AN ORGANIZATION STUDY AT

TOLINS TYRES PVT LIMITED

KALADY, ERNAKULAM
Submitted by
VINEETH. P .KURIAN
(Reg. No: 14050)

Under the Guidance of

Asst.Professor ROMMEL STEPHEN.

Submitted in partial fulfillment of the requirements

For the award of the degree of

MASTER OF BUSINESS ADMINISTRATION

of Mahatma Gandhi University, Kottayam

MAY-2015

DE PAUL INSTITUTE OF SCIENCE AND TECHNOLOGY

(DiST)
ANGAMALY SOUTH P.O., ERNAKULAM DIST., KERALA
(Affiliated to Mahatma Gandhi University, Kottayam & Approved by AICTE, New Delhi)

DE PAUL INSTITUTE OF SCIENCE AND TECHNOLOGY

ANGAMALY SOUTH P.O., ERNAKULAM DIST., KERALA
(Affiliated to Mahatma Gandhi University, Kottayam)

CERTIFICATE
This is to certify that the work entitled

AN ORGANIZATION STUDY AT TOLINS TYRES PVT

LIMITED, KALADY.
Submitted to Mahatma Gandhi University
in partial fulfillment of the requirements for the award of the degree of

MASTER OF BUSINESS ADMINISTRATION

is a bonafide record of work done by

VINEETH.P.KURIAN
(Reg. No.14050)

ROMMEL STEPHEN (Faculty Guide)

___________________________
Fr. (DR.) James Chelapurath VC (Principal)

Dr.Unni C. J. (HoD)

Submitted for the viva voce examination held on ________________________

ACKNOWLEDGEMENT
I would like to take this opportunity to express my sincere gratitude to all those who
have helped me throughout this project work. It gives me immense pleasure to
acknowledge all those who have rendered encouragement and support for the
successful completion of this work.

I express my heartfelt thanks to Fr.(Dr.) James Chelapurath VC (Principal) De

Paul Institute of Science and Technology(DiST). I like to express heartfelt
gratitude to my guide Mr.Rommel Stephen, Assistant Professor, School of
Management, DiST, Angamaly and to Mr.Abraham Kuruvila General Manager
and all other department staff.

I also extend my sincere gratitude to Prof. (Dr) Unny C. J. , HoD, School of

Management, De Paul Institute of Science and Technology(DiST), Angamaly,
whose advice and guidance helped me in the successful completion of this work.

Angamaly
Kurian

Vineeth P

DECLARATION

I, VINEETH P KURIAN hereby declare that the

report titled AN

ORGANIZATION STUDY AT TOLINS TYRES PVT.LIMITED,KALADY,

ERNAKULAM ; submitted to the Mahatma Gandhi University in partial
fulfillment of the requirement for the degree of Master of Business Administration ,
is a bonafide work, carried out by me during the period of my study 2014-2016 at
De Paul Institute of Science and Technology(DiST), Angamaly, under the guidance
of Mr.ROMMEL STEPHEN

Angamaly
KURIAN

VINEETH P

CHAPTER 1
INTRODUCTION

1.1 INTRODUCTION

Organizational study is the systematic study and careful application of

knowledge about how people as individuals and a group act within an
organization. Purpose of an organizational study is to define the legal
and corporate structure of the business. An organizational study may
also include professional background information about the business
and its principles of the business and what skills they can contribute to
the business.

As part of Master of Business Administration program, the researcher

conducted organizational study in TOLINS TYRES PVT.LTD,
KALADY. This work will give a complete picture about the
organizational structure and departments of the organization and also
study each department process and function.

Tyres are essential to road and surface mobility, providing the moving
surface of many transport vehicles and the only contact point with the
ground. Simple in appearance, tyres are quite sophisticated products.
While concluding the study the researcher got a real idea of the working
of the organization and harmonious working conditions of the
employees in TOLINS TYRES PVT.LTD, KALADY. A fair
organizational study will help an organization and the researcher to
develop a lot. The suggestions given by the researcher will help to
improve the efficiency and effectiveness of the organization in a
systematic manner.

CHAPTER 2
DESIGN OF THE STUDY

2.1 OBJECTIVES OF THE STUDY

To study the organizational structure and functions of the various

departments.
To know about each department of the organization.
To identify and evaluate the strength, weakness, opportunities
and threats faced by the organization.
To know about the export procedure.
To study about the products.

2.3 METHODOLOGY

The term research refers to the systematic methods of formulating the

research problem, formulating a hypothesis, collecting facts and data
analyzing these facts and researching certain conclusions towards the
concerned problem. It can also be defined as a scientific and systematic
research for pertinent information on a specific topic. In facts, research
is an art of scientific investigation. It is actually a voyage of discovery.

2.3.1 Research Place

Tolins tyres Pvt.Ltd, Kalady

2.3.2 Period of study

It was conducted in 30 days
May 2-31st May 2015

2.3.3 Sources of data

The information and data were collected from both primary and
secondary sources
Primary Sources
Secondary Sources

1. Primary Sources
Primary data do not exist already in records and publications. The
researcher collected the information through different methods. It
includes,

Direct interview with the department heads

Direct interview with the managers
Direct observation
Interaction with the workers

2. Secondary sources
Secondary data refers to those data, which are gathered for some
other purposes and are already available in the firm internal
records and commercial trade or government publications.
The various sources used in the form of:

Various company records

Company manuals
Journals
Magazines
Internet

2.4 LIMITATIONS OF THE STUDY

 The time period was inadequate to conduct a

detailed study
Lack of time to officers and workers

The officials were not ready to show their

financial statement

CHAPTER 3
INDUSTRY PROFILE

3.1 WORLD SCENARIO

The automobile industry is one of the dominating sectors because many

economic activities rely on and are linked to automobile production. If
you include suppliers, car services, garages or retailers a total of about 5
million employees depend on the success of the automobile industry.
With changing technologies, production concepts, strategies and
products, the automobile industry is often an initiator of innovations in
other related industries as well.
As the world comes out of economic recession, the first sector to
witness positive movement has been the automobile sector and since its
linked to related sectors like tyre industry, plastic industry and metal
processing, all the sectors are witnessing a silent revival. As more and
more people look at buying automobile, slowly the tyre industry is also
set to attain a positive movement from the pits, where it has been for
most of last year. The recession had people reducing spending across
the board, which meant they had been putting of those new tyres on
hold until things start to look a little better on the economic front. Now
as the economy is moving out the red slowly, tyre sales are witnessing a
welcome revival even better than the automobile companies and a lot of
second hand car owners have also been investing in the new set of tyres
instead of buying a new automobile altogether.
According to a report from The Freedonia Group, "World demand for
tires is forecast to rise 4.7 percent per year through 2015 to 3.3 billion
units. In value terms, the tire market is projected to advance 6.5 percent
annually over the same span to $220 billion. The large motor vehicle
tire market will see acceleration in growth through 2015. Stronger gains
will be registered by the industrial and other tires segment, which
includes a variety of tire types, including bicycle, motorcycle and offroad tires. The Asia/Pacific region is by far the largest market for tires.
Tyre companies were first in the early on 20th century, and grown in
partnership together with the automobile business. In the present day,
above 1 billion tyres are created annually, in over 400 tyre factories,
with the three top tyre makers commanding a 60% total market share.
The US tyre manufacturing industry alone consists of about 100
companies with combined annual revenue of about $15billion. The

industry is highly concentrated and the top four companies generate

more than 75% of revenue. Major companies include Goodyear,
Bridgestone, Michelin, Cooper.
Tyre manufactures has become extremely technical and forward
thinking as manufactures look to push the boundaries of what can be
achieved through new technologies. Whether its improvements in fuel
economy, handling performance or safety, technological development in
the tyre world are making a big difference.
No matter if the vehicle is old or new, the need for tyre remains a
constant and with number of second hand vehicle sales increasing and
as compared to new vehicles, the world wide consumption of tyres to be
more than automobiles. With the developing nations churning the
growth engines of the world, commercial vehicles (van, utility and light
trucks) are much in demand in both developed and developing nations;
such vehicles require both more and larger tyres than passenger cars.

3.2 INDIAN SCENERIO

The Indian tyre industry has been witnessing tremendous growth for the
past few years on account of growth in automobiles demand, especially
in passenger vehicles and two-wheeler segments. In fact, availability of
raw material (natural rubber) and ultramodern production facilities has
led the country to emerge as one of the worlds most competitive tyre
markets. Driven by the strong demand in automobile OEM sector and
replacement market, the India tyre industry has been witnessing
stupendous growth from since the last two fiscal years.
Further, according to research reports, Indian Tyre Industry Forecast to
2015, the tyre production in India is anticipated to reach 191 Million
Units by the end of FY 2016. Moreover, manufacturers are expected to
invest huge amount into the industry over the next few years, with a
major proportion of this investment directed towards the radial tyre
capacity expansion.

Tyre manufacturers are coming up with new technologies to provide

customers with better products and services. The concept of green
tyres is becoming a paradigm of the countrys competitive edge.
Technologies like self inflation by Goodyear and run flat tyre (RFT) by
Bridgestone are paving the way in Indian market. This new category of
tyres is now being widely accepted in India. Several greenfield projects
are also there in pipeline to facilitate an increase in the domestic
production capacity to meet the growing tyre demand in the country. It
has also been found that Indias market for radial tyres in commercial
vehicles section is still in its infancy.

3.2.1 ACQUISITION OF TECHNOLOGICAL

CAPABILITIES

Radialisation has been a significant dimension in the acquisition of

technological capability in the indian tyre industry. The degree of
radialisation is a clear indicator of the status of road development,
vehicle engineering and the economy in general. In spite of some
constraints and limitations, the tyre companies in india have kept pace
with the technological improvements that radicalization signifies and
offered state of the art product, comparable to the best of the world.
Radialisation ids linked to factors such as road development, overload
control and retreading infrastructure. Some of the advantages of
radialisation are additional mileage, fuel saving and improved driving.
The passenger car segment switched to radial tyres in a short period of
time, with radial tyre penetration level for the category reaching 100%.
However, penetration level of radial tyre has also started to increase
rapidly in the light commercial vehicles and truck & bus segment. This
segment will be the largest growth area over the next few years.

3.2.2 TECHNOLOGY GENERATION

Technology generation in the Indian tyre industry is essentially geared
to development research, involving the change of tread design,
reinforcement material etc. most of the major players dont engage in
basic research due to the high costs involved. The source of technology
for the domestic firm has been through reverse engineering, joint
ventures and collaborations.
The emphasis given by Indian tyre companies to applied research and
the setting upof well equipped in house R&D centres by the companies,
which are manned by the experts and experienced professionals, have
also helped in technology upgradation. Indian tyre technology has
exhibited versatility in maintaining inflow of technology through
foreign collaboration and tailoring to the Indian needs. R&D is
essentially business or markets driven. However, raw material suppliers
could also help in conceiving new projects. Compound development
and in process problems have been the main thrust of in house R&D in
the Indian tyre industry.
Tyre technology upgradation is an extremely difficult process,
particularily in the Indian scenario, due to several factors. First, since
tyre technology encompasses various disciplines such as polymer,
chemical, steel etc. compromises have to be made in the upgradation of
technology because of,
a) The conflict and complimentary inherent in these disciplines
b) The usage pattern of the tyres
c) The cost factor.

Further, a tyres performance could be affected due to factors such as

the weather, loading pattern etc. Despite these bottlenecks
technology upgradation in Indian tyre industry during the last few
decades has significant. The emphasis given by Indian tyre
companies to applied research, the setting up of well equipped in

house R&D centers by large tyre companies, manned by experts and

experienced professionals have also helped in technology
upgradation. Indian tyre technology has exhibited versatility in
maintaining inflow to technology through foreign collaborations and
tailoring the same to Indian needs.

3.2.3 AUTOMATION
Tyre production traditionally, is a multi stage, with significant inter
stage difference in the intensity of labor requirement and a highly
complex process involving the use of around 37 different materials
including rubber, steel, fabrics and vulcanizing materials. The
production system in the tyre industry has been traditionally very
labor intensive. The automation of manufacturing processes has
increased gradually, which has slashed the size of the workforce to a
considerable degree and has effected a change in its composition.
The degree of automation has been greater in the area of radical
technology, while cross ply technology is still labor intensive. The
firm has been resorting to automation in order to tackle problems
related to labor unionization and indiscipline in the sector. The
rationale provided by the firms for the increasing drive towards
automation of the manufacturing facilities has been that high quality
and uniformity of the final product usually cannot be guaranteed
with a labor intensive process.

3.2.4 NEW POLICY INITIATIVES

The tyre industry in india has had to grapple with raw material price
volatility, rupee appreciation and cheap Chinese imports. In this
connection, some of the recent initiatives by the government to
facilitate the growth of sector include;
a) No WTO bound rates for tyres and tubes

b) No restrictions on the imports of all raw materials required for

tyre manufacture excepts carbon black, which has been placed in
the restricted list
c) Increasing thrust on development of road infrastructure.
3.2.5 FUTURE PROSPECTS OF THE INDIAN TYRES
The Indian tyre industry is expected to show a healthy growth
rate of 9-10% over the next five years, according to a study by
Credit Analysis and Research Limited(CARE). While the truck
and bus tyres are set to register a compounded annual growth rate
of 8%, the light commercial vehicles segment is expected to show
a CAGR of about 15%.
The growth of the sector is closely linked to the expansion plans
of the automobile companies, the governments thrust on
development of road infrastructure and the sourcing of auto parts
by the global original equipment manufacturers (OEMs). Some
significant hurdles towards attaining these projected growth rate
could be raw material related price volatility, rupee appreciation
and the looming threat of cheap Chinese imports. The Indian tyre
companies need to make active efforts to explore newer markets
as the existing markets for Bus-Truck tyres, which account for
about 45% of the total exports volume, is nearing saturation.
There is also an urgent need to increase the degree of
radialisation in order to safeguard their share in the exports
markets. Global tyre manufactures have been making constant
efforts to innovate and offer a diverse range of products such as
tyre with pressure warning system, run flat tyres, eco friendly
tyre and energy efficient tyres. In this context, the Indian
domestic companies have to pursue a growth strategy of
continuous innovation and increasing emphasis on product
differentiation.
3.2.6 MAJOR DOMESTIC PLAYERS
Major players are MRF, JK tyres, Apollo tyres and CEAT, which
accounts for 64 % of the organized tyre market. The other key

players include Modi rubber, kesoram industries and Goodyear

india with 11%,7% and 5% respectively. Dunlop, Falcon, Tyre
corporation of india ltd (TCIL), TVS-srichakara, Metro tyres and
Balakrishna tyre are some of the other significant players in the
industry.

CHAPTER 4
COMPANY PROFILE

4.1 COMPANY VISION AND MISSION

Standardization of operations at all levels, right from
procurement to the last mile, is the mission in front of us.
Procurement of right quality raw materials from source,
sophisticated R&D, quality control implementation at all
production plants, ultra modern machinery and a chain of
retail outlets etc. are leading factors which help us to
accomplish this mission. As always we are confident of
achieving these essentials and fulfill our goals to become
the leading player in the continent.

4.2 QUALITY POLICY

1.
2.
3.
4.
5.
6.

TOTAL CUSTOMER SATISFACTION

OPPORTUNITY COST
LESS PRICE
INNOVATIVE
NATURE GOOD RELATIONSHIP
SYSTEM FOR CONTINUAL RELATIONSHIP

4.3 THE HISTORY OF THE COMPANY

The companys corporate headquarters and production

plant are spread over an area of 50 acres suited along
the M.C road state high way KALADY. TOLINS group is
headed by its founder and chairman Shri. K P Varkey and
competently assisted by his son and the Managing
Director shri. K V Tolin, along with well qualified and
dedicated workforce. During 1982, shri. K P varkey has
sparked the start, as an SSI unit and submitted his
entrepreneurial skills, vision and commitment over the
years to become this flagship venture TOLINS GROUP.
Over a short span of time, the group has succeeded in
developing TOLINS brand into one of the leading rubber
product and tyre manufacturing companies in the
country. Our overseas manufacturing unit in UAE has also
started producing quality product with the latest
technology.

4.3.1 FUTURE AND GROWTH PLANS

The companies turnover has already crossed Rs.5, 000

million and it is expected to touch rs.10, 000 million in
the next two years. Tolins capacity is projected to
expand from the present 2,000 tons a month to 4,000
tons. R&D lab is equipped with highly sophisticated and
rare equipment in order to develop and monitor
innovations, stages of production, and create critical
computing parameters for the present and future
requirements.
The company believes theat the quality is the last word
rather than the price. The company always tries to treat
their customers with great respect, striving to go to the
extra mile and achieve highest excellence in the service
provided to the customers. The management strongly

believes that the experience combined with the drive,

honest, handwork, and the clean positive attitude of the
working personnel in the company carries the image and
reputation of the company.
Over the last years, Tolins group of companies earned
and maintained an excellent track record on the strength
of its superior quality product and totally dependable
services. It has become an icon amongst the tyres and
retread industry and crated a vast knowledge base in
both rubber and tyre industry which is most crucial to its
future organic growth.
The group has entrenched itself as a major tyre
retreading solutions provider across India, Middle East,
East Africa, Jordan, Israel, Kenya, Syria and Egypt etc.
TOLINS is the first Indian to enter and survive in the
American market for pre-cured retreading product, in the
worlds toughest and competitive environment.
The company is entering into producing tyres for two
wheeler and three wheeler segments.

4.3.2 PRIORITIES AND FOCUS

At present, 30% of Tolins production is devoted to

addressing the export requirements. In the domestic
market the company has a solid client base comprising
major State Public Sector units (STUs). Company has
also opened up sales in the US market recently and is
now procuring special moulds to develop patterns for the
US Market. Expanding the dealer networks in the

domestic market and opening up exclusive shops in

niche areas are our priorities.

4.3.3 AWARDS AND ACHIEVEMENTS

Best Exporter Award from Govt. of India for five

consecutive years.
2006-07
2007-08
2008-09
2009-10
2010-11

BERCHNOVA 2007 Entrepreneur of the Award for

the year 2006-07 by Berchmans institute of
management studies, S.B college changanassery.
GSO CERTIFICATION (2011)
ISO 9001 (2008)
Export Award for the best performance from
CAPEXIL (Chemical and Allied Export Promotion
Council of India)
The global malayalee councils business award for
the year 2004 to Chairman Mr.K.P Varkey.

4.4 PRODUCT OF THE COMPANY

1.
2.
3.
4.
5.
6.
7.
8.

Super Lug XT tyres.

Blocked Pattern tyres.
Farm King tyres.
Logan tyres.
Rib Pattern Roger tyres.
Farm tyres.
Rib Pattern Van tyres.
Star rib tyres.

9. Super lug tyres.

10.
Rubber molded components.
11.
Dies and moulds.
12.
Gears.
4.4.1

PRODUCT PROFILE

1) Super lug XT tyres

Salient Features:
Extra high traction treads design.
Excellent stability in wet and dry
conditions.
Deep tread design for extra long
service life.

2) Blocked Pattern tyres

Salient Features:
Block pattern for highway designed for
drive axle use.
Excellence in traction and breaking
performance
and
improved
long
mileage because of tough deep tread
block.
3) Farm king tyres
Salient Features:
Excellent stability in wet and dry
conditions.
Deep tread design for extra long
service life.
4) Logan tyres
Salient Features:
Block pattern for highway, designed for
drive axle use.

 Excellence in traction and performance

and improve long mileage because of
tough deep tread block.
5) Rib Pattern Roger tyres
Salient Features:
Rib/Lug pattern dedicated for all
position use.

Excellence in traction and

performance
and
improve
long
mileage and resistance to irregular
wear.
6) Farm tyres
Salient features:
Excellent stability in wet and dry
conditions.
Deep tread design for extra long
service life.
7) Rib Pattern Van tyres
Salient features:
Rib pattern dedicated for highways,
designed for all position use.
Excellence in traction and performance
and improved long mileage and system
to irregular wear.
8) Star Rib tyres
Salient features:
Tyres of vans and light trucks with
tread
pattern
adopting
stress
dispersion.
Long wear life and realizes excellence
in steering low noice and demonstrates
strong traction performance.

9) Super Lug tyres

Salient features:
Cross lug pattern for on and off road
conditions designed for drive axel use.
Tyre for dump trucks with excellence in
traction and breaking performance on
winding roads.
10) Rubber molded components
The rubber molded components are widely
used in various applications. Our rubber
molded components are made from high
quality rubber materials. These rubber
components can be availed at industrial
leading price.
11) Dies and molds
With the help of our modern like CNC
machines, we are able to fabricate a wide
range of dies and molds. These dies and
molds are designed and developed to make
suitable
for
applications
in
varied
temperature and pressure. Further, the
superior angled set and floating disc
arrangement allow them free from jam and
leak.
12) Gears
Company offers Gears, which are machined
from wrought bar stock and subsequently
heat treated to develop the required surface
hardness and tooth bending durability.
These are used in trucks, car, buses and
motor bikes and geared cycles. Further,

Tolins gears control speed and are of various

types such as ring and pinion, spiral gear,
hydraulic gears, reduction gearbox etc.
Further Tolins sprockets are teeth like
projections arranged on a wheel rim to
engage the links of a chain. These are used
in various applications in cement plants,
sugar mills, sponge iron plants fertilizer
plants, thermal power station, mineral
plants and other manufacturing industries.

CHAPTER 5
ORGANIZATIONAL STRUCTURE

5.1 ORGANISATIONAL STRUCTURE

TOLINS Tyres Pvt.Ltd is following the functional

organization structure. In this various organizational
activities are classified and divided according to
functions like Production, Marketing, Finance, Human

Resources, Material Department, Research and

Development Department etc. These classified
departments are put under the charge of individual
specialists to deal with the particular department.
This structure depends entirely on the organizations
objectives and strategy chosen to achieve them. A good
organizational structure will help the organization to
increase efficiency in its operations and it will also help in
the optimum utilization of available resources. The line of
command will be much clear in this type of
organizational structure. Individuals specialize and
departments tend to develop common knowledge across
the group. The disadvantages to this structure are poor
communication across groups and slow response to
changes in the environment.

5.2 ORGANIZATIONAL CHART

MANAGING
DIRECTOR

MANAGER

COMMERC
IAL &
FINANCE

MANAGER

MANAGER

QUALITY &
CONTROL

HUMAN
RESOURCES

FACTORY
MANAGE
R

FACTOR
Y
MANAG
ER

TYRES

TRM

OFFICER

LAB

COMMERC
IAL

ASSISTA
NT

PRODUCTI
ON

SUPERVISO
RS

SUPERVIS
ORS
WORKERS

OFFICE
ASSISTANT

WORKERS

RECEPTIONIST

SECURITY

CHAPTER 6
FUNCTIONAL DEPARTMENTS

In TOLINS TYRES PVT LTD, there are different

types of departments;

6.1
DEPARTMENTS

PRODUCTION

6.2
DEPARTMENT

HUMAN RESOURCE

6.3

MARKETING DEPARTMENT

6.4

FINANCE DEPARTMENT

6.5

MATERIAL DEPARTMENT

6.6

RESEARCH DEPARTMENT

6.1 PRODUCTION DEPARTMENT

6.1.1 PRODUCTION DEPARTMENT

Production means application of process to the raw
material to add use and economic value to arrive
at desired product by the best method, without
sacrificing desired quality. Production department
is headed by production manager who looks after

the timely production of products. The production

process is done by the production department.
The production department deals with the most
important function of Tolins Tyres Pvt.ltd. all
activities of the company are related with
production. The production department controls all
the production process in the organization. The
production manager is the main head of this
department. Factory manager and the store
manager come under the production manager. The
production processes are being carried out in three
different plants.
Production is the functional area responsible for
turning inputs into finished outputs through a
series of production processes. The AGM is heading
the department and makes sure that raw materials
are provided and made into finished goods
effectively. He ensures that work is carried out
smoothly and supervises procedures for making
work more efficient and more enjoyable. Production
manager gives leadership to the production
department. Around 150 workers are there in the
production department.

6.1.2 PRODUCTION DEPARTMENT HIERARCHY

PRODUCTION MANAGER

ASSISTANT MANAGER

EXECUTIVES

PRODUCTION
SUPERVISORS

WORKERS

6.1.3 PRODUCTION FLOW CHART

RAW MATERIAL

BATCH WEIGHING

MIXING
RE
PROCE
SS

LAB
TESTING

OK
COMPOUNDS

SCRAP

EXTRUSION
IN PROCESS
INSPECTION

OK
RAW MATERIAL

TREAD
CALENDARING

COMPOUNDS

IN PROCESS
INSPECTION
SCRAP

CALENDERED FABRIC

BIAS CUTTING

IN PROCESS
INSPECTION
SCRAP

OK

CUT PLIES

PLY CUSHIONING

CUSHIONED PLY

INCOMING
MATERIAL

BREAD WINDING
COMPOUN
D
IN PROCESS
INSPECTION
BEAD WRAPPING
OK

TREAD

COVERED BEAD
WOUND BED

CUSHI
ONED
PLY
CUT
PLIES

TYRE BUILDING

SCRAP
CUT
PLY

COVER
ED
IN PROCESS
INSPECTION

SCRAP

GREEN TYRE

TYRE PAINTING &

POKING
TYRE CURING

OK

IN PROCESS
INSPECTION
TRIMMING

SCRAP

IN PROCESSS
INSPECTION
SCRAP

IN PROCESS
TYRE
INSPECTION
REPAIR

SCRAP

OK

STOCKING

DESPATCH

6.1.4 PROCESS MAP

TECHNICAL
SPECIFICAT
ION

RAW
MATERIALS

MONTHLY
PRODUCTI
ON PLAN

MOULDS
SPECIFICATI
ON &
GUIDELINES

MANUFACTURING
ENGINEERIN
G
MATERIALS
&

HUMAN
RESOU
RCES

TYRES
POWER &
FUEL

DESPATCH PLAN

TO
6.1.5 MATERIAL USED INDESPATCH
RUBBER COMPONENTS
VARIOUS
LOCATIONS
The essential ingredients in rubber compound are as
given below:

Raw rubber or natural rubber.

Vulcanized rubber.
Carbon black.
Zinc oxide.
Accelerators.

 Activators.
Reinforcing agents.
Process oils or aromatic oils.
Anti degrader.
Filler.
Process aids.
Special additives.

6.1.6 MANUFACTURING PROCESS ACTIVITIES

A)COMPOUND MIXING
A Compound is made by mixing the required
additives into rubber. This mixing is accomplished in
two or more steps using a Banbury mixer. This
mixing is done in the chamber of the Banbury mixer
under high share and pressure using the rotors of
the machine so that the ingredients are uniformly
dispersed inside the rubber matrix. Different rubber
compounds are used in the different components of
the tyre.

The rubber compound is thus used for the

preparation of different components in subsequent
stages of manufacture.
1) Thread made from rubber compound
2) Sidewall - -do3) Thread cushion - -do4) Piles made from dipped tyre cord and
compound.
5) Chafer made from dipped square woven fabric
and compound.
6) Flipper made from dipped tyre cord and
compound.
7) Filler made from rubber compound.
8) Bead made from bead wire and rubber
compound.
9) Breakers made from dipped tyre cord and
rubber compound.

B)Cement preparation
Various cements, solutions, lubricants and paints
are prepared in the cement house using rubber
compound solvents and other raw materials. These
are then used at various stages of tyre
manufacturing.

C)Fabric dipping
Raw fabric (Nylon) as received is having very poor
adhesion to the rubber compound and has poor
dimensional stability. During the dipping process an
adhesion coating is applied to the surface of the
fabric to improve adhesion. The fabric is also
stretched and hot set to increase the dimensional
stability.
D)

Extrusion

Here compounds of the tyre like tread and sidewall

are prepared from rubber compounds using a dual
extruder. Extrusion is the process by which the
rubber compound is given definite continuous
shape. A thin sheet of rubber compound prepared
using a small 2 roll calendar is applied to the
bottom side of the thread. This thread is called
thread cushion. The continuous profile is then
cooled, and cut to required length which is used in
the assembling of tyre at tyre building.
E) Calendaring
Fabric calendaring is the process of coating both
sides of the dipped fabrics using rubber compound.
This is accomplished using a 4 roll Z type calendar.
The coated fabric is cooled and wound in liners to
avoid sticking. This goes to the next stage of ply
cutting.
F) Ply cutting (Horizontal and vertical BLAS
cutting)

For assembling a tyre several plies are used. For

example, a 16PR nylon truck tyre uses 8 plies and 2
breakers. Each ply is cut from the coated fabric rolls
prepared by calendaring.
Cutting is accomplished in a bias cutter. Each ply is
cut at definite width and angle and mould in liners.
The cut plies then go to 3 roll calendars for
squeegee application. Components like chafer and
flipper are also made at the bias cutter. These are
further shift using a slitter into small widths and
mould into rolls. Chafer rolls from slitter go to the
tyre building and flipper rolls go to bead flopping.
G)Squeegee calendaring/ squeegee application
Squeegee calendaring is the process of making thin
sheet of rubber compound usually by using a 3 roll
or 4 roll calendar squeegee are used at the inner
most layer of the tyre( drum squeegee) and also in
between the different piles. Drum squeegee is
prepared in the 4 roll Z calendar. It is n liners and
the squeegee rolls are sent to tyre building for
assembling. The ply squeegee preparation and its
roll calendar. After squeegee application the piles
are sent to tyre building assembling.
H)

Beads preparation

Bead preparation consists of three stages:

a. Bead winding
b. Bead fillering
c. Bead flipping
6.1.7 Tyre building or tyre assembling

Tyre building is the process of assembling various

components into semi finished product called a GREEN
TYRE. This is accomplished by a tyre building machine.
The components like drum squeegee, piles are
assembled using a tyre building drum. The flipped beads
are applied next. Finally the thread and sidewalls are
applied. The assembly is taken out after collapsing the
drum.

The different components that make a Green tyre are the

following:

Plies
Breakers
Chafer
Beads
Thread
Sidewalls

6.2 HUMAN RESOURCE DEPARTMENT

6.2.1 HUMAN RESOURCE DEPARTMENT

HIERARCHY

GENERAL
MANAGER

H.R MANAGER

OFFICE
ASSISTANT

RECEPTIONIST

SECURITY

6.2.2 HUMAN RESOURCE DEPARTMENT

Human beings are the key resources in any organization.

The success of any organization depends on the

efficiency with which its resources are managed. Human

beings are the total of the inherent abilities adequate
knowledge and skill.

The HR department of TOLINS is much effective. MR.

Abraham Kuruvila as its General Manager. The main
function is it aids in the better performance of an
organization by identifying the right type of people with
the right combination of skills, attitude and interest. The
main function of HR department are training,
recruitment, employee welfare, grievance handling,
bonus, incentives, prevention of accidents, maintaining
good relation with customers, employees etc.

HR department functions start with security that issue

passes to the people and checking vehicles. Then it goes
through the reception where the messages received and
sent. They also give canteen facilities, cleaning and
sanitation, transportation, fire and safety, housing
facilities for workers. All the above, maintaining good
relationship in the organization is the main function of HR
department.

Human resource is ensured that the personnel

performing work affecting product, quality are
competent. Company competence standard for each
position in terms of education, training, skills and
experience. The competency of the current personnel
performing the activities is compared with the
competency gaps. Training will be provided to fill the
gaps of the existing employees.
6.2.3 Functions of HR department

The various functions of HR department are as

follows:

1. Recruitment
Recruitment is the most important function of HR
department. It is the process of searching for
prospective employees and stimulating and
encouraging them to apply for the job in an
organization. There are three types of
recruitment. They are:
Campus selection
Examination
Advertising agency
2. Selection
Selection is the process of identifying the most
suitable and promising candidates from the list of
recruited persons.
3. Placement and Induction
After selecting a candidate, he/she should be
placed on a job. Placement is the actual posting
of an employee to a specific job. It involves
assigning a specific responsibility to an
employee.
4. Training
Training is the method of increasing the knowledge,
skills and aptitudes
of an employee for performing a
particular job. Training policy of TOLINS is formulated by
the training organizing committee, which consists of the

representative of the entire line department with the

advice and assistance of the staffs personal policies.
5. Compensation
All the employees of the company are paid
according to the scale. Workers are paid their
daily wages and staff is paid monthly salary
which is decided by the Managing Director.
6. Performance Appraisal
Performance appraisal is the systematic
evaluation of the individual with regard to his/her
performance on the job and his potential for
development. It provides feedback to employees
so that they come to know where they can
improve their job performance.
7. Trade union
There are two types of trade unions.
CITU
Pvt. Union
8. Attendance and Leave
There is a routine check about leave and
attendance of every person in the organization.
Every employee has a separate register for
keeping his/her attendance and the whole
information entered into the computer. Earn
leave for workers are 16 and staff is 21. Casual
leave is 12days and medical leave is 10 days for
each employee.
9. Medical and Insurance

TOLINS provide medical facilities for employees

and it covers their family members also. All the
members in the organization come under
insurance policy. Policy is different according to
the job. All the machineries and factory itself is
covered under the insurance policy.
10. Contract labor administration
Welfare of the society is the real motto taken by
the company. The company employed more
people on the contract base. More than 20% of
the workers belong to the locality is legible for
the work.
11. Safety of workers
Fencing of machinery
Maintenance of building and machinery
Prohibition of women employees in the
factory
Providing uniform dresses to the workers
12.

Welfare of workers

Facilities for sitting

First aid appliances
Canteen and shelters
Restrooms and lunchrooms
Welfare officers

13. Health of workers

Cleaning of the factory

Disposal of the wastes and affluent
Ventilation and temperature control
Dust and fume control
Artificial humidification

 Lighting
Provision for drinking water

6.3 MARKETING DEPARTMENT

6.3.1 MARKETING DEPARTMENT

GENERAL MANAGER

MARKETING MANAGER

ASSISTANT MANGER

OFFICERS

EXECUTIVES

TOLINS TYRES PVT LTD has got a very good marketing

department controlled by efficient and dynamic
marketing manager. Marketing department is divided
into three such as Marketing, Advertisement and Sales
promotion. Under each section, assist. Manager,
Marketing Executives, Sales man etc are there to assist.

6.3.2 Functions of the Marketing Department

To
To
To
To

conduct market survey for future requirement.

make detailed survey on the trends
maintain relationship with customers
maintain relationships with government

6.3.3 Objectives
1. To establish and maintain a quality system
suitable for organizations vision and
commitment towards marketing and sales of
products and services rendered to the
customer.
2. To improve upon customer satisfaction by
reducing customer complaints.
6.3.4 Functions of MARKETING MANAGER
Marketing Manager is personally responsible for
performance of marketing activities which include
number of functions such as marketing research, strong
transportation and advertising, selling, distribution,

promotion etc. he is accountable to the chief executive of

the company.

Marketing analysis
Determining market goals
Organizing the marketing activities
Assembling
Product management
Controlling marketing activities.
6.3.5 Marketing Mix
Product, Price, Place, Promotion are the factors of
marketing mix. These 4 Ps are equally important
for the marketing of the product. If any P is weak
product will be a failure. Marketing activities taken
place in Tolins involve the marketing survey.
Information is collected from the market through
the market survey. In order to know the pulse of the
market, market information is collected from various
sources like Dealers, Distributers, Competitors,
Newspapers, Magazines and Sales force.
6.3.6 Advertising and Sales promotion
Advertising and sales promotion tools are used to
promote the product in the market. The ultimate
object of advertising should be modifying the
attitudes or the behavior of the customers.
Advertisement includes the customer to buy the
product. In advertisement, media plays vital role in
the effectiveness of the advertisement. So it should
be carefully selected by considering the nature of
the product, target consumers etc. sales promotion

activities are displays, coupons, contest,

replacement guarantee etc.

6.3.7 The important marketing strategies are:

Pricing strategy
Price is important factor in marketing mix.
Without pricing no product can be sold.
Product strategy
Packing, brand image of (product features) is
related to product strategy.
Distribution strategy
Product quality, distribution channels, market
survey, dealers etc are important in
distribution strategy.
Promotion strategy
Replacement guarantee and new product
development are included in promotion
strategy.

6.4 FINANCE DEPARTMENT

6.4.1 FINANCE DEPARTMENT Hierarchy

FINANCE MANAGER

ACCOUNT
MANAGER

OFFICERS

The basis for financial planning analyzing and

decision making is the financial information.
Financial information is needed to predict, compare
and evaluate the firms earning ability. It is also
required to aid in economic decision making
investment and financing decision making. The
financial information of an enterprise is contained in
the financial statements or accounting reports.

The financial functions are performed by the finance

department. It determines sources, quality and of
funds together with efficient management of funds.
The major activities of the finance department are
the data entry, book keeping, preparing the budgets
etc. the financial year of the company is from 1 st
April to 31st March. The finance department verifies
all the bills passed by various departments and the
bills are cleared, either on the same day or some of
the customers have credit for one month.
6.4.2 Functions of Finance department
The following are some of the main functions of this
department
Preparation of cash flow budget(monthly,
quarterly, yearly)
Preparation of capital expenditure budget
Preparation of revenue budget(monthly,
quarterly, yearly)
Budget varies statement(monthly, quarterly,
yearly)
Closing statement
(Standard costing statement on yearly
basis)
(Actual costing statement on monthly
basis)
Preparing monthly profit and loss account and
balance sheet on or before 5th of every month
Banking (Working capital loan management)
(Cash flow management)
(Tolins provide periodical
performance to the bank)
Accounting

Start with data entering, sources of data with

document. Accounting is done according to the
account manual of the company. Account also
follows the policies and procedures of the
company.
6.4.3 Functions of Finance Manager
To select the best sources for
procurement of funds
To make investment decisions
To manage cash inflows and outflows
To help in tax administration and tax
planning.

6.5 MATERIAL DEPARTMENT

6.5.1 MATERIAL DEPARTMENT HIERARCHY

MATRIAL MANAGER

EXECUTIVES

OFFICERS

HELPERS

Material department for maintaining the material in the

organization required for running its day to day affairs.
Department manager is heading this department. Under
him, the assistant manager, the executives and the
supervisors.

It is the department which deals with the procurement

and maintaining the stock of raw material and essential

items which are needed for the production and

performance of the industry. Each and every item for the
company is purchased through the materials and
supplying the same to the various department of the
company.

6.5.2 Functions of Material department

Purchase
a) Purchase of raw materials
Whenever the raw material is wanted in the day to
day process, it is the duty of the material
department to make sure the availability of raw
materials. All raw materials may not get in bulk
quantity every time.
b) Purchase process

It will be carried out as per documented

procedure to ensure that purchased products/
services conform to specified requirements.
It will be made only from approved suppliers,
primal purchase orders will be used for all
production related materials except semi
finished compounds.
All materials including semi finished
compounds are procured by managercommercial & finance.
Selection, evaluation and re evaluation of
suppliers shall be conducted as per procedure
for purchase.

c) Production materials
It means the materials that are wanted other than
the raw materials.
d) Purchase of capital goods
Capital goods mean goods that have capital value
or it has a long term use. It may be tangible or
intangible assets. Eg; Machinery, land, building etc.

6.7 Research and Development

department

6.6.1 Research and Development

department hierarchy

MANAGER

EXECUTIVES

EXECUTIVES

Areas of research and plant development are the

main functions of research and development
department.

6.6.2 Development department

New product development

Energy utilization
New product technique

 Instrumentation and product quality

New technique of packing
Always techniques are practiced inside the
organization.

CHAPTER 7
SWOT ANALYSIS

7.1 SWOT ANALYSIS

The SWOT analysis includes the evaluation of the
companies Strength, Weakness, Opportunity,
Threats. It is the identification of the strength,
weakness, opportunity and threats in the
environment of the firm along the formulation of
business policies. It is the facts that determine the
course of action to ensure the survival of the growth
of the firm. The environment might present
opportunities. Sometimes a firm will not have
strength to meet threats.

7.1.1 STRENGTH
Quality of the product
Managed by a team of professionals
Strong brand image in the minds of
customers

Better stability in the market

Good customer relationship
Energetic leadership
Well trained workers
Supportive environment
Staff development
Generator for emergency
Knowledgeable employees
Reputation of the employees
Reputation of the organization
Cooperation with partners
7.1.2 WEAKNESS

Trade union issues

Breakdown of machines
Heavy workers
Company is struggling to meet customers
growing demand
Limited number of loyal customers
7.1.3 OPPERTUNITIES

Productivity can be increased

Increased awareness
Innovative replacement of retiring staff
Carrier development and training facilities
Find out new sources of funds

7.1.4 THREATS
Tight competition in the market
Change in the price of raw material
Increased competition

CHAPTER 8
FINDINGS & SUGGESTIONS

8.1.1 FINDINGS
TOLINS Tyres Pvt.Ltd has a good

reputation in tyre retread manufacturing

and its supply.
The environment of the company is
good.
All the departments are well structured.
Maintaining healthy and peaceful relation
between superiors and subordinates.
Tolins is concentrated on consumer
satisfaction.
They maintain good customer relation.
They give importance in health and safety
of workers.
A good coordination exists between
various departments.

Leave rules and procedures followed

by the organization are fair.
1.1.2

SUGGESTIONS

Improve the publicity of the company.

Proper motivation programs must be
conducted
Conduct market research every year or
twice in a year.
The management should give more
importance to employee related matters.

 Production capacity should be increased

according to the order.
Advertisement efforts should be
improved.

CONCLUSION
I have done my organizational study in TOLINS
TYRE PVT.LTD, Kalady. It gave me a lot of
experience and knowledge about the organization.
This study helped me to meet a lot of workers,
supervisors and had some valuable discussion
regarding the production. It is a very good example
of organizations which strives to give products
according to the customers needs and satisfaction
to employees in their jobs. The function of an
organization is clearly understood by this study.

REFERENCES

1.
2.

3.
4.
5.
6.

http://www.rubberworld.com/RWmarket_report.asp?
id=750
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ja&uact=8&ved=0CEYQFjAG&url=http%3A%2F
%2Fwww.researchandmarkets.com%2Freports
%2F2356223%2Findian_tyre_industry_forecast_to_2
015.pdf&ei=w7pMVbvvLY69uAS4YHYCA&usg=AFQjCNG_xVqLmb2HwMjXNKM8z1puk
wDqmA&bvm=bv.92765956,d.c2E
DR. Sharma D.D, Marketing Research, Sultan Chand
and sons, Educational Publishers Pvt.ltd, New Delhi
Mr. Potti L.R, Business statistics, Yamuna
Publications, sreekanteswaram, Trivandrum
Company records
www.tolins .com