MAHARAJA AGRASEN INSTITUTE OF MANAGEMENT STUDIES

SUMMER TRAINING REPORT ON MARKETING OF STEEL PRODUCTS

CARRIED OUT AT

NEW DELHI

Submitted in partial fulfillment of the requirement for the award of degree BACHELOR OF BUSINESS ADMINISTRATION SESSION :- 2011-2014 Submitted by :SARVDAMAN PRASHAR ENROLLMENT NO :- 09761101711

CONTENTS
Topic Declaration Preface Acknowledgement Chapter-1 Introduction to MULTI COLOR STEELS Chapter-2 Various Departments Chapter-3 Research & Development List of Major Plant & Machinery Chapter-4 Production of Steel roofs and claddings Bibliography
Page No.

STUDENT UNDERTAKING
This is to certify that I have completed the Project titled "MARKETING OF STEEL PRODUCTS " in MARKETING DEPARTMENT of MULTI COLOR STEELS INDIA PVT. LTD " under the guidance of Mr. Ravi Jain" in partial fulfillment of the requirement for the award of degree of Bachelor of Business Administration at Maharaja Agrasen Institute of Management Studies, Delhi. This is an original piece of work & I have not submitted it earlier elsewhere.

Sarvdaman Prashar

CERTIFICATE This is to certify that the project titled "MARKETING OF STEEL PRODUCTS in MARKETING DEPARTMENT of MULTI COLOR STEELS INDIA PVT. LTD" is an academic work done by " SARVDAMAN PRASHAR " submitted in the partial fulfillment of the requirement for the award of the degree of Bachelor Of Business Administration from Maharaja Agrasen Institute of

Management Studies, Delhi, under my guidance & direction. To the best of my knowledge and belief the data & information presented by him/her in the project has not been submitted earlier.

Mr. Jatin Vaid (Assistant Professor)

ACKNOWLEDGEMENT
Apart from the efforts of me, the success of any project depends largely on the encouragement and guidelines of many others. I take this opportunity to express my gratitude to the people who have been instrumental in the successful completion of this project. I would like to show my greatest appreciation to Mr. Jatin Vaid. Thank you won't be enough for him tremendous support and help. I feel motivated and encouraged every time I attend his meeting. Without his encouragement and guidance this project would not have been materialized. The guidance and support received from all the members who contributed to this project, was vital for the success of the project. I am grateful for their constant support and help.

SARVDAMAN PRASHAR

EXECUTIVE SUMMARY

Practical training imbibes an integral part of management studies. One cannot merely rely upon the theoretical knowledge. It is to be coupled with practical for it to be fruitful. Classroom lectures made the fundamental concepts of management clear. They also facilitate the learning of subject in a comprehensive manner. Practical training in a company has a significant role to play in the subject of. To develop leadership skills in future managers and enhance their analysis skills , it is necessary that they combine their class room learning with the practical knowledge of manufacturing and other operations.

I consider myself lucky to get my summer training in India's respected organization and the leader in Indian metal buildings business in quality, productivity and customer satisfaction MULTI COLOR STEELS INDIA PVT. Ltd. I under went six weeks of practical training at M.C.S. It helped me to get a practical insight into the actual industrial environment and provide me opportunity to make my management concept more clear .

It is difficult to elaborate everything which I have learned during the training. However, I have endeavoured many comprehensive pictures of details about working in the following pages. I have accumulated the desire information through personal observation, self practice over machines and discussion held with officer at different levels.

CHAPTER - 1
INTRODUCTION TO M.C.S.
INTRODUCTION
OF M.C.S. HISTORY MEMBERS OF MCS GROUP DIRECTORS OF THE COMPANY COMPANY ORGANISTION FUTURE PLAN EXPANSION PLAN QUALITY MANAGEMENT VISION & MISSION

INTRODUCTION
Founded in March 1972, MULTI COLOR STEEL INDIA PVT. LTD. Nuts and similar parts for Automobile and other Industrial Sectors. is one the

leading manufacturers and suppliers of high tensile fasteners such as Bolts , Screws,

LPS have grown steadily over

the past 31 years on the strength of our

in house

technological developments innovations coupled with our reputation as the company with strong commitment to customer satisfaction and quality improvement.

LPS understand what we have to do for our customers. We assure that we will do our best to make our products safe and reliable for our customer's assembly line.

LPS promise to improve our products to meet the ever increasing expectations of our customers and are always obliged for their continued guidance and patronage.

LOCATION OF PLANT
The company is situated on PLOT NO.4, SECTOR-6 IMT MANESAR, GURGAON, (HARYANA). The company has got excellent manufacturing facilities and conditions. Manufacturing plant exceeds over a space of about 25 - 30 acres .

RESEARCH METHODOLOGY
A) Primary Data B) Secondary Data

Primary Data- Primary data is that kind of data which is collected by the investigator himself for a specific study. The data search collected is original in character. The advantage of this method of collection is the authentic. Primary data is collected from women entrepreneur. Questionnaire as a tool is used as primary data in this research. Questionnaire contains: 1. Self prepared questions and size of questionnaire is appropriately taken so as to avoid any adverse affect on response rate. 2. Instructions which make it simple and easy to understand.

Secondary Data- When an investigator uses the data that has been already collected by others is called secondary data. It may be official or unofficial. The secondary data is collected from Website, Journals, Reports and various publications. The advantages of secondary data can be It is economical in terms of money and time spent.

BOTH PRIMARY AND SECONDARY DATA ARE USED.

SAMPLING DESIGN
In the theory of finite population sampling, a sampling design specifies for every possible sample its probability of being drawn. Mathematically, a sampling design is denoted by the function probability of drawing a sample which gives the

Descriptive Research=Descriptive research, also known as statistical research, describes data and characteristics about the population or phenomenon being studied. However, it does not answer questions about. eg: how/when/why the characteristics occurred, which is done under analytic research.

Although the data description is factual, accurate and systematic, the research cannot describe what caused a situation. Thus, Descriptive research cannot be used to create a causal relationship, where one variable affects another.

The description is used for frequencies, averages and other statistical calculations. Often the best approach, prior to writing descriptive research, is to conduct a survey investigation. Qualitative research often has the aim of description and researchers may follow-up with examinations of why the observations

SAMPLING TECHNIQUE
Probability Sampling = A probability sampling method is any method of sampling that utilizes some form of random selection. In order to have a random selection method, you must set up some process or procedure that assures that the different units in your population have equal probabilities of being chosen. Humans have long practiced various forms of random selection, such as picking a name out of a hat, or choosing the short straw. These days, we tend to use computers as the mechanism for generating random numbers as the basis for random selection Probability sampling is a sampling technique wherein the samples are gathered in a process that gives all the individuals in the population equal chances of being select

A Simple random sample is a subset of individuals (a sample) chosen from a larger set (a population). Each individual is chosen randomly and entirely by chance, such that each individual has the same probability of being chosen at any stage during the sampling process, and each subset of k individuals has the same probability of being chosen for the sample as any other subset of k individuals. This process and technique is known as simple random sampling, and should not be confused with systematic random sampling. A simple random sample is an unbiased surveying technique

MEMBERS OF MCS GROUP

.

NAV BHARAT INDUSTRIES

LAKSHMI PRECISION SCREWS LTD.

LPS FASTENERS AND WIRES PVT. LTD

UNIVERSAL ENTERPRIES.

LAKSHAMI PRECISION SCREWS LTD. (PLANT II).

JC FASTNERS LTD.

LAKSHMI PRECISION SCREWS LTD. (PLANT III)

SWADESH ENGINEERING INDUSTRIES

DIRECTORS OF THE COMPANY

MR. DEEP GUPTA

MR. DIPANE GUPTA

MR. ASHISH GUPTA

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CHAPTER-2:COMPANY PROFILE

BOARD OF DIRECTORS

CHAIRMAN AND MANAGING DIRECTOR

QUALITY MANAGEMENT CORPORATE STRATEGY

MARKETING

R&D

PLANNING

PRODUCTION

FINANCE

GENERAL

D E V E L O P M E N T

S A L E S

D E V E L O P M E N T

L A B O R A T O R Y

CPP ERL NOA TDN RUN ACI LTN - IG -O-N-

P L A N T

P L A N T

II

P U R C H A S E

F I N A N C E

H R D

E D P

12

FUTURE PLAN

Its future plan includes :Continuous investment in R&D. More concentration on hard currency market of USA , UK, Japan and Europe with the objective of doubling the exports and to bring invaluable foreign exchange for the country. On the corporate agenda isa massive expansion program which include

diversification into chemicals and engineering. To improve quality in design and manufacture through implementation of ISO-9002 system.

EXPANSION PLANS
To meet the challenges is an open economy and competitive edge, the company had undertaken and expansion scheme with a total capital out of Rs.1655 lakhs.

13

QUALITY MANAGEMENT

The company has embarked upon the ambitious plan of furthering the cause of quality through total customer satisfaction after achieving the ISO GUIDE 25 & ISO 9002 . Towards this end the company has initiated steps for obtaining QS:9000 . In addition fastener quality act. 1996 of USA is now under implementation which is a mandatory requirement for exporting to USA after May 1998.

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MISSION & VISION

VISION :MISSION :-

Be recognized as the best and preferred supplier of National / International standard.

To be a growth oriented professional company promoting high standards of business ethics and producing best quality products thereby achieving international standards of excellence.

To establish a strong R&D facility to fulfill the demands of the automotive industry as comprehensively as possible.

To make each member of the company feel proud and empowered by fostering a culture of participation and innovation.

To strive for reduction in defects and achieve 6 Sigma and beyond so as to make quality a way of life

To reduce cycle time in all processes as a step towards over-all improvement.

To provide prompt and excellent service to customers anywhere in the world.

To maximize shareholder's wealth.

Their motto:- Total customer satisfaction and leadership. Their target:- Annual growth rate of 30% of which export contributed up
to 50%

Their people:- To diversify after 100 crores. Their function:- System oriented . Their people:- The main force behind it.

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VARIOUS DEPARTEMENTS

PRODUCTION DEPARTEMENT PRODUCTION PLANNING AND CONTROL INSPECTION AND QUALITY CONTROL TOOL ROOM DEPARTMENT PURCHASE DEPARTEMENT PERSONEL DEPARTEMENT MARKETING DEPARTEMENT

17

PRODUCTION DEPARTMENT

The function of production department is to effectively plan and regulate the operations of that part of enterprise which is responsible for actual transformation of raw material into finished products. The production activities in L.P.S. are looked after by Works manager who is responsible to report the general manager.

For efficient production, the department has being divided departments are part of production workers of production department.

into various units such as

PPC department , Quality Control department , Heat Treatment department etc. All the department and responsible for regulating all the

The production system is a part of a longer system of a business firm.

The production system can be viewed as a frame work or skeleton of activities within which the creation of values can occur.At one end of the production system are the input and the other end are outputs. Connecting the outputs and inputs are a series of operation or processes storages and inspections.

The production system is applicable for both production of components and production of services also.

The production of any component can be viewed in terms of a production system. For example, the manufacture of Fasteners in values such as inputs, wire, machines, workers, tool, etc. After these inputs are acquired, the several operations are performed which are necessary for the formation of bolts. By these operations the inputs are converted into outputs such bolts, screws, nuts etc. After finishing operations, a final inspection occurs. Then outputs are held in the stock rooms until they are supplied to the customers.

18

Factors affecting scheduling

Customer's demand.

Customer's delivery date

Stock already lying with dealers . Stock already lying with the firm.

How much time available and how much time is required for manufacture.

Availability of machinery and other facilities.

Availability of raw materials.

Availability of manpower.

Feasibility of economic production/batch size.

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PRODUCTION PLANNING AND CONTROL

FUNCTIONS :Production planning and control has following functions: 1. Planning 2. Routing 3. Scheduling 4. Dispatching 5. Inspection Following chart can show these functions:

FORECASTING PRODUCT DESIGN AND

PRODUCTION PLANNDEVELOPMEN ING AND T

CONTROL

PRODUCTION CONTROL

PRODUCTION PLANNING

INVENTORY CONTROL

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OBJECTIVES OF P.P.C :Objectives of production planning and control department are closely linked with the objectives of the enterprise whole. Keeping in view, the main aim of the customer's satisfaction, objectives of P.P.C can be summarized as follows :To deliver the product the customer when he wants it.

To follow-up production schedule to ensure that delivery promises are maintained.

To maintain quality at desired level, i.e. same as that of approved sample.

To maintain adequate level of inventories, as excess or shortage both are harmful.

To utilise optimum plant capacities

To maintain flexiblities in manufacturing operation, so that emergency rush can be accomodated.

Production planning and control system which converts the objectives into action is shown on the chart below.

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p PRODUCTION PLANNING AND CONTROL PRODUCTION LANNING PRODUCTION BUDGET MANUFACTURING METHODS PROCESS MACHINERY & EQUIPMENT PLANT LAYOUT TOOL DESIGN INVENTORY CONTROL PRODUCTI ON TRAFFIC

MATERIAL BUDGET STORES RECOR D EEPIN G MATERIL REQUIRE

MANONTRO UFAC RECEIVING TURI L&N G SUBSIDIA SHIPPING RY ORDER INTERNAL K ROUTING TRANSPORTATION SCHEDULING & MACHINE LOADING DESPATCHING EXPEDITING FOLLOW-UP

STORE KEPING SOLVEGIN G

OPERATION SHEET INSTRUCTION CARDS

TOOL KEEPING

MOTION AND TIME STUDY M/C AND MANPOWER REQUIREMENT MASTER SCHEDULE

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Objective A Analyses

PRODUCTION PLANNING

Plan

FURTHER ACTION

IMPLEMENT

COMPARE

MEASURE AND OBSERVE

PRODUCTION CONTROL

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INSPECTION AND QUALITY CONTROL

FUNCTIONS OF INSPECTION :Inspection of raw material. Inspection during manufacturing.

Metallurgical and metallographic inspection. Purchase and inspection. Finish goods inspection. Tool inspection.

TYPES OF INSPECTION :Dimensional inspection. Testing of mechanical properties. Surface finish inspection. Performance testing.

The inspection is done commonly at two places, stage inspection and final inspection, but sometimes patrol inspection is also done to check the effectiveness and efficiency of machines. Thus patrol type of inspection is done to manufacturing of components.

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INSPECTION METHOD :In a repetitve type of manufacturing inspection should be done at several placed.

Process inspection Sampling inspection Batch sampling inspection Final inspection

PROCESS INSPECTION :Process inspections the inspection of the components during the manufacturing. It is also reffered as inspection is to prevent scrap, rework, reduce operation levels and detect hidden defects and to attain a higher quality of finished products.

SAMPLING INSPECTION :In sampling sample is taken and analyzed for machine and tolling faults. This type of inspection is performed by stage inspector. This inspection helps in detecting only fault which may be in machine as tooling. Thus report also benefits the operator by letting him know his quality of work.

BATCH INSPECTION :This type of sampling generally concerns parts there have been removed from the sho door and sampled according to statistical methods based on the past experience.

FINAL INSPECTION :Final inspection is done at the end of all the operations being performed.All the parameter are checked again. Thus inpection is very critical and all the parts are screened and combed to detect any faults which might have crept in during manufacturing.

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STORAGE INSPECTION :In storage inspection components come in lot are checked by stage inspectors. The components are checked functionally and dimensionally. Different guages for different dimensions are used to reduce the inspection time.

PARTIAL INSPECTION :In the partial inspection, the components are inspected in the machine itself during their manufacturing. This type of inspection helps as follows : Reduce scrap. Better control and dimensions. Time saving. Man power saving.

QUALITY CONTROL :Quality control means degree of perfection achieved. It is not absolute but it can be judged and realized by comparing with some standards.

OBJECTIVES :To see that the products being manufactured are in tolerance limits. To Take necessary steps, so that products which are not up to the standard don't reach the consumers.

ADVANTAGES :Quality of the products is improved and thus the consumers attracted with the effect quality control, scrap, rejection and re-working are minimized and thus avoiding wastage, which reduces the cost of production. Reputation of the company is enhanced by good quality of its products.

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RESPONSIBILITIES OF Q.C.DEPT. :To allow sale of product of uniform and required specification. To reject the defective goods and shield the consumer from defective items. To correct the rejected goods if possible.

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TOOL-ROOM DEPARTMENT

Tool Room is a very important department of a company. All the repairs in dies and manufacturing of new dies are performed in the Tool Room. The main function of the tool room is to deal with the dies used in the Production Department. To maintain & repair the dies used in power press, equipped with various punches, is an important function of Tool Room. Without the help of tool room, the functioning of production department seems impossible. Production Department can't work without the existence of Tool Room, even for a single day. For efficient working of any company, or Production Department, in particular a Tool Room with efficient workmanship is must. Tool Room consists of two section.

Turning Section Grinding Section

In Turning section soft material is used for work then hardening is done for attaining its required hardness , after this material is transferred to grinding section for its required surface finish .

Various Machine Used in Turning Section: Lathe Machine Milling Machine E. D. M(Electric Discharge Machine ) Engraving & Marking Machine(Pentograph )

Various operation on Lathe Machine are :Centering Thread cutting Drilling Turning

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Various operation on Milling Machine are :Keyway cutting Gear cutting Slotting Tapering Drilling Facing

Various machine used in Grinding section are:Surface Grinding Machine Cylindrical Grinding Machine Lathe Machine

Various operations on Grinding Machine are :Internal Grinding Surface Grinding Hex./Pent. Grinding Outer Diameter (cylindrical grinding)

Some of the grinding machines used in grinding operation in tool room are :Grinders Maker's Name 1) Universal Tool & Cutter Grinder 0200* 500 Stanlaso, US 2) Surface Grinder 3) Internal Grinder 4) Cylindrical Grinder Rectification is done on lathe in grinding section . Power Hex Saw is used in tool room store for cutting of material of required size (length wise). Drilling Machine is also used in tool room . Paraga, India Fort VNA, USA HMT, USA

29

After turning section and grinding section final inspection is done whether required tool or m/c part or die is according to required specification. Material used in tool room is basically High Carbon High Chromium, Hot die Steel, High Speed steel ,Mild Steel etc.

PURCHASE DEPARTMENT
The purchase department is that section of an organization, which deals with the arrangements of various physical inputs used, in actual production, maintenance and establishment. The purpose of purchase department is to purchase the selected material at minimum cost. The organization hierarchy of purchase department is shown as:-

PURCHASE MANAGER

PURCHASE OFFICER

PURCHASE ASSISTANT
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Firstly the purchase department bought the raw material from the market, which is passed to the laboratory for inspection. The laboratory test involves which type of material is that, what's its composition and what's its strength. After this test the report is supplied to general manager of production department. If material is o.k. then order is placed by the purchase department. The purchase process to buy a raw material can be shown as:-

INDENT

QUOTATION (TO BE SOUGHT WITHIN 15 DAYS AND FOR CAPITAL ITEM-1 MONTH)

COMPARATIVE STATEMENT

PURCHASE APPROVAL BY G.M.

PURCHASE ORDER(4 COPIES)

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PERSONNEL DEPARTMENT

The activities of personal department are : Recruitment Training/Placement Welfare Activities Welfare Action Industrial Relation

RECRUITMENT :It is based upon the work load for a predetermined target and with the consent of the Managing Director.The qualification standard for each job is laid down as approved by the M.D. of the company. GENERAL POLICY :According to the company all the promotion vacancies are fulfilled through internal recruitment . Usually recruitment from outside is for workmen grade category administration department and trainee in the technical department. TRAINING/PLACEMENT :The company has different types of training programs.Trainees are trained to improve the basic skill and work knowledge on the basic machine . After completion of the two Years training, Specialists trainees,Engineer trainees, Technician trainees and Trade trainees are posted as Forman with two increments.

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WELFARE ACTIVITIES :As per factories act following are the welfare activities for worker and staff :

A) STATUTORY ACTIVITIES Provision of toilets Provision of drinking water Separate washing facilities Sitting facilities in side the factory First-Aid and Medical facilities Subsidized Canteen facilities Rest room and lunch rooms Apartment of welfare officer For every 200 employees there will be one welfare officer . For every additional 500 ,one additional officer is posted . b) NON-STATUTORY ACTIVITIES Transport facility Quarters/Housing House building allowance scheme Uniform Recreation activities Death Relief

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M.C.S. MARKETING

The company has established its various sales representatives in various parts of India ; Mainly in Industrial cities of India like Chennai , Bangalore ,Coimbatore, Kanpur etc. Their main test is to find out market or customers for their product. The marketing division has been divide into 2 parts Export Marketing Domestic Marketing

The Domestic marketing then divides the customer into two parts OEM (Original Equipment Manufactures ) Dealers

OEMs are the ones who are designers of the product themselves . They are the ones who can supply the design and we have to make the fastener according to the design given . Similarly the OEM are divided into future 2 Sub-Categories:

New Customer Existing Customers

WORKING WITH NEW OEM :-

Company gets the purchase order from the new customer through our sale personnel and the customer provides the Drawing . Then the drawing is taken to the Research & Development as the feasibility report about the product .Whether we can make it or not and if we can make what are the requirements?

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The R&D Then prepares the feasibility report about .

After the feasibility report the

report the sent to the Finance Department for the costing . The Finance Department then prepares the unit price of the product and then this is forward to the marketing department ,who gives the quotation to the customer.

If the customer approves the quotation then sample of some pieces is made and given to the customer for the approval . If the customer approves the sample then pilot lot is prepared and given to the customer and . The size of the pilot lot can be 50,100,or 200 also. If the is again approved then we get purchase order (PO) from the Customer and a CC is sent to the production , planning and control department(PPC).

After completion of the manufacturing of the product , the material is to given to the finished . Goods stores who dispatches it to the customer .

WORKING WITH EXISTING OEM :-

If the customer is existing then purchase order is directly given to the PPC department then Engineering department releases the drawing and the product is made . The format of dispatching is same in every case.

WORKING WITH DEALERS :Sometimes our the customer is the manufacturer but the dealer and instead of quoting the price we have the price list for our products and we give them the price. After that it the same working procedures as the rest.

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MAIN MARKETS

DOMESTIC (USER INDUSTRIES) Automotive Aviation Heavy & Light Machinery Hydraulics/Pneumatics Pumps Machine Tools ,Jigs & Fixtures Railways Refrigeration & Air Conditioning

INTERNATIONAL (COUNTRIES) Australia Germany Holland Japan Singapore South Africa South Korea Sweden Switzerland United Kingdom United States of America

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MAJOR CLIENTS :Berwick PTY Ltd. (Australia) Muller & Wilde (Austria) Hussaini Brothers (Austria) Bossard France (South Africa) Berner France Sarl (France) Nestinox B.V (Holland) China Crystal Metalware Limited (Hong Kong) Nuova Ferro and Acciaio SRI (Italy) National Socket Screw Company (South Africa) L & W fasteners Co. (USA) Heads and Threads Company (USA) Lindstrom Metric. Inc (USA) Bangkok Salakphon Ltd. (Australia)

RESEARCH & DEVELOPMENT

The company's R & D efforts continue to be dictated by the need for market orientation.

In the face of stiff competition , in order to maintain the profit margin , the focus is on developing products of increased value addition. Accordingly manufactures of sems, track bolts, automotive nonfasteners components like steering knuckles , gudgeon pins,

startermotor, pin ions are being planned. The fully computerized five station part former and boltwasher assembly machine presently under installation and commissioning/ordered would facititates this. Stainless-steel fasteners & fasteners which are percolated with micro encapsulated anaerobic thread cocking adhesive are also being considered as value added products.

Special purpose machines and CNC turning centers are being added to the manufacturing facilities to increase productivity and consistency in quality of SPECIAL FASTENER, especially for the automotive application.

Since the tools form considerable parts of the manufacturing cost, in house heat treatment of the tools has already started. Plans are being drawn up to introduce vacuum hardening, organic treatment and other tribiological coatings to improve the tool life.

In order to cut down development cycle time for SPECIAL FASTENER in the automotive industry which is the largest consumer for company's products technical collaboration is being entered into a leading manufacturer of automotive fasteners in the world . The company's effort on the whole should meet the today's customer's requirements, namely, zero defects, low cost, just in time delivery and short development cycle time.

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LIST OF MAJOR PLANT AND MACHINERIES

Sl. no.

Plant and Machinery

No. Off

CNC Machines

Flat Rolling

12

Circular Rolling

16

Nut Tapping

Drilling

Single Spindle Secondary Operation Machines

Centreless Grinding

Pointing

Turning

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PRODUCT PROFILE

LPS has a capacity to produce over 10,000 MT of precision engineered fasteners.

LPS offers over 6000 / 8000 kinds fasteners with diameter ranging from almost all product category .

3mm to

24mm and in grade of 8.8 , 10.9 , 12.9 45H , R , S , T , V , Grade 5 & Grade 8etc. for High - grade alloy steel goes into LPS high tensile

precision fasteners for superior fatigue resistance and closer tolerance level. The company produces two types of items : Standard fasteners Specialized fasteners

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The standard fasteners confirms to international and national standards. These are as follows: Socket head cap screw (allen bolt)

Socket shoulder screws

Low head socket cap screws

Button head socket screws

Socket set screws

High tensile hex head wrenches

High tensile hex head bolts

High tensile friction grip bolts and nuts

High tensile hex nuts

Dowell pins

Hexagonal wrenches (allen keys)

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A very comprehensive range of special high tensile bolts/screws, studs, nuts, and special cold forged components in the size range of 3 mm to 30 mm are manufactured . These special products are made to satisfy a very exacting Engineering standards.

LPS Range of Special Products cover the automobile, tractor, heavy earth moving equipments, textile machinery and machine building industries. To name a few of the special products in which LPS is the undisputed leaders are:-

Durlock Bolts WheelHub Bolt Flange Bolt Connecting Rod Bolt Gear Shaft Axles Stud

The special fasteners are made to customers specification of size, grade and finish to the point of precision. Specials currently being manufactured.

Wheel bolts/ hub bolts and nuts Connecting rod bolts Cylinder studs Axle bolts Flange bolts Counter weight bolts Round head bolts

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PRODUCTS DETAIL'S

SOCKET HEAD CAP SCREWS:-

One can get the extra strength and fatigue resistance that is needed for total reliability. In high strength fastening from L.P.S Socket Head Caps Screws. L.P.S Socket Head Cap Screws have cold forged head, which ensures stronger heads. Due to uniform grain flow of the material. Threads are rolled and kept uniform with closer tolerances, smoother surface and better size controls. Socket head cap screws are made out of high-grade alloy steals and heattreated in atmosphere controlled furnaces which surface carburisation and decarburisation.

COUNTERSUNK SOCKET HEAD SCREWS :L.P.S countersunk socket head screws are manufactured out of high grade alloy steels to suit the specifications of every lot. One can achieve smooth flush mounting with reliable and dependable fastening. They also provide increased fatigue. L.P.S-CSK screws assures flush seating and close all round head contained due to closely controlled head angles in cold forging closely controlled rolled threads ensure tighter fit And stronger assemblies. Non-slip wrench engagement for full tightening is achieved with deep socket.

BUTTON HEAD SOCKET SCREWS :These are manufactured from grade alloy steel and forged head provide greater strength. Non slip wrench engagement for full tightening is achieved with deep sockets, which prevents the surface in which they are installed from getting marred . Threads are rolled with close controlled tolerances which ensures greater strength and superior fatigue resistance.

LOW HEAD SOCKET CAP SCREWS :Socket low head cap screws are used in applications where the clearances are limited. They are manufactured out of high-grade alloy steels for precision fastening. Rolled threads with

45

root radius increase fatigue life of threads and reduce the stress conservation. Uniform concentric socket depth helps in full engagement of wrench in for proper fastening.

SOCKET SET SCREWS :L.P.S SOCKET SET SCREWS are available in knurled cap point, cone point, flat point and dog point. They are manufactured from special grade alloy steel and heat treated in atmosphere controlled furnaces which ensures uniform hardened and higher strength without decarburisation rolled threads provide strength. Deep socket and reduced corners gives more key engagement and distributed stress which eliminates points of weakness where cracks may starts.

HIGH TENSILE HEX. HEAD BOLTS :LPS high tensile hex head bolts are manufactured in strength levels 80 kg/mm to 120 kg/mm and it offers several benefits to the economy minded, such as reduction in the size and number of fasteners required compared to conventional mid-steel fasteners there providing valuable savings in the cost and space. There are manufactured in the size range M3 to M24 and length from 6mm to 210mm.

HIGH TENSILE HEX. NUTS:L.P.S high tensile nuts are cold forged using quality steel on high-speed nut former. Heat treatment is done in atmosphere-controlled furnaces to suit the chemistry of every lot of steel and to ensure correct mechanical properties and tightening fatigues to fulfill standard requirements. Dimensions finish are costly and controlled to ensure smooth assembly with L.P.S high tensile Hex head bolts.

HIGH STRENGTH FRICTION GRIP BOLTS AND NUTS:L.P.S high strength friction grip bolts are mainly developed to have bolted with higher fatigue strength, than riveted or welded joints. They help in having fastener assembly and fewer number of bolts thus economizing the cost and main power requirements.

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SPECIAL FASTENER :L.P.S special fasteners are tailor made to meet the specific requirements of customers in range of 3mm to 24mm and in property grades 4.8 to 12.9. L.P.S special fasteners include wheel bolts and nuts, connecting rod bolts, counter weight bolts, cylinder studs, flange screws, axel bolts, shock absorber-mounting paints etc. Dimensions, finish and mechanical properties requirements are closely controlled to satisfy very exactly engineering needs of the customers. L.P.S special fasteners are very widely acknowledged and are in greater demand.

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PROCESS CHART

The process of manufacturing NUT & BOLTS are explained below with the help of flow chart :-

RAW MATERIAL FROM STORE

SAMPLE OF RAW MATERAIL FOR APPROVAL

WIRE DRAWING

FORGING

ROLLING

HEAT TREATMENT

GRINDING

PLATING/PHOSPHATING

FINISHING

OILING

LABORATORY
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PACKING

STORING

MARKETING

49

RAW MATERIAL :The Raw Material for production, comes in form of coil/wire bend. The basic raw material used in the production of these screws are CHQ carbon boron /alloy steel. The source of raw material is both INDIAN MARKET and FOREIGN COUNTRIES .

The Indian Market from where L.P.S purchase are :Mukund Limited Bombay. Bihar alloy Limited. Main Foregin countries from where L.P.S imports raw material are : Dongbou cooperation South Korea . Komorowaski company West Germany. Mitsui company ltd. Japan. Indian raw material is used in the production of HEX. NUTS and imported raw material is used in the production of high tensile screw and nuts.

VARIOUS DEFECTS IN RAW MATERIAL ARE :Loose scale Crack Seams Blow holes Decarburisation Hardness Pitting Chemistry

FORGING :This is an important step in making the product . There are two types of forging that are being done . Hot Forging Cold Forging

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M.C.S is mainly concerned for the cold forging operations. Cold Forging is another form of

swaging operation and is used for the manufacture of bolts ,rivets ,hexagonal Sockets screws ,screws and similar headed item. The importance of cold heading operation lies principally in the saving of material, very little or no scrap being produced . A header being a high speed automatic production machine, it result in low labour cost with proper cost with proper production runs . Because of the method flowing the material ,it often result in the better structure of the metal and hence stronger parts. The machine produces parts to close tolerance and fairly smooth finishes. Cold heading can be done on a wide variety of materials(capable of being cold worked without hardening too rapidly e.g steel having 0.45% carbon or lees and alloys which work rapidly). A typical examples for manufacturing the bolt from cold headed operation is described below. A ductile material in the form of rod is fed on to the machine , where it is cut in standard pairs of jaws , and subjected to two or three blows to form the head roughly . It is then repositioned in the another die for final shaping and sizing and then thread rolling is done on automatic machine whose output rages from 50 to 150 pieces per minute . Some of the machines used in cold forging are:Bolt Maker 5L4 3/8 100LS Quarter B.M 6L4 5/8 S-325 S-340 CHD 82 CH16 SSSM Nut Former 124 CLF Maker's Name National Kayser, Germany -do-do-do-doSakaMuRa Co Ltd Japan -do-doChun-Zu Taiwan -doDavenport , U.S.A Maker's Name National Kayser, Germany

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ROLLING :The rolling of the bolt depends upon the requirement of the customers. It is very important step in manufacturing process. Rolling is the only thing which differentiate the screws and bolt . If the threading is on the whole cylindrical surface , then it is called screw, otherwise it is called bolt. There are two types of Rolling machines:FLAT ROLLING MACHINE :In this machine the die are flat and the bolt is fed through the 2 rolled dies .There are 4 flat rolling machine available. We can have different dies for different pitch diameters. CIRCULAR ROLLING MACHINE :There are 2 rolling dies between which the bolt is kept and the threads are formed on the bolts or screws. In this machine there are two division:In Feed Through Feed (Automated) (Manually)

HEAT TREATMENT :Heat treatment is an important operation in the manufacturing process of machine parts and tools . It may be defined as an operation of heating and cooling of metals in the solid state to induce certain desired properties into them . Heat treatment can alter the mechanical properties of steel by changing the size and shape of the grain of which it is composed , or by changing its micro constituents. It is generally employed for the following purpose: To improve machinability . To change or refine grain size. To relieve the stresses of the metal induced during cold or hot working. To improve mechanical properties e.g tensile strenth, hardness, ductility , shock resistance to corrosion etc. To improve magnetic and electrical properties.

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To increase resistance to wear, heat and corrosion. To produce a hard surface of ductile interior.

The heat treatment of the product is divide mainly into 2 portions: HARDENING TEMPERING

HARDENING :Hardening is done to increase the strength of the material. There 3 furnaces and each furnace has 2 zones with it . The first zone is for pre heating the material and the second zone is to used for soaking the product till the required temperature is attained in the product . The furnace is called the shaker hearth furnace . It is electrically heated and the atmosphere inside it is ENDO GAS(AIR +LPG, 1O:1). There are 12 heating elements in the first chamber and 6 in the second chamber . The soak in time in each chamber depends on the diameter of the products .

TEMPERING :There are 2 furnaces . The furnaces is vertically tempering furnaces .There are heating elements on the chamber and hot air is continuously circulated inside the chamber .

In High Temp furnace hardening and tempering is done simultaneously . Hardening chamber has three zones and Tempering chamber has four zones.

GRINDING :Grinding is mainly done for finishing the shininess of the product . Grinding eliminates tiny cracks due to hardening and tearing is always present to some extent in any material removal method .

Centerless grinders ( CLG ) are used for grinding purpose . These are semiautomatic and manually.

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PLATING AND FINISHING :Finishing and plating is done to remove the impurities in the product and to increase its corrosive resistance and to give it a better look. This operation is done after the material has been heat treated . The plating department receives the work order from the PPC department as to what type of finishing is required for the product . The type of finishing required for the product is given by the customer , alongwith the design . The plating and finishing is divided into 3 main portion Pre treatment Plating (electro plating) Post treatment PRE TREATMENT :This is basically the clearing and activation of the products so as to get an adherent deposits (i,e. Oil removal etc.) on the products. PLATING :The product are mainly zinc plated , depending upon the requirement of the customer . This is done to improve the corrosive resistance of the material . Electrolyte used during plating is a combination of (Zinc metal +Zinc Chloride +Boric Acid). Zinc Metal = (25 gms to 35 gms )/litre.

Zinc Chloride = (100gms to 120gms)/litre. Boric Acid = ( 30 gms to 35 gms )/litre.

During plating Zn plate is positive charge and material to be plated is negatively charged. Plating tank is combination of two electrodes one of which is consumable i.e. Anode and electrolyte.

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POST TREATMENT :This is done to increase the corrosive resistance of the steel. The process is called passivation. According to the requirement Zn plated or phosphated (black finishing) products are dipped into the respective passivation solution . The product is kept for 1 minute in the solution and dried after wards . Different colours imparted during Passivation Colours Yellow Nitric Acid + Solution Sulphuric Acid + Sodium Dicromate (330gms.)/lts

(8ml to10ml)/lts. (55ml to 60ml)/lts. White Nitric Acid

+ Ginthon Oil 550 ( 8ml to10ml)/lts.

( 4gms to 6gms)/lts Green Black

Olive 862 (120ml to 140ml)/lts Kempass 66A+Kempass 66B (90ml)/lts. (90ml)/lts

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SECONDARY OPERATION

The operations, which are done after first operation that is forging are known as secondary operation.

Following are the secondary operations and machines used for those operations. Sl. No. 1 2 3 4 5 6 7 8 Operation Thread Rolling Grinding Pointing Bend Removing Drilling Machine Nut Tapper Facing Undercutting Name of machine used Thread Rolling Machine Thread Rolling Machine Center less Grinding Machine Adda / Drilling machine Center less Grinding Machine Adda / Drilling machine Traub Traub

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PRACTICAL EXAMPLE Product Name Material Grade Hardness Required Finish Tolerances Allowed :Linear 0 - 60.1 6 - 30 0.2 30 - 1200.3 0- 30` 14 - 2913 M12 x 1.75 x 42 Hex Collar Bolt 4140/4037 10.9 32 - 38HRC Blackened & Ground

Angular Part No.

Let us consider an example of HEX. Collar Bolt from Raw Material to the finished product.

As required material of product is 4140\4037, so the wire from the Raw material ,of size M12 is brought on to the forging machine. The colour code & any defect of material is inspected on the machine by operator Quality Control Supervisor.

Then the wire is loaded on the forging machine and the forging of the bolt is started . There are four steps in forging of the bolt i.e. there are a set of four dies in which the formation of bolt takes places. After forging the supervisor of Q.C Deptt. check all the dimension of bolt according to the given dimensions in the drawing . The main dimension ,which are kept in mind , are Body Dia. , Thread Rolling dia. ,Collar dia ,across flat Stamp, under head Radius head height etc. After completion of forging , the bolt is transferred to Automatic lathe / Traub for pointing ,undercutting Grooving and Collar dia Turing.

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After the completion of process on auto lathe the floor inspection is done by Q.C Supervisor . The under cut angle , radius and pointing angle are checked on the profile projector.

After the completion of the process, the bolt is sent to the grinding machine for the thread rolling dia grinding. The final size of T.R.D is maintained at this machine.

After finalizing the T.R.D. dia ,the bolt is sifted to the rolling deptt. Where ,thread are formed on the rolling machine . The die no. is given in the drawing so that same die is used for rolling . There are two gauges for the checking of threads one is GO & another NOT GO. One of gauges should satisfy the conditions. The major dia. is checked by simple micrometer where as pitch dia. is checked by the pitch micrometer. The minor dia. is checked on the profile projector.

After thread rolling ,bolt is transferred to heat treatment section required hardness is obtained their, hardness is checked on Rockwell Hardener Tester .

After heat treatment, finishing is done for required surface finish. If required oiling is according to customer requirement. Final inspection is done in laboratory for approval of finished product. Then product is send to packaging dept.

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CLASSIFICATION OF DEFECTS Sl.no fasteners ( 1.) Types of fastners Hexagonal socket ,Head Cap Screw Width across flat Thread length,screw length, pitch dia. Thread shank dia., height of head major dia. concentricity, fillet radius, depth of socket ( 2.) Hexagonal Bolts and Screws Thread major Thread pitch dia. under size, Major Defects Minor Defects

dia. Thread picth thread length, bolt length. dia. Oversize, width across flats Height of head,end of screws Perpendicular of head to shank

Black ( 3.) Hexagoanl bolt

Thread major dia Thread picth dia. under size, thread picth dia. Oversize, width across flats thread length, bolt length. Height of head,end of screws Perpendicular of head to shank

( 4.)

Socket head Cap screw

Thread major

Minor dia., thread length, bolt

dia. Thread pitch length. dia. Oversize,depth of socket key ,head height

( 5.)

Coach bolts

Thread major dia Thread picth dia under size, thread picth dia. length, bolt length.

thread

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Oversize,width of square necks.

Shank dia of square neck, height of head ,head dia., end of screw

( 6.)

Slotted counter sunk

Thread major dia Head dia, slot width, slot thread picth dia. depth ,screw length, thread length,thread picth dia under size, end of screw perpendicular head to shank

head machine Oversize. screws

( 7.)

Grub screws

Thread major dia Head dia, slot width, slot thread picth dia. Oversize. depth ,screw length,head length, thread picth dia.

( 8.)

Slotted cheese head screws

Thread major dia Head dia, slot width, slot thread picth dia. Oversize. depth ,screw length,head length, thread picth dia

METHODOLOGY Primary Data: For obtaining the primary data for my project, I used two research instruments: Questionnaire Structured Interviews 1.For Questionnaire: Sample size: 10

CHAPTER-3:DATA ANALYSIS & DATA INTERPETATION Q1.Can you describe steel company's overall approach to maintaining its competitive position ?

Chart showing steel companies overall approach

Product Oriented Price Oriented Brand Oriented

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Q2.What have been the main challenges that the company has had to face and how has it dealt with these challenges?

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Q3.Does the company have specific plans for growth in the next few years?

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Q4.What do you think which growth strategies is most effective?

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Q5.Is the Government supporting the steel industry?

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Q6.Is the growth and expansion strategies of the company are effective?

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Q7.What are people experiences about the steel company product ?

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Q8.Does Steel industry has good impact on the Indian economy ?

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Q9.What type(s) of machinery do you use?

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Q10.What type of facilities you get fom your suppliers ?

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CHAPTER-4:Suggestions
1. Key Challenges for Retail Managers:
A retail manager's goal is to maximize

productivity. This is tough. Store staffs likely include inexperienced, part-time or seasonal employees. Retail hours are long. Sales targets may seem unreachable. Yet, in this setting, good retail managers thrive. They are skilled in four primary areas which are: Managing time. Recruiting and supervising staff. Building skilled and motivated sales and service teams. Managing change.

2. Time -- a Fixed Resource: Tight budgets. Lean staff. Information overload. It's never been
harder for retail managers. Those who manage time well can do these things: Know when to solve a problem immediately, when to put something off and when to delegate. Eliminate time wasters. Handle interruptions. Say "no" to unreasonable demands.

3. Teamwork Lightens the Load: For retail managers to have any personal life, they must
be able to trust staff to work and solve problems on their own. Skilled managers continually work at: Delegating responsibility. Establishing group goals. Aligning staff people and their roles so that cross-training and cooperation can thrive. Identifying and securing resources so people can do their jobs well. Motivating the team to work together and support each other even in stressful times.

4. In Retail, Change Is a Given: Change in retailing is what drives success. Styles change.
Customer needs and wants evolve. Competitors jockey for market leadership. Retail management means managing change by: Anticipating change. Leading group problem solving. Managing transition. Championing innovation. Reducing resistance to change. 5. Retailers Value Training: According to a study released at the National Retail Federation's 90th Annual Convention, management skills are the most frequently addressed training subject of US retail companies. "As retailers expand, acquire properties, reposition or rebrand, managers become the critical players in communicating and instilling change throughout the organization," stressed Michael Patrick, CEO of MOHR Learning, the company that conducted the study. "Clearly retailers want to make sure their managers have the skills needed to do this

CHAPTER-5:LIMITATIONS AND CONCLUSIONS

I have noticed that the most commonly talked about disadvantage of the fast fashion model in retail business is the cost of production due to the short production runs. What are the other likely disadvantages? I seem to find this model to assume or rather target people with readily disposable incomes which may make it difficult to plough money back if this group is small. In this context, can lack of disposable income on the part of customers be a disadvantage? What does the group think about this line of thought and what could other disadvantages be Lack of disposable income is inevitably a disadvantage in retail, but when customers leave one market segment in favour of another there is a benefit to those operating in that segment - fast fashion retailers targeting the value market achieve large volume through their low pricing. By providing close copies at a fraction of the cost of the originals they appeal both to low incomes and also higher income groups, who purchase more frequently. Other disadvantages include sustainability issues - short product lifecycle - more frequent purchases linked with more clothing going to landfill - more transportation - more natural resource Ability to offer personal service A small retailer may know all his clients personally due to constant interaction with them. He would know the tastes and preferences of his clients to be able to offer them a better personalized service, catering for their unique needs. A large retailer would not be able to do this as its aim is to sell, sell and sell. Time is money is such a large business and the more rapidly it sells, the higher the profit. Special small orders from customers are rarely accepted, especially if these do not generate enough cash to generate the required rate of return for the business. The customer may be considered nothing more than a number in a large superstore, but he would be a treasured regular customer for the small retail store. Labour problems The fact that it is constrained by time, pressure is transferred to the large retail stores staff, which is expected to do more in less time. Most of the work is repetitive and they can hardly engage in conversations with the client or with colleagues. This leads to lower morale on the place of work and more costs of recruitment and retraining if workers regularly resign from their work.

Less control over pilfering

With a huge surface area full of thousands of items, it is difficult to have eyes all over the place to control pilfering. Large retailers are faced with the problem of people stealing small amounts from the shelves while no one is looking. Installation of closed-circuit cameras is essential but having someone to go over all the tapes in real-time to check that no one is slipping items into their handbag or clothing comes at a large cost. The temptation to steal is higher in a large shop than it is in a smaller shop where it is easier to be spotted by someone. Thieves may also think that it is less likely for larger retailers to notice occasional pilfered items due to the large quantities of material. Shoplifters are regularly convicted by large retailers than they are by the smaller ones. The business is faced with a loss-loss situation where it either invests in security or else it suffers the loss of pilferage. On the other hand, the retail inventory method is only accurate if all pricing across the board is the same and all pricing changes occur at the same rate. In most cases, this is not realistic in retail because of the many variations that exist in merchandise pricing. For example, depreciation, markdowns, product damage and theft can affect the price of the retail inventory. For this reason, any calculations made using the retail inventory method should serve only as an estimate.

CONCLUSIONS
The Retail Sector in India can be split up into two, the organised and the unorganized. The organized sector whose size is expected to triple by 2010 can be further split up into departmental stores, supermarkets, shopping malls etc. In terms of value the size of the retail sector in India is $300 billion. The organised sector contributes about 4.6% to the total trade. The retail sector in India contributes 10% to the Gross Domestic Product and 8% to the employment of the country. In terms of growth the FMCG retail sector is the fastest growing unit and the retail relating to household care, confectionery etc, have lagged behind. The foreign retail giants were initially restricted from making investments in India. But now FDI of 51% is permitted in India only through single branded retail outlets. Multi brand outlets are still beyond their reach. Again they can only enter the market through franchisees,. This was how Wal-Mart had entered joining hands with Bharti Enterprises. On line retailing is still to leave a mark on the customers due to lacunae that we have already mentioned.

In a nutshell we may conclude that the retail industry in India has a very bright future prospect. It is expected to enrich the Indian Economy in terms of income and employment generation.

BIBLIOGRAPHY

To make this project, I took help from some secondary sources and these are :The Books: Business Organization, T.N Chabra, 3Rd edition , 2010, Srijain publishing. Marketing Management, T.R Jain , 2nd edition, 2005, oxford publisher. Marketing Research, Naresh Malhotra, 3rd edition,2011, Pearson publishers. Marketing Strategies, Michael porter, 8th edition, 2012, Tata MacGraw Hill.

WEBSITE www.multicolorsteels.com www.wikipedia.com/marketingofsteels.html