Professional Documents
Culture Documents
Mba Organisational Study
Mba Organisational Study
AUTOKAST LIMITED
CHERTHALA
Of
By
Abishek P Kumar
Reg. No. 85051
Mr. Santhosh S
Asst. Professor
Kalamassery,Cochin
(Affiliated to Mahatma Gandhi University, Kottayam & Approved by AICTE, New Delhi)
2016 – 2018
SCMS SCHOOL OF TECHNOLOGY AND MANAGEMENT
KALAMASERY,COCHIN
CERTIFICATE
ABISHEK P KUMAR
Place : ERNAKULAM
Date :
ACKNOWLEDGEMENT
First and foremost, I thank the Lord Almighty for his perpetual showers of blessings,
which led to the successful completion of this organizational study. I take this
opportunity to express my deep sense of gratitude to all those who have helped me
throughout this organizational study. It gives me immense pleasure to acknowledge all
those who have rendered encouragement and support for the successful completion of
this work. I would like to convey my sincere thanks for giving me proper directions
and suggestions and make use of this opportunity to express my heartfelt gratitude to
Mr. P.V JITHEESH, (HR manager, Autokast) for providing me all the faculties for
making my project a successful one.
ABISHEK P KUMAR
CONTENTS
1. INTRODUCTION 1
4. FUNCTIONAL DEPARTMENTS 33
FINDINGS, SUGESTIONS
AND CONCLUSION
BIBILOGRAPHY 71
LIST OF CHARTS
CHAPTER 1
INTRODUCTION
2
INTRODUCTION
The primary purpose of this study is to fulfillment of the requirements for the degree of
MBA. For this I conducted my Organization Study in Autokast Limited, Cherthala for
a period of one month. The era of liberalization has opened up new vistas for Indian
Economy. In the fast changing economic scenario it is imperative for every aspiring
entrepreneur to have a vivid understanding of the functional application of the new age
business. Organizational studies is “the examination of how individuals construct
Organizational structures, processes and practices and how these, in turn, shape social
relations and create institutions that ultimately influence people. Organizational studies
comprise different areas that deal with the different aspects of the Organizations.
3
The primary objective of the organization is to make the students to know the practical
applicability of the theoretical concept in to business decisions of the organization.
This project reports covers the functioning of all major departments of Autokast
Ltd. Cherthala. The findings of the study would give valuable information about
improving the current performance of the Organization towards its goal
achievement. It also includes the Organizational structure of the firm.
1.3 METHODOLOGY
Primary data are collected through personal interviews and personnel discussion
with managers and other officials of the Organization. And also through
observation. The information obtained relates to what is currently happening in the
Organization. The study needs to have a personal visit to the different departments
of the company.
Secondary data are from published and unpublished records of the firm. Published
sources include annual report of the Company, newspaper articles, journals of the
firm etc. Unpublished sources of data are files and records maintained by the
Company.
The study was conducted for a limited period and the time is a major limiting
factor for an in-depth study.
Secret nature of certain files, records and information that could not be
revealed.
Since the official were busy, it was difficult to spare their time for detailed
discussion.
CHAPTER 2
INDUSTRY PROFILE AND COMPANY PROFILE
6
Autokast Ltd. Is the equipped with most modern and sophisticated equipment
such as inductions furnaces, high pressure molding etc. Autokast Ltd. Had related
various component of different nature including automobile casting were tested and
proven on the machine before it has exhibited. Autokast was established in 1984, it is
fully equipped to manufacture all kind of ferrous casting weighing form 5 kg to 8000
kg to single piece. The annual production capacity is 1800 metric tons. Autokast
produces and markets different grades of grey iron and SG iron casting for the domestic
and international markets.
It is estimated that the total number of founding units in the country in the large
medium, small and tiny sectors put together vary between 7000 to 8000. Out of this
states of Kerala has around 150 units connected with act of foundry mostly on the small
scale barring a few units of medium sized capacity. It is a pleasant task to list Autokast
Ltd. In to this selected brand of industry fearing up to latter the needs of sophisticated
casting in the industry.
7
INDUSTRY DESCRIPTION
For example, the product of alumina refinery is the input to an aluminum wire
drawing plant and aluminum wire is the input for the fabricated wire product
manufacturing establishment.
The United States led all othe countries in the world in producing metal casting
in 1997, supplying one-fifth of the world’s total shipment of 67 million. The nearest
competitor in China, with about 16% of the total public and private institutions and
organizations are part of infrastructure of metal casting in industry. Research and
development expenditures in 1997where about evenly divided between non ferrous
metals and ferrous metal (NFS) 1997.
2) Bronze age : Eventually, he learned that tin could be mixed with copper to
produce a stronger, durable and attractive metal which was called bronze.
He found bronze favorable because it could be used to make artifacts and
tools like knife, armor, pottery that we more durable and harder
3) Industrial age : Also known as the age of technical revolution this age say
rapid increased in the demand for casted products. Mass production was
made possible by the intervention of new machines in the age. Iron casting
was used not only for the creation of decorative objects but was also for the
production of machined component and house hold articles.
3300 B.C. Ortiz, the oldest natural mummy had an axe with copper casted axe head
3200 B.C. A frog casted in copper is the oldest proof that shows the complexity
and intricacy of molding
3000 B.C. Weapons and cult objects made of copper of this age recovered from the
Middle East and India
1400 B.C. Iron where excavated which indicates the earliest production of steel
There have been almost revolutionary changes in the global iron scene fierce
competitive pressure.
Many different metal casting techniques are in use today. They al have in
common construction of mould with a cavity in the external shape of desired cast part
followed by the introduction of molten metal in to mould.
For the purpose of their profile, the metal casting process has been divided in to the
following five operations:
Pattern making
11
All five operations cannot be applied to each casting method. Since the major
limitation between processes occur in different type of moulds used, moulds and core
preparation is divided and sub divided in to subsections describing the major casting
process. In addition to casting technique described below, there are numerous special
processes and variations of those processes that are not discussed here as it is outside
the scope of this report. Nevertheless, such processes may play an important role in the
facility’s effort to comply with environmental requirements.
Foundries and die casters that product ferrous castings generally operate on a
job or order basis, manufacturing casting for sale to other companies. Some foundries
termed captive foundries produce castings as a subdivision of a corporation that uses
the casting to produce larger products such as machinery, motor vehicles, appliances or
plumbing fixtures. In addition many facilities further work on castings such as
machinery, assembling and casting.
INTRODUCTION TO CASTING
12
Casting is one of the most ancient ways of forming metals. Man has derived a
multitude of other watts of forming metals. Casting may be very small weighing few
grams and very big weighing of tons. Casting may be custom made or mass produced.
They can be cast in to many combinations of alloys. The first step of casting is to melt
the metal. The molten metal is poured in to the mould which is an important step in
casting that is going to be made. The steam of molten metal lighting up the foundry
like sunray vanishes in the gat of the mould. As soon as the metal has become solid,
the mould may be broken up, it has served its purpose and cleansed of clinging and
core.
Moving on from metal casting process, Autokast has its own facilities to
discharge liquid metal to intended chemistry, from modern induction and electric area
furnaces in to sand moulds prepared from conventional moulding machines and also
through high Foundry or casting is the process of producing metal alloy component
parts of desired shapes by pouring the molten metal alloy in to prepared mould and then
allowing the metal alloy to cool and solidify. The solidified piece of metal or allow is
known as casting.
The Indian Foundry industry is striving to rewrite history and emerge as green
history. India is currently one among the tenth largest producers of ferrous and non
ferrous casting and has over 6500 foundries in the small, medium and large sectors.
Tractor Industry
Earth moving industry
Pumps, Compressors, Pipes Valves & Pipe fittings
Electrical/Textile/Cement/Agro Machinery
Machine Tools & Engineering Industries
Sanitary Castings
Engineering Exports
Approx 32% Output of Foundry Industry goes to Auto Industries & balance to other
downstream Engineering Sector.
Produce all grades of Grey Iron Castings up to 8.5Mt single pc (18700 lbs) and
all grades of Ductile Iron Castings up to 7 MT single pc (15500 lbs) and Steel Castings
weighing up to 3MT single piece. Commonly produced grades are IS 1030 and WCB
range Casting, Induction melting furnace of 5MT and 3MT are exclusive.
1. Air impulse type high pressure moulding line with box size of 750 x 750 x
400/350mm capable of producing 80 moulds per hour. The line is fully computer
controlled and is supported by automatic core shooting machines employing
different sand systems like cold box, shell core etc. Product range varies from 10kg
to 130 kg.
15
Pattern shop at AKL acts as a service shop for pattern equipment used in production.
Autokast is fully equipped with state of the art testing facilities like:
The Company’s products at present cater to the needs of following segments of Indian
and overseas Industries.
1. Automotive
2. Tractor
3. Butterfly Valve and Disc assembly
4. Agricultural
5. Wind mill energy and
6. General Engineering Industries
Clientele
Agricultural sector
16
Eicher tractor – Carater housing, crank housing, fly wheel housing, crank case
(3 bore etc)
KAMCO main gear case cylinder frame etc
International Tractors Differential Housing
TAFE hydraulic lift cover
Automotive Sector
NEG Micon India Ltd Wind mill hub, Br-disc (GGG 40.3)
Suzion Engery Ltd wind mill hub, Extenders (GGG 40.3)
Vestas RRB wind mill castings GGG 40.3
Pioneer Wincon Wind mill castings in GGG 40.3
NEPC wind mill casting in GGG 40.3
Marine Engineering
Kirloskar Oil Engines Heavy Duty Blocks for marine application and components
The high pressure molding line can produce grey iron and graphite. Iron in casting,
which are repetitive in nature and required in large numbers. The entire mechanism is
controlled through a computerized control panel. The system can produce 8 mould per
hour and its best suited for more production of precise casting required for automobile
and engineering industries. This high precise system is separated by modern core
shouters from M/s Roperwerk from West Germany, using hard box, card box and shell
process and equipped with core handling transport system.
Location
The location has yet significance. It is located near sand mine (pallipuram). Sand even
though not a raw material is most important supporting material which is significant as
the raw materials.
Export
From a modest beginning Autokast Ltd has grown strength over the years in meeting
the requirements of casting in the overseas market. The company is leading towards a
turnover of one crore in the current financial year which is expected to have quantum
jumps in such current year. At present castings from the company are exported to USA.
Customer base
From an ordinary foundary unit in 1981, Autokast come great way through to become
one of the most sophisticated foundries in India. It is the level of sophistication and
precise quality control that helped Autokast to built is strongest customer base.
18
Kirloskar, Nasik
ABM steel, Delhi
Mecawber, Delhi
OSM, Delhi
Pioneer, Pondicherry
Global, Mumbai
Kakathi Karshak Pvt Ltd, Hyderabad
KAMCO (Kerala Agro Machinery Corporation), Kerala
Competitors
In South Asia, Autokast is the first to implement BMD (Mis Badische Marchienen
Fabric Duciach) Air Impulse Techonology for sand compression which is the latest in
the field of casting. Autokast has always been with the trend of technological changes.
From a modest beginning Autokast Ltd has grown strength over the years in meeting
the requirements of casting in the overseas market. The company is leading towards a
turnover of one crore in the current financial year which is expected to have quantum
jumps in such current year. At present castings from the company are exported to USA
19
The high pressure molding line can produce grey iron and graphite iron in casting,
which are repetitive in nature and required in large numbers. The entire mechanism is
controlled through a computerized control panel. The system can product 8 mould per
hour and its best suited for more production of precise casting required for automobile
and engineering industries. This high precise system is separated by modern core
shouters from M/s Roperwerk from West Germany, using hard box, card box and shell
process and equipped with core handling transport system.
Autokast Ltd is fully equipped with the stat of the art test facilities like:
MISSION
VISION
This quality Management system covers manufacture, inspection, testing and supply of
Steel, Grey Iron and nodular Iron Castings for automotive, tractor, butterfly valve wind
mill energy and general Engineering Industries.
ISO CERTIFICATION
Autokast is an ISO 9002 : 2008 certified Company. It has got the certification in 1990.
ISO 9000 is a family of standards for quality Management systems. ISO 9000 is
maintained by ISO, the International Organization for Standardization and is
administrated by accreditation and certification bodies. The ISO 9002 : 2008 agency in
Autokast is Netherlands agency KEMA. The agencies studies on various department
and prepares a manual on each department. There is managing committee on ISO 9002
: 2008 certification procedure. If there is any default or defect in the department, the
agency prepares a detailed copy of changes to each department for modification. The
Autokast which has export relationship with the foreign companies, the ISO
certification enables a prompt on the functioning procedure. The agency also does
Internal Audit in the Company. The NVT is the Indian Agency which does the
certification procedures. It is granted by KMEA.
21
BUSINESS PURPOSE
QUALITY OBJECTIVES
A. CUSTOMER SATISFACTION
2. Minimize reworks.
C. EMPLOYEE INVOLVEMENT
Meetings conducted under various shop councils & Defect Analysis review
committee.
The quality policy, quality objectives and targets are reviewed annually for it
continued suitability
Autokast is the foundry unit producing iron castings for a variety of industries. The iron
castings made of cast iron, cast iron is general terms that describes iron, carbon, silicon
alloys which are produced by pouring the molten metal in to sand/metal moulds. Cast
iron is brittle and grey in colour. The carbon content in cast iron is more than that in
steel which makes it less malleable. By varying the silicon and carbon content at alloy,
several types of core iron can be produced each with different properties and uses
“IF YOU CAN DIESGN IT, WE CAN CAST IT” is the caption of Autokast Ltd. Over
the year Autokast has developed the expertise of manufacturing iron castings for a
variety of industries and different casting material like cylinder blocks and IC engine
cast iron.
Machine tool structures and water pipes for underground purpose are grey iron.
Hydraulic cylinder, valves, pipe fittings, cylinder head for compresses and diesel
engines are in spheroidal cast iorn.
1) Automotive casting
2) Machine castings
3) Pump castings
4) Vacuum and slurry pump casting
Grey iron can be readily cast in to desired shapes by pouring in to moulds. So it is the
most commonly used type of cast iron for the manufacture of castings. The other
distinguished characteristics of grey iron are
SGI or nodular cast iron is higher grade of iron because unlike structures grey iron, the
graphite in SGI is precipitated as spheroids. This attained by adding sheroidizingagents,
which changes the solidification characteristics and account for notarization.
PRODUCTION FACULTY
50 Kg to 150 Kg
120kg
contracted
The major raw materials used for manufacturing are silica sand, it is obtained from
silica sand mines in Pallipuram, a place near Cherthala. Mid Steel and CRACA scrap
pig iron are raw materials obtained from MSTC
Purpose
Scope
All products including purchased or outscored products at inter mediate states and final
product.
Functions
Receiving Inspection
It is ensured that any accepted materials are released for further processing.
When incoming materials are released for urgent production without proper verification
it is positively identified and recorded in order to permit immediate recall and
replacement in the event of non confernments and requirements.
In Process Inspection
Finished Products
28
All finished products are inspected and tested in accordance with documented
procedure or quality plan to verify conformance of the finished products to the
requirements.
No products dispatched or released for next stage until all the activity specified have
been satisfactory completed.
It is ensured that any accepted materials are released for further processing.
When incoming materials are released for urgent production without proper verification
it is positively identified and recorded in order to permit immediate recall and
replacement in the event of non conferment ‘s and requirements.
Grey iron can be readily cast in to desired shapes by pouring in to moulds. So it is the
most commonly used type of cast iron for the manufacture of castings. The other
distinguished characteristics of grey iron are
It is ensured that any accepted materials are released for further processing.
When incoming materials are released for urgent production without proper verification
it is positively identified and recorded in order to permit immediate recall and
replacement in the event of non conferment ‘s and requirements.
29
The major raw materials used for manufacturing are silica sand, it is obtained from
silica sand mines in Pallipuram,, a place near Cherthala. Mid steel and CRACA scrap
pig iron are raw materials obtained from MSTC
Grey iron can be readily cast in to desired shapes by pouring in to moulds. So it is the
most commonly used type of cast iron for the manufacture of castings. The other
distinguished characteristics of grey iron are:
Machine tool structures and water pipes for under ground purpose are grey iron.
Hydraulic cylinder, valves, pipe fittings, cylinder head fir compresses and diesel
engines are in spheroidal cast iron.
Foundry casting is the process of producing metal alloy component parts of desired
shaped by pouring the molten metal alloy in to prepared mould and then allowing the
metal alloy to cool and solidify. The solidified piece of metal or allow is known as
casting.
Foundering or casting is one of the oldest manufacturing process which date back to
approximately 4000 BC. The first foundry Centre came in to existence in the days of
Shan dynasy in climes number of foundries using cast iron as structural material come
in to being after industrial revolution.
30
CHAPTER 3
GENERAL MANAGEMENT PRACTICES
31
(b) Frame the policy: To frame the policy and chalk out the plans to carry out the
objectives and policies. Policies may relate to different aspects of the organisation.
For example, production policy deals with the quality, product variety, scheduling of
production to meet the market demand etc.
1) Market policy: This policy deals with such matters as advertising and
sales promotion techniques, pricing product, channel of distribution, commission,
discount, placements, training, remuneration promotion, appraisal of performance etc.
of the personnel.
2) Financial policy: This relates to the procurement of funds, source of finance,
management of earning, etc.
(d) Assemble the Resources: For the purpose of executing the plans, the resources of
men, machines, materials and money have to be assembled. This again is the task of
top management.
(e) Control the operations through organisation: Controls the top management
regarding operations through budgets, cost and statistics quality control and
accounting devices.
32
MANAGER ASSISTANT
MANAGER
(ENGG &PATTERN)
MANAGER
(MARKETING) MANAGER ASSISTANT
CONTROLL MANAGER
MANAGER ASSISTANT
MAINTANANCE MANAGER
MANAGING MAINTANANCE
MARKETING
MANAGER ASSISTANT
MANAGER PPC &
( PPC & MATERIAL) MATERIAL
MANAGER (PCO)
MANAGER ASSISTANT
(MELTING) (MANAGER
MANAGER
MELTING)
(FINANCE)
MANAGER
OFFICER (HRD & A)
(HRD & A)
33
CHAPTER 4
FUNCTIONAL DEPARTMENTS
34
It is specialized branch of management which deals with the employees and other
people. This department strives use human resources in effective manner so as to
transform them for releasing the objectives of the organization. It aims at relating people
at work with the activities necessary to achieve goals.
It’s people in an organization that carry out many important work activities. Managers
and the HR professionals have the important job of organizing people so they can
effectively perform these activities. The requires viewing people as human assets, not
cost to the organization. Thus human resources are exactly it says: resources for
humans- within the work place. Its main objective is to meet the organizational needs
of the company it represents and needs of the people hired by that company. In short,
it is the hub of the organization serving as a liaison between all concerned. Also
organizations are managed and staffed by people. The challenge, the opportunities and
the frustration of creating managing organizations frequently stem from people related
problems that arise between them. People related problems arise mainly because people
are not alike. These differences demand attention so that each person can maximize his
or her potential, maxi so that organization can maximize their effectiveness.
To ensure its success, a company must establish a hierarchical reporting system. The
funnel of responsibility is critical to the efficiency of a smoothly operating business
entity in which there is a clearly defined understanding of who is responsible for what.
35
Objectives
Sunday : Holiday
Recruitment Process
Sources of recruitment
Recruitment Procedure
Performance Appraisal
It’s peoples in an organization that carry out many important work activities. Managers
and HR professionals have the important job of organizing people so they can
effectively perform these activities. This requires viewing people as human assets, not
cost to the organization. Thus human resources are exactly it says resource for humans-
within the work place. Its main objective is to meet the organizational needs of the
company it represents and need of the people hired by that company. In short, it is the
38
hub of the organization serving as a liaison between all concerned. Also organizations
are managed and staffed by people. The challenge, the opportunities and the frustration
of creating and managing organization frequently stem from the people related
problems that arise between them. People related problems arise mainly because people
are not alike. These differences demand attention so that each person can maximize his
or her potential, maxi so that organization can maximize their effectiveness.
39
MANAGING DIRECTOR
The terms finance is defined as the provisional of capital required at the time when it is
needed. The finance is needed for making goods and service and for their distribution.
Every functions of the firm depends on how effectively the finance utilized
Objectives
Functions
All financial transactions of Autokast company Ltd through the finance department,
which is called amount department
All receipts in cash and deposits and withdrawal of cash are entered in the cash
book by this department
It is the finance department that enters all transactions of the company in the
bank book
Finance department enters all purchase bills regarding suppliers account, bill
passed, payment made etc in purchase journal and ledger and the expenses
incurred like general expense to expense ledger
Sales tax for central and state government is finance department
The audit file for every financial year to be certified by the auditor is prepared
by finance department
The finance department prepare ash flow budget, capital expenditure, revenue
budget and budget variance statements.
41
MANAGING
DIRECTOR
MANAGER
FINANCE
ASSISTANT
MANAGER
Objective
It facilitate and coordinates activities with the kind, amount, location, movement
and timing of various material used in and produced by firm
It aims to produce the right product in right quality, right quantity and the right
time
It aims at optimum combination of resources and methods so that there is lowest
average cost of production
It requires minimum inventories of raw material and finished products so that
capital investment is reduced resulting in high return on investment
The heavy casting of Autokast ranging from 80 kg to 8000 kg are manufactured section
43
Objectives
Small casting of the firm are done in this section. The line of manufacturing section has
the same objective of conventional moulding line.
Melting Department
The melting of pig iron, scrap steel and other chemical component for casting are
provided by this section.
Objectives
In this department the black casting is whitened in a shot blasting machine using small
steel balls. Then the runners and the raisers of the whitened casting are removed
wherever necessary, to turn in to finished goods.
Objectives
Production Process
Sand is a principle moulding material in the foundry shop where it is used for all types
castings. The most important characteristics of sand are its refractory nature and
chemical resistivity, high degree of permeability and flexibility these property vary
from sand to sand and only those and are characterized by the forgoing features which
is considered for moulding works of casting.
Core may be defined as that portion of the mould, which forms the hollow interior of
the castings or a hole through the casting cores must have sufficient hardness, strength
in dry and green states, permeability and collapsibility, temperature resistance and
should produce only maximum amount of gas when it contact with molten metal.
The ingredients of core are sand and binder. Generally high silica sand containing a
very little clay is found best suited as it can withstand high temperature. The function
of core binder is to cement the grey of sand in to desired shape and to impart sufficient
strength to the core to prevent breakage, distortion and erosion in the core making.
Stage 3 : Melting
Pig iron which is the most important raw material is melted in furnace in to molten iron.
Scrap steel is also melted. For this purpose Autokast use induction furnace
Stage 4 : Pouring
If it is too hot it will produce a technical defect called low holes in casting and if it is
too cold due to premature solidification, proper filling will not be attained.
When cooling period is over, the casting is removed from the mould. Then the core in
the casting is removed
Stage 6 : Fettling
Fettling is the process by which un wanted parts of the castings are cut cleaned and
finished. This include removal of gates, resersetc from casting, removal of fins and
other unwanted projections etc.
Even after fettling there may be minute sand particles attached to casting. These are
removed by shot blasting. Shot blasting is the process by which cast iron shots are
blown to the surface of castings to remove the adhesive sand. Product process is carried
out in the following departments:
MANAGING
DIRECTOR
MANAGER
MANAGER MANAGER
MANAGER
MAINTENANCE MELTING
MATERIALS
The essence of modern economic process is quality. Quality refers to the degree of
excellence of a product. Modern age is “era of quality” . Every employee in company
spends a lot of effort to make quality products and thus tries to maximize the profit.
Autokast has an effective quality control department with a spetro lab capable of
detecting whether the casted products have the standard quality. The company has
adopted service measure to ensure quality.
Objectives
Inspection Department
MANAGING
DIRECTOR
MANAGER
MANAGER
MANAGER CONTROLL
ENGG & PATTERN
The pattern is the pattern shop is only a half part of one to be casted. The BMD high
pressure moulding system in Autokast allows two such halves of the pattern combine
to a single casting as the customer requires.
Objectives
MANAGING DIRECTOR
MANAGER
ASSISTANT MANAGER
ENGINEER
SKILLED WORKERS
51
The department deals with firms and records relating to staff of finished goods, their
marketing and advertisement etc. This department also conducts carnivals and market
the programmers, advertisement and market research etc. It prepares sales invoice and
delivery of products and maintenance of sales journals.
FUNCTIONS
Marketing involves various, which may be called as marketing function. This aims at
achieving the final objectives of the company fulfilling the customer satisfaction.
Marketing function is an act, operation or service by which the original procedure and
final customer are linked together.
The marketing departments conduct market study and find out the taste and
preference of the customers
They formulate the pricing strategy
The export formalities ae handled by marketing department.
52
MANAGING DIRECTOR
MANAGER MARKETING
The company’s purchase of raw material is from applied suppliers only. The approval
is given on the basis of quality text of the raw materials, price negotiations and delivery.
The company to make forecasting on purchase. The raw materials purchased by
Autokast is copper, manganese, and CRCA scrap pig iron. The company adopts mainly
just in time purchase.
Any person who needs a material can make a purchase requisition, but it has to
authorized by the department head. This has to be routed through engineering store. In
case of items involving capital expenditure, it should have capital nature that is not
required. Based on indent, necessary quotations are invited and purchase orders are
releases. The copy of purchase order is send to the supplier, indenter, accounts, stores,
file copy for plant purchase.
Functions
Objectives
MANAGING DIRECTOR
DIRECTOR
PURCHASE MANAGER
OFFICE ASSISTANTS
55
Since Autokast uses several machines and large electric power for its operation, there
exists a department to maintain machines and electric equipment called maintenance
department.
Objectives
Under this department there are two other department that are as follows:
The company has a 110KV substation in itself which serves the required electric power
for the company, 110KV is stepped down to 11KV and 440KV for the working of
induction furnace and as a power of other machines and lighting facilities. The
maintenance and necessary replacements of electrical items done by this department.
The failure of machines and other repair in machine are done in this department. The
induction furnace in the conventional molding line requires huge copper wires to be
wounded over it. Mechanical maintenance does this work.
56
MANAGING DIRECTOR
ASSISTANT MANAGER
MAINTENANCE
ENGINEER MAINTENANCE
DEPUTY ENGINEER
ASSISTANCE ENGINEER
SKILLED WORKERS
UNSKILLED WORKERS
57
The PPC department plans the product realization process. They prepare the production
and dispatch schedule, material planning, production follow up, dispatch and
improvements. The departments also monitors the stage wise progress of the process
and it is recorded.
Process Planning
Based on word order, collected all input documents from marketing department
and check the input for adequency, if adequate, call for required data
Prepare pattern method drawings and arrange to manufacture
Customer supplied patterns are to be procured from vendors, forward four sets
of patter drawing to purchase department to arrange procurement
Major raw material requirement are assessed and necessary indents are raised
for procurement
Prepare a draft quality plan and circulate it to production, quality control and
inspection department
Open up a product file which shall contain all input documents together with
method drawing and copy of quality plan
Based on quality plan, the make arrangement for necessary inspection and
testing activities
58
Production Planning
The high pressure molding line can produce grey iron and graphite. Iron in casting,
which are repetitive in nature and required in large numbers. The entire mechanism is
controlled through a computerized control panel. The system can produce 8 mould per
hour and its best suited for more production of precise casting required for automobile
and engineering industries. This high precise system is separated by modern core
shouters form M/s Roperwerk from West Germany, using hard box, card box, and shell
process and quipped with core handling transport system
59
Autokast Ltd is fully equipped with state of the art test facilities like,
MANAGING DIRECTOR
MANAGER PPC
ASSISTANT OFFICER
SKILLED
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The maintenance activities include both preventive break down maintenance works,
spare parts management, coordination with purchase and user departments,
maintenance records, labor management and cost control in maintenance. The objective
of this department is thus to minimize the down time and keep all machineries in good
condition for maximum utilization of equipment’s to achieve the maximum quality
production, as instructed in the quality policy of Autokast.
The company cannot use the 110 KV electricity supplied by KSEB for running its
machines. So by using 20 MVA transformer the 110 KV is step down to 11 KV. This
110 KV is again step down to 440 V with help of 1 MVA transformers. In total company
has transformers
20 MVA
1 MVA TR-1
1 MVA TR-2
1 MVA TR-3
Maintain frequency induction furnace 1700 KVA
Medium frequency 2300 KVA
Equipment’s used
These are the equipment’s used in the company that run on electricity. In the brackets
number of those items used in Autokast is given
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CHAPTER 5
SWOT ANALYSIS, FINDINGS, SUGGESTIONS AND CONCLUSION
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SWOT ABALYSIS
Identification of the treats and opportunities in the environment and strength and
weakness of the firm are the cornerstone of business policy formulation; it is these
factors that determine the course of action to ensure the survival or growth of the firm.
The environment might present opportunities but a Company might not have the
strength to exploit all opportunities. Similarly a firm will not have the strength to meet
the environment threats.
STRENGTHS
WEAKNESS
OPPRTUNITIES
The new joint ventures with railway will open a wide opportunity for future
growth of the company
There is high potential for export to Europe and USA due to better quality of
product
Reduction in input cost is possible
Less competition for wind mill casting
Composited foundry can produce 5 Kg in size of 5000 kg. GU &SGI casting
for different applications
Access to global source for raw materials at competitive due to globalization
Highly satisfied overseas customers who encourage for more exporting of
products
THREATS
Autokast Ltd manufactures all types of ferrous Casting under the same roof.
Autokast is a modern industrial Casting unit with ISO 9002 Certification. The
Company has an optimum capacity of 18000 tons per annum and covers an area of
21500 sq. meters. The Company can manufacture ferrous Castings of all grade and
sizes ranging from 5 kg to 8000 kg.
FINDINGS
Autokast Ltd has the potential for producing good quality Castings
It owns all sorts modern testing equipment’s
The location of Company is advantageous while considering the availability
of Silica sand which is a major raw material, but when considering the
major Customers and other Raw materials the problem of transportation
arises.
The company has lot of skilled workers, but influence of trade unions
weakens the Management
Recruitment is not often done in the Company. Now they make only
temporary selections which results in low commitment of Employees
towards Organization.
Promotional activities for their products are not conducted efficiently.
The Company is in loss and it has heavy burden of past liabilities
The Company lost major portion of its equipment due to insufficient
maintenance
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SUGGESTIONS
Company uses trial and error method for pattern drawing. Also introduce SAP
based Technology to the Organization.
Give more importance to R&D Department. Find out methods for reducing the
operating expenses. Recruit more experienced people to R&D. At present there
is a lack of manpower. With the help of R&D department the Company will be
able to diversify its product line and find alternative uses for its existing
machinery.
Implement Cost Control techniques aiming at reducing cost to be more
competitive. Establishment of a costing department will help the Company to
analyze the cost structure and find out the loopholes
Increase the capacity utilization. The present production of the Company is less
than its total capacity. If the Company utilize the capacity at its best, it can
generate profits.
Give importance to Customers. A consumer analysis will help to trace out the
reasons, which makes them turn to Autokast. This will help to know the
strengths and weakness of the firm. So a consumer analysis will help the
Company to understand the consumer more and cater to their needs more
successfully. Continuous and healthy client relations should be maintained.
Deliver proper maintenance to the existing machineries. Shut down
maintenance is not done so far. It’s always better to give Preventive
maintenance rather than waiting for the machinery to breakdown
Provide some safety methods to the workers for ensuring protection to their life
Company officials and government authorities should collectively interact and
evolve plans for implementing the decisions for revamping the firm to potential
areas. Effort for overcoming the political bias is required
Make more sales realization in the domestic market. Generating more sales in
the market can reduce cost burden of the Company and thereby increase the
profit
As the Company is owned by government, they should take initiatives to settle
the loans, which are already overdue and prepare the ground for the Company
to obtain working capital support.
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CONCLUSION
Autokast is a modern Industrial Casting unit with ISO 9002 : 2008 Certification. The
unit is located at S N Puram near Cherthala. The Company has an optimum capacity of
18000 tons per annum and covers an area of 21500 sq. meters. Autokast is the largest
Foundry in the Public Sector in South India. Most of its customers are located outside
Kerala. The Company exports Castings to USA and Europe also. In spite of its past
liabilities Authokast is striving to turn around. Even though it is a Public Sector
Company it does not enjoy any privilege or patronage from public bodies. It is
competing with the private sector in the open market.
The company has specialized in the manufacture of Castings required for the
Windmills. Windmills from non-conventional energy source and therefore the
functioning of this Company contributes towards a priority sector of the economy
BIBLIOGRAPHY
www.autokast.com
www.google.com
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