance 20 points excellent performance Evaluation done based on many factors such as punctually, discipline creativeness, leadership,communication,etc..
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10 FINANCE DEPARTMENT
In BHEL-EPD to work more effectively the finance department is divided into 7 sections which look after entire unit are as follows:
Establishment Section Bills Payable Section Bills Receivable Section Books Sections Costing and materials Accounts Section Cash Section Provident Fund Section
10.1 Establishment Section:
conveyance reimbursement, tour advance settlement, and air fare settlement, payment of medical expenses of retired employees, provident fund and gratuity. Apart from these activities the department is also concerned with recording and
maintenance of attendance, leave taken and over time work 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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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, 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. Where in inspection department will certify and then clear the stores receipt vouchers. The cleared stores receipt will then come to material management who will value it. After this it is forwarded to bills payable section. They will release the payment.
10.3 Bills Receivable Section:
This is the unique section which usually does not exist in money organizations.
As the product of EPD is made to order, the organization should make a follow up of customers after sales. Thus the function of this section is mainly: over which is done by commercial department, the sales department follow the Maintenance of customer accounts. Follow up of after sales procedure. The payment/amount which has to be received by the customer is
checked by this section. After the sales is done that is after the dispatch of products is
invoice raised by commercial department and collects the amount from the customers. Each customer is identified with a unique customer code. This code is common to all the branches of BHEL and is identified by corporate office. With reference to the invoice raised by the commercial department this section raises the bill. It is also concerned with speedy recovery of period barred 40
debtors as early as possible. This section has to maintain a debtors ledger that will periodically be reviewed in terms of recoveries, whether customer is paying regularly or not, whether there is any outstanding, and reasons for that.
This main work of this section is maintenance of general ledger and coordination
with other sections. It is also entrusted with passing journal entries, transfer entries passed by the various sections of finance, and to ensure that proper code are used while passing the codes. Because BHEL follows the common code system for all its units, so that consolidation of accounts will not be a big problem for them. In order to maintain the uniformity of the codes BHEL follows this system. This is also concerned with preparation of budgets.
10.5 Costing and material Account Section:
Coasting section in EPD is a part of finance department. The main task of this
department is to classify, accumulation assignment and control of cost. The information supplied by this department has a great importance to the management in decision making. By cost splits the management will be in a position to know where exactly wastages is more, or which method is causing runoff profits etc., it also prepares the cost estimates, based on which the marketing department will make the bidding. Another important function of this section is preparing the price stock ledger and major task of this section is to looks after the capital payments.
10.6 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 labors wages, suppliers amount and receipt of customers payment all are through this section. Here the books maintained for cash and bank transaction are: 41
employees. Company also contributes 12.5% in addition to the employees contribution. This department maintains the records that whether the employee has taken loan or no, if an employee has taken loan the loan amount is deducted from the total provident fund. If he has not taken the employee gets the lump sum amount at the time of his retirement.
10.8 Internal Audit:
and evaluation of records, both financial as well as others. This section mainly functions as a service to 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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Enquiry from the customer Acknowledge to that enquiry Offer-quoting of tender Negotiation Order Internal order allocation Market Exploration Order Booking Bidding Preparing the Annual Budget Projections Billing, Invoice and Dispatch In enquiry there will be a qualifying requirement, which specifies certain condition for any company to qualify for the offer that is capacity, assets involved etc, enquiry
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Enquiry
will
go
to
engineering approval of
department the
for
recommendation
and
technical
specification. If the engineering department thinks it is not possible to manufacture according to that specification then marketing department will exchange a word of mouth with the customers regarding issue and comes to a conclusion. After the order is accepted the production is carried out according to the desired specification. After production is over the company calls the customers for the inspection, which may be conducted by the customers representatives or they may insist for the company to go for internal inspection or they may send third party for the inspection. After the inspection is over and if the product is found to be according to the required norms then the customers will give the packing and dispatch instruction according to which the company should go for the dispatch of the materials.
Once the dispatches of the products are sent according to their requirements then the marketing department will follow up the payment if it is fewer amounts. If the amount is more finance department will follow up. The marketing
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department also will keep in touch with the customer to maintain good rapport. 11.1 Marketing Strategies: This section provides broad overview of the plan for achieving the marketing objectives, and ultimately, the organizational goals. Marketing strategy focuses on defining a target market and developing a marketing mix to gain long run competitive advantages. Marketing strategy guides the firms direction in relationships between customers and competitors.
11.1.2 Pricing Policy
In BHEL, they are different pricing policy in the market, they are
Penetration Price: it is intended to help the product penetrate into market
to hold a position. This can be done only by adopting low price in the initial stage or till such time the product is finally accepted by the customers. This is done to capture the market.
Hot and Cold Pricing: in this, the pricing is fixed on the basis of quality
ordered i.e., higher the quality ordered, lower will be price fixed, whereas less the quality ordered then high price is charged.
Follow Leader: in this, the pricing is fixed by following to the leaders in
the market.
Skimming the Price: it involves setting a very high price initially and
reduces the price, gradually as competitors enter the market. Usually this method of pricing is used while introducing a new product into the market.
Promotion Tools: promotion consists of those activities that are designed
Seminar Presentation
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They promote their product by conducting seminars and presentation through videoconferencing.
11.1.4 Customer Satisfaction Level:
Customer is the central point and all the marketing activities revolve
around him. Manufacturer produces what the customer wants. Consumers behave in a particular manner as directed by his inner motive. The marketers to study and analyze the consumer behavior in order to sell and improve the product. In BHEL, they conduct a customer perception survey, which reveal the satisfaction level of the customer.
Global market means doing business globally, BHEL as entered the global market and they market their products through trade and merchants exporters.
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Enquiry Forwarding to Engineer for technical offer Technical Offer Either by Marketing / Engineer By Marketing
Shop Loading Offer Submission Tender Opening Negotiation Order Placement Scrutiny Clarification Acceptance
Allocation of Order
By Customer Conditional
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Note:
14.1 Functions of material management are as follows: Material planning, activity and budgeting
To organize for keeping an appropriate stock so as to feed the production To register the purchase indent before reaching various groups in purchase Identify direct material requirement for the succeeding financial year based on Preparation of material budget taking into account the price allocation. Identify the requirement of direct material, consumables, material based on The entire revenue budget is working out taking the prevailing price and
pervious requirement and consultation with various departments. anticipation escalation in consideration. This is worked out at the unit level.
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This section mainly deals with procurement of material at the right time, from the right place, at the right price and makes it available to the right department. In case of purchase of capital item, the concerned department is to make a project report specifying the requirement and send it to the corporate office. On studying the report, the corporate office decides whether to purchase the item or not. Once the sanction to purchase the item is received, immediately specification are given and tender are invited from each tender, L1 is selected.(L1 = first tenderer)
Tender system has been adopted to produce material at competitive rate. The kind of tender in vogue are:
14.2.1 Open Tender: Such tender restored when adequate number of approved
vendors are not listed. On known source shall be addresses to the enquirer.
14.2.2 Limited Tender: Limited tender shall be addressed to a few handful
response to an open tender or limited tender shall be treated as Single tender. The unit procures the materials from its sister unit also, when and where there are requirements, and materials are available in excess on either side.
14.3 Store Department:
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Goods are received into the store after inspection and they are held and issued into
production as and when required. The stores department renders service mainly to the production and finance department.
To ensure steady supply of material to the required department. To keep proper account of material in its custody so that the capital of the To preserve the material in custody from deterioration, loss or pilferage. To keep inventory to the minimum and to ensure that non-moving items
are speedily disposed. This ultimately results in reduction of inventory carrying cost.
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Procurement Disc, MP, Packing Ceralin, Stores, Sub-Contract, SAP, ISO-System (E5)
RM => Raw Material INDL => Industrial DGFT => Director General of Foreign Trade MP => Metal Parts
SAP => System Application Product Data Processing ISO => International Standard Organisation
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Collection of data from various departments & preparation of ceramic production All servers hardware/software planning. Consumables Antivirus and hardware related issues PC& printer maintenance coordination Stationery & consumables Stock position maintenance including indenting General office administration & other miscellaneous work Intranet site development Website development Network server & backup SAP BASIS administration ERP issues coordination
report
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The company implemented SAP in the year 2004. SAP stands for Systems Applications and Products in Data Processing. Since then the units function has gradually changed from traditional way of working to the usage of the systems. The implementation of SAP using given resources in various levels and in different departments has made the functioning smooth, since IT maintains the systems around the clock.
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Sr. ENGINEER / IT
SAP BASIS ADMINISTRATION SAP ABAP DEVELOPMENT ERP ISSUES COORDINATION INTRANET SITE DEVELOPMENT WEBSITE DEVELOPMENT NETWORK SERVER & BACKUP
Engineer / IT
SAP BASIS ADMIN ALL SERVERS HARDWARE/SOFTWARE PLNG VPN & LEASED LINES NETWORKING CONSUMABLES ANTIVIRUS H/W RELATED ISSUES
Sr. IT Operator / IT
(COLLECTION OF DATA FROM VARIOUS DEPARTMENTS & PREPARATION OF CERAMIC PRODUCTION REPORT)
Sr. IT Operator / IT
(COLLECTION OF DATA FROM VARIOUS DEPARTMENTS & PREPARATION OF CERAMIC PRODUCTION REPORT)
AOS / IT
PC & PRINTER MAINTENANCE COORDINATION STATIONERY & CONSUMABLES STOCK POSITION MAINTENANCE INCLUDING INDENTING GENERAL OFFICE ADMINISTRATION & OTHER MISC WORK AMC RENEWALS
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In the production operation, the quality department will check for product characteristics after suitering operation. It is only after the kiln operation the quality department verifies the conference of the product to customer requirement. Once the product is fully manufactured and tested by the production in charge, it will be inspected and product is accepted for dispatch to customers.
16.1 Various Functions Carried by Quality Department: 16.1.1 Verifying the Compliance of Raw Materials: All incoming products and raw
materials are inspected prior to the release to the production or for further processing. Items received from suppliers or sub-contractors of EPD at stores are released for production either based on verification of suppliers inspection/test reports or after test/inspections by quality department. Goods delivered are inspected and segregated based on the decision there of as to acceptance/rejection and identified by tags, paint, markings or display of boards. Rejected goods are segregated and suitably identified as non conforming. Quality control reports of acceptance/rejection are maintained for all items.
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be certain situations when customers want to conduct certain tests on their own for their satisfaction regarding quality of product. This department helps the customer to carry out this operation insight or at BHEL-EPD itself as mentioned in the contract.
17.2 Quality Circle:
in exploring its possibilities as means of realizing its productivity and quality goals, the quality circle process can be a valuable tool. Quality circles themselves are relatively simple. A circle consists of small group of people within the company who do similar kinds of work. This group meets on a regular basis that is once in a week to identify, analyze and solve problems in its member work area. As a problem solving forum the Quality circle is to select problems within the
members work area to study and solve. In the early stages of circles life time it is important that members relatively easy problem to solve. Quality circles are not permitted to work on problems whose causes are outside of their area of responsibility.
17.3 BHEL Unified Quality System 17.3.1 Impacting on Customer Satisfaction:
Shop product non-conformance handling & processing (NCR) Field non-conformance handling & processing (MDR/SAR/CAR/SDR) Corrective and preventive actions Implementing special contract requirements-contract review Design control-review, verification and validation Vendor/Subcontractor management
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equipment.
17.3.2 Impacting on Business:
Improvement projects Evaluation of process capability Quality audits and management reviews Collaboration technology implementation Document and record control
The company is implementing TQM i.e. total quality management since 2001.
TQM can be descried as Management approach of an organisation, centered on quality, based on the participation of all its members and aiming at long-term success through customer satisfaction and benefits to all members of the organisation and to society. The company has chosen to adopt the European Quality Award Model for TQM-
activities.
17.4.1 Basically developed on 9 criteria such as:
Leadership Policy & Strategy People Management Resources Processes People Satisfaction Customer Satisfaction
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type of materials to be used, the method of manufacture, the shape of various parts and their function.
18.4 Type Testing:
Here the design, outline is coordinated with the specific requirements of the
customer needs.
18.5 Technical Offer:
Maintenance of the drawing Shop floor coordination Shrinkage follow-ups and immediately corrective active actions are taken. Once the work order is been issued, manufacturer information is prepared.
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malpractices. The security department ensures that the workers arrive at the right time to the premises and the entry of trespassers into the premises is checked. The visitors and suppliers etc., has to seek permission of the security before entering the premises and are given pass to enter into premises.
19.1.1 Functions:
To collect information for effective performance. Preventive Vigilance. Punitive or taking stern actions erring employees Reformative/ educating the employees. Monitor the guidelines.
19.1.2 The procedures followed are: 19.1.2.1 Men Movements: It is an Access Control System which records in and out time,
purpose of all employees. The kinds of passes are: Personal pass in Red colour Official pass (on duty pass) in Yellow colour. Supervisors and Heads have different pass. It checks the purchase order numbers, references. Any doubts regarding
Materials are referred to a concerned department and then entered into the log book & then materials are allowed inside the factory.100% checking is done. back. Any materials rejected will be sent back with Returnable Gate Pass (RPG). For this returnable follow log book is maintained and the material rejected are sent
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(NRGP).
19.1.1.3 Excise Goods Pass: For protection of production with proper security and check books. 19.2 Vigilance: Vigilance department investigates any illegal acts done within the organization. All government sectors should have Central Vigilance Commissioner. Vigilance has no boundary for itself. It starts with departmental procedures and files and specific purchase policy. All executives are bound to follow the policy. Works instructions are provided to all departments.
19.2.1 The main functions of the department are as follows:
To collect source of information. To undertake preventive vigilance that is surprise check, random check etc. Constructive vigilance for executives, supervisors. Punitive actions to be provided wherever necessary. Reformative action also provided. Causes of Corruption and Measures to Eradicate
Lecture on Moral Ethics Routine checks Surprise checks Scrutiny of Purchase/Contract files Scrutiny of Annual Property Returns Scrutiny of Personal files Suggestions or Feedback Follow up of Job rotation
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Every year 31st October to 5th November vigilance week is celebrates. During this week, various training programs, seminars and other activities are conducted for the employees.
Structure
Skill
Staff
Style
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The model starts on that an organization is not just structure but consist of seven elements.
Skills: -
the employees at BHEL possess a highly qualified technical engineering, communication and problem solving managerial skills. For the employees both on the job and
Off the job training:Artisans Supervisors Executives Visit to other industries for the purpose of learning. Seminar conducted in other places. Visit to other industries for the purpose of learning. Seminar conducted in other places. Executives are sent abroad to learn about new technologies and participation in seminars and conferences.
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Style: - the style of an organization according to Mckinsey frame work becomes evident through the patterns of actions taken by members of the top management team over a period of time. BHEL being a PSU there no opportunity for grievances while making decisions regarding any problem on project. Here employees i.e. artisans are consulted for the ideas view points regarding any problems. Here there is no autocratic style of leadership. BHEL believes in participative style of decision generated is favorable to everyone and it could be one of the best.
strategy refers to the determination of purpose and the basic long term objective of an enterprise and the adoption of course of action and the allocation of the resources necessary to these aims. Pricing strategy: Pricing of the insulator product is market driven. In ranges where insulators are in direct competition pricing strategy are evolved with the objective of ensuring retention of market in key ranges and preventing overseas bidders from capturing domestic market. BHEL also adopts de marketing strategies with the confidence of its clients and assuring on delivery levels and reasonable prices. In the view of the dynamics situation the market strategies are made to suit the environment prevailing.
Strategy: -
Systems:
- BHEL is an organization which is systematic in doing its day to day work. This is evident from the facts. BHEL has well managed HR department systems and management information system. System followed in HR department:Performance evaluation method:- every authority maintains an annual confidential report of all his subordinates with the performances recorded very often. It is kept highly confidential and is available only to the senior authority and the personal department. During the time of performance appraisal, the various positive and negative factors discussed by HODs. Appraisals for executives in BHEL EPD is known as moving ahead through performance. it is a self appraisal and it is online.
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Staff: - Human resource for the organization is vital and assuring that they have the
potential to contribute to the achievement of the organization goal. BHEL generally prefers to have highly qualified engineers and dedicated management professionals in case of staffing process at BHEL. Every executives, supervisors, workers need to be technically sound. Executive E1 Executive E2 Executive E3 Executive E4 Executive E5 Executive E6 Executive E7 Executive E8 Executive E9 Engineers or MBAs Senior engineer Deputy manager Manager Senior manager Deputy Senior manager Additional general manager general manager Executive director
Shared values:1. Integrity and fairness in all matters: - we must conduct our business fairly with honestly and transparency. Everything we do must stand with public scrutiny. It shows transparency in its deal and there is no chance for misappropriation and while issuing the tender a person who quotes lowest and specification which matches companys technical specification will be placed an order. BHEL shall prepare and maintain accounts fairly and accurately in accordance with the accounting and financial standards and the books of accounts are kept open or public scrutiny. 2. Respect for dignity and potential of individuals: - we must be caring. Show respect and humanity for our colleagues and customers around the world and always work for the benefits of our nation 3. Ensures speed of response: - if a client asks for any information regard products of the company. No individual can make organization to succeed but what required is group effort, any discussion to be taken regarding particular problem each and every employee will be consulted through their heads of department.
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4. Loyalty and pride in the company:- each and every employee in the organization will be loyal to his organization and they are proud of their organization.
21.1 Strengths: The greatest strength of BHEL-EPD is its highly skilled and committed employees. Company following ethical and transparent business practices. BHEL has acquired Quality certification namely ISO 9001, ISO 14001 and ISO 18001. Organisation is decentralized which encourages employees participation. Good industrial relations. Ability to raise funds.
21.2 Weaknesses: Excess labour force, majority of the profit will be given in the form of salary, bonus, allowances etc. More causal labours than permanent labours. Government intervention is more in strategies design making which create difficulties to under take business decisions 100% employee participation is not adopted
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21.3 Opportunities: The company must give more emphasis on team building and quality circle for Increase profit margin through automation of work. Increase in market share by expanding business through globally. better performance and results.
21.4 Threats:
Pay scale of lower level employees can bring unrest and turnovers, which may affect the work in progress.
Stiff prices competition for insulators. Competition from its own sister units.
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Company should improve the facilities of crche, as most of the employees are uncertain about these facilities.
It is also suggested that company should provide better rest rooms. Although the company provides welfare facilities to the employees for their betterment, the management should take certain measures to improve the welfare facilities. And the satisfaction leads to better performance.
Proper rules have to be followed in recruiting contract labors as this contract labours after some period may convert into permanent labours.
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A suggestion box can be maintained by the HR department which helps the employees to give their suggestions.
Provide signboards within the factory premises to facilitate easy identification of the department.
Conduct seminars on communication, so that employees can improve their communication skills.
Increase market share in existing and new products. Entering new country for business
25. BIBLIOGRAPHY
BOOKS: Personnel Manual of various Departments Porcelain Insulators & how they grew by Brent Mills
JOURNALS: Ceramic
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