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Industrial report on Rail wheel Factory...... Date of Visit: 14-10-2010 Teacher coordinators: Ms Aruna Gururaj and Mr.

Ravi Kiran RAIL WHEEL FACTORY, YELAHANKA HISTORY: Till early 1980s Indian Railways was importing about 55% of requirement of wheels and axles. Indigenous capacity was available only at Tata Iron & Steel Company [TISCO] and Durgapur Steel Plant [DSP]. The TISCO plant was technically not capable of meeting the changing requirement of wheels and axles for the new designs of rolling stock and production was discontinued. DSP was only able to partially meet Indian Railways needs. Financing of imports of railway things, delays in supplies and limited availability of foreign exchange adversely affected wagon production and rolling stock maintenance. It was in this context that in the early 1970s the Railway Ministry felt the necessity for setting up a new specialized Production Unit for manufacture of rolling stock wheels and axles as import substitute. The ultimate objective was that DSP and the Rail Wheel Factory [RWF, formerly Wheel & Axle Plant] should be able to totally meet Indian Railways requirement for standard wheels and axles so that their import could be stopped. The Planning Commission sanctioned the Rail Wheel Factory Plant project in 1978 at a cost of Rs.146 Cores. Trial production commenced during 1983. Late Smt.Indira Gandhi, the then Prime Minister of India formally commissioned the plant on 15 September 1984. The factory was renamed as RAIL WHEEL FACTORY on 15 February 2003. VISION To become a renowned global leader in the Business of developing and manufacturing Cast Steel Rail Road Wheels, precision Forged Axles and immaculately assembled Wheel sets. MISSION

To emerge as a unique global centre for design, development and manufacturing excellence of our products through continuous improvement by upgrading our quality, reliability, dependability and value addition in a deliberate and proactive manner. To perennially endeavor to sustain excellence in customer satisfaction by consistently exceeding their expectations.

To develop our human capital by constant enhancement of their technical, managerial & innovative capabilities. To promote ethical business practices and values in the true spirit of corporate governance.

DEPARTMENTS OF RWF 1. Mechanical: - RWF manufactures cast steel WHEELS by a controlled pressure pouring process. In this process, the raw material used is pedigree scrap (old used wheel sets, axles etc, rejected as unfit for use by the Railways). The scrap steel is melted in Ultra High Frequency Electric Arc furnace. The correct chemistry of molten metal steel is established through a Spectrometer. The wheel undergoes the process of cleaning, checking, penning and various stages of inspections. RWF buys high-quality vacuum-degassed steel blooms from large-scale steelmakers. AXLES are manufactured from billets cut from the blooms. These blooms are forged in a precision long-forging machine supplied from M/s GFM, Austria. The billets are heated in a rotary hearth furnace to forging temperatures. Billets then forged in Axles on a special purpose long forging machine. The forged axles are gas cut to required length. The assembly of WHEEL SETS is done on a highly automated wheel assembly complex. The wheel seat size of the axles is measured on an automated measuring unit and the dimensions are transferred to two wheel borers. The wheels are then pressed on axle in a 300 T Wheel press. 2. Stores: - This department deals with the procurement of necessary materials, purchase, vendor registration, renewal of registration and also takes care of supplies and material in transit. This department is responsible for the application and notices of Vendors. 3. Accounts: - This department handles the billing part of RWF. It checks the status of bills and also prepares the bills for contractors and suppliers. 4. Personnel: - This section deals with the human resource management such as recruitment, training & development, transfer and so on. It also deals with the matters of holidays and pension. 5. Civil engineering: - It deals with the mechanism and process of production. It also contacts the contractors to know the exact requirements. 6. Electrical: - The major concern of this section is to deal with S & T (Signal & Telecommunication) and E-Lab (Electronic Laboratory) department of RWF.

7. Management Information service: - Keeping in tune with the latest trends in modern management philosophy, Rail Wheel Factory (RWF) realized the need for a powerful online information system for exercising effective management control and ensuring optimal utilization of resources. To fulfill this imperative need, RWF embarked upon establishing a Local Area Network in the factory and Administrative offices. The following Application Systems have been deployed on the State-of-the art Fiber optic backboned LAN which works on Windows 2003 and SQL 2005 as Database server. The applications were developed and deployed on Dot Net Framework. 8. Vigilance: - The objective of Vigilance wing is to maintain Purity, Integrity and Efficiency of the Organization. Scope of Vigilance work includes prevention & detection of corruption, misconduct and other malpractices, stream lining the system through system corrections and punitive actions. Following tools are employed in achieving the objective of Vigilance wing: Educative by creating awareness amongst general public & employees through training Preventive by conducting regular checks in various areas Detective by investigating complaints Reformative by suggesting improvements to systems and disciplinary actions against guilty personnel. 9. Medical: - The Railway Hospital of Rail Wheel Factory was commissioned in the year 1984. The hospital is accredited with ISO 14001 and OHSAS 18001 certifications along with Rail Wheel Factory. The Railway Hospital caters medical service both in curative and preventive health for the employees and their dependents. In addition it also provides medical service to large number retired employees and their dependents. The hospital caters primary and secondary level medical services in the field of General Medicine, General Surgery, Obstetrics & Gynecology, Peadiatrics, Occupational Medicine, Ophthalmology and Orthopedics, also a consultant service in the field of Dental medicine. 10. General Administration: - It takes care of the general administration tasks and coordinates with all the other departments of RWF.

MOTHER DAIRY By Indrajit Roy in BBM Batch Mates (2009) Edit Doc Karnataka Cooperative Milk Producers' Federation Limited (KMF) Date of Visit: 9-02-2011 Teacher coordinators: Ms.Rashmi, Ms.Archana and Mr.Iqbal Khan.

Karnataka Cooperative Milk Producers' Federation Limited (KMF) is the Apex Body in Karnataka representing Dairy Farmers' Co-operatives. It is the second largest dairy co-operative amongst the dairy cooperatives in the country. In South India it stands first in terms of procurement as well as sales. One of the core functions of the Federation is marketing of Milk and Milk Products. The Brand "NANDINI" is the household name for Pure and Fresh milk and milk products. Coordination of activities among the Unions and developing market for Milk and Milk products is the responsibility of KMF. Marketing Milk in the respective jurisdiction is organized by the respective Milk Unions. Surplus/deficit of liquid milk among the member Milk Unions is monitored by the Federation. While the marketing of all the Milk Products is organized by KMF, both within and outside the State, all the Milk and Milk products are sold under a common brand name NANDINI. Vision

To march forward with a missionary zeal which will make KMF a trailblazer of exemplary performance and achievements beckoning other Milk Federations in the country in pursuit of total emulation of its good deeds? To ensure prosperity of the rural Milk producers who are ultimate owners of the Federation. To promote producer oriented viable cooperative society to impart an impetus to the rural income, dairy productivity and rural employment. To a bridge the gap between price of milk procurement and sale price. To develop business acumen in marketing and trading disciplines so as to serve consumers with quality milk, give a fillip to the income of milk producers. To compete with MNCs and Private Dairies with better quality of milk and milk products and in the process sustain invincibility of cooperatives.

MISSION

Heralding economic, social and cultural prosperity in the lives of our milk producer members by promoting vibrant, self-sustaining and holistic cooperative dairy development in Karnataka State.

KMF UNITS:

KMF Corporate Office Training Centres Mother Dairy Hi Tech Products Nandini Milk Products Cattle Feed Plants Nandini Sperm Station Nandini Packaging Film Plant Dempo Dairy

Unit of visit: MOTHER DAIRY, Yelahanka. Mother Dairy, Bangalore, a flagship dairy of KMF having ISO22000:2005 Certification was set up during the year 1984, primarily for dispensing liquid milk to customers through Bulk Vending system. Today, the Dairy stands expanded from 2 Lakh Litres to 7 Lakh Litres milk processing per day. Also, it has facilitates to pack and distribute milk & curd in different packs formats in the most hygienic way. Besides, it has a state of the art facility to manufacture Skim Milk Powder, Dairy Whitener, as well as Whole Milk Powder to the tune of 30 MTs per day. It has established a facility to manufacture more than 20 varieties of Ice cream in the various pack formats to the tune of 15000 Litres per day. Presently, it is undertaking manufacturing and co-packing of 'Amul' brand of ice cream for GCMMF.

Milk Process description: The present data refer to milk production in Mother Dairy,Yelhk. The main production processes at the two dairies are following: 1) Milk from dairy farms is received, 2) The milk is centrifuged and separated into cream and skim-milk 3) The two fractions are mixed in different ratios depending on desired quality of milk (standardization) 4) The standardized milk is low pasteurized (heat treatment 72oC in 15 seconds) and eventually homogenized

5) The milk is parked and stored cool until distribution to consumers. Some cream is converted into butter and buttermilk and some skimmed milk is converted into milk powder by evaporation in subsequent processes. Waste water generated during the process is diverted directly to municipal waste water treatment. The dairy are characterized by a high degree of specialization in milk production for the consumer market (cream, full milk, low-fat milk and skimmed milk). All production processes are automatic and modern.

Data collection and treatment: Data are derived froM KMF Dairies' records (Green Accounts 2001/2002). Avarage inputs and outputs per produced unit of milk have been calculated ignoring minor contributions from other products. All products are subject to the same main processes and no differences between products have been considered regarding energy consumption and emissions to water. However, fatcontent vary between milk products (see table below) and differences in milk consumption and cream production have been taken into account assuming 4.3% fat content of the fresh cow milk.

Type(MILK) Fat content (%) Skimmed milk 0.1 Low fat milk 1.5 Full milk 3.5 Mini milk 0.5

Homogenization requires about 4% of total electricity for milk production and differences between homogenized and non-homogeniosed milk with respect to electricity consumption have been ignored.

The exclusiveness of Mother Dairy is because of: Mother Dairy cares for quality, hygiene and food safety and hence the dairy was certified for certified for ISO 9001-2000 during the year 2000 and has been certified for ISO 22000-2005 during 2008. The Dairy has Export License for Skimmed Milk Powder, Whole Milk Powder, Dairy Whitener, Ghee and Butter. The Dairy has embarked on Environmental Protection, Energy Conservation Programme and have been suitably recognized by Bureau of Energy Efficiency, Government of India and KREDL, Karnataka. Time being the essence of working Mother Dairy has brought the activities underLAN by adopting appropriate technology. Any business enterprises assessed for its status on the financial performance and Mother Dairy fully believes in this philosophy and has constantly posted positive financial results ever since its existence

Industrial Visit Report on Parle Factory (Bangalore) Industial Visit Report on PARLE DATE OF VISIT: 15th November 2009 Teacher Coordinator (Guide): Mr. Syed Wajid Ahmed & Mrs. Usashi HISTORY Parle Products emerged in the year 1929 when India was still under the British Rule. This company was started by Shri Mohanlal Dayal Ji, who learned confectionary from Germany. A small factory was set up in the suburbs of Mumbai, to manufacture sweets and toffees. A decade later it was upgraded to manufacture biscuits as well. Since then, the Parle name has grown in all directions, won international fame and has been sweetening people's lives all over India and abroad COMPANY PROFILE Parle has a market share of 60% in the organized sector and that of 40% in the organized sector. It is giving tough competition to established players like Britania etc. Its Market penetration in urban area is 75% to 85% and that in rural areas is 55% to 65%. If we look at the region wise market share then Parle enjoys maximum share of 28% in the East Zone. While compared with the peers Parle

enjoys maximum share of 40% followed by Britania38% than Priya Gold 15%, ITC 11% and other players 6%. The company has been observing a decent growth rate of 15% to 17% annually over the years. The total product mix of Parle consists of 17 products in biscuits category, 14 from sweets and 7 products in snacks category making a total of 38 products rolling out from various factories of Parle.

ABOUT THE UNIT The Unit that we visited was Bangalore ( Tumkur Road) factory which is producing

Biscuits Snacks Sweets During the visit we were given a detailed presentation about the creation, evolution and functioning of the brand Parle and different processes that are combined to manufacture a host of Parle products like biscuits, confectionaries and chips. We were then taken around the factory and each process was explained to us in a easy to understand and clear manner. We could see how efficiently, hygienically and smoothly Parle was carrying out its manufacturing operation. Later on a question and answer session was held where all questions asked by the management were answered to our complete satisfaction.

Operation Procedure of Parle Factory (Bangalore) 1. Standard of 12 hrs a month breakdown. Maintenance department has to maintain this level. 12 hrs a month is the permissible limit for breakdown of machines. 2. Large and efficient machines ensure the sufficient production to meet the demand.

3.Proper network of supply chain. There are 90 depots owned by Parle, which further distributes the products to distributors, retailers and then finally to consumers. 4.The products manufactured in Parle factory are shipped to depots same day at any condition. This is done in order to ensure inventory is kept properly. 5. Hygiene factors are maintained. All the employees in manufacturing unit have to follow certain restrictions in order to maintain the hygiene of the products. Marketing Management Parle has been a market leader in biscuit market. This has been possible because of the dedicated marketing team of Parle. Amir Khan was selected by Parle as the brand ambassador for Parle products like Monaco, Smart chips, Parle G. Various strategies adopted by Parle are: 1. Emphasis on quality of the products. This has been the main factor for Parle for being the market leader. Products have to pass the specific quality test to be sold in market. Quality of Parle products is such maintained that even WHO has given preference to Parle products over other products while distributing them to calamity hit areas. 2.Value for money is another approach to invite more and more customers. Parle products are priced aggressively to counter the competition by other brands. 3.Rural market is the priority for the Parle. The major source of revenue for Parle is from rural markets. Products like Kismi Bar, Poppins, Rola Cola, etc which are gradually disappearing from the urban market still are very popular among rural population

Industrial Visit Report on Karnataka Soaps & Detergents ltd, Bangalore By Bishesh K Sah in BBM Batch Mates (2009) Edit Doc Date of Visit: 28-09-2011 Teacher Coordinators: - Ms Swetha S, Ms Pushpa das & Ms Jayshree Bora

Karnataks Soaps & Detergents ltd About the Company: The Government Sandalwood Oil factory was established by the Maharaja of Mysore His Highness Nalwadi Krishna Raja Wodeyar and Diwan Sir, M. Visvesvaraya, during the year 1916 at Mysore, to extract Sandalwood Oil from Sandalwood. The foresight and enthusiasm of Maharaja of Mysore, to keep the Mysore State in the Global Map, by introducing "THE WORLD'S BEST NATURAL SANDALWOOD OIL" and to make it as a "FRAGRANCE AMBASSADOR OF INDIA". Toilet soap production capacity was enhanced from 112MTs/annum to 750MTs/annum in the year 1932. In 1980, Government Soap Factory was converted into a Public Sector Enterprise and the Company incorporated on 9th July 1980 and re-named as KARNATAKA SOAPS & DETERGENTS LIMITED.The ISO certification was upgraded to 9001:2008 in 2010 from 9001:1994 & 9001:2000.

Vision Statement : Karnataka Soaps & Detergents Limited has a clear Vision for all round development of the Company. This is reflected in the form of a well conceptualized and cogent blue print called VISION 2013. The VISION 2013 sets the goals and milestones and suggests the strategies and plans necessary to relies the Vision. The Vision of the KS&DL is embodied in the following statement:"KARNATAKA SOAPS & DETERGENTS LIMITED WILL LEVERAGE LATEST SOAP MANUFACTURING TECHNOLOGY AND INFORMATION TECHNOLOGY BY IMBIBING PROFESSIONAL MANAGEMENT TECHNIQUES TO IMPROVE ITS FUNCTIONAL ACTIVITIES, TRANSPARENCY, BUSINESS AND TO TRANSFORM ITSELF INTO A COMPETITOR IN THE FMCG MARKET IN INDIA AND ALSO TO SPREAD ITS FRAGRANCE IN THE FMCG GLOBAL MARKET". Mission Statement : Karnataka Soaps & Detergents Limited shall strive to achieve:

Rs.235.00 crores sales turnover during the year 2010-11. Minimum 10% of savings of cost in various activities during the year 2010-11.

PRODUCT CATEGORIES

Toilet Soaps Detergents Cosmetics Agarbattis Sandal Wood MANUFACTURING PROCESS The Karnataka soaps and detergents ltd manufactures its wide variety of products at three locations which serve as the steps in preparing the final products. 1. Shimoga: - The cultivation of Sandal wood is done from the nursery situated at Shimoga, Karnataka. It is the place where all the products are initiated because the basic requirement for all the products is Sandalwood oil. Sandalwood cultivation is a good candidate and a natural choice for Organic Farming with good hostorial inter plantation. The focus is not on yearly yields, but rather over an extended period of time ranging upto 12 to 15 years, reduce the gesture period of harvesting. It is not to a large extent dependent on fertilizers and pesticides. It is not to a large extent dependent on intensive irrigation facilities. 2. Mysore: - The major task of Sandalwood extraction is done at the facilities established at Mysore. It involoves various processes for the complete extraction of oil which can be actually used for the production of final products. First the wood is cut into pieces and then crushed and then after adding some moisture, it is then kept in the special vessle where the oil is extracted int the time period of 48hours but it doesnot become useful at the moment. The oil is kept for 3-6months to gain its fragnance and quality that is beneficial for the skin. 3. Bangalore: - The actual production of various soaps and detergents and other products is done at the factory situated in Bangalore. There are several processes for the several varieties of products. But the basic ingredient for any toiletries is Palmolive oil which is exported as per the requirement. Depending upon the quality of product, the amount of Sandalwood oil is added to add fragnance and benefits of nature. The various products are Mysore sandal soap, Mysore sandal gold, Mysore detergent cake, talcum powder, Mysore sandal premium incense sticks, Sandalwood oil and so on.

MARKETING OF THE PRODUCTS The varieties of products are made available throughout india by the strong distribution channel owned by the company in various cities. One can get the products from the specific outlets situated in Mysore, Bangalore, Mumbai, Kolkata, Secunderabad, New Delhi, Pune, Chennai, Shimoga etc. Some of the products are even exported to US and European countries.

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