SCHOOL OF DISTANCE EDUCATION

UNIVERSITY OF CALICUT

PLACEMENT TRAINING REPORT ON APCO

MALABER TILE WORK

SUBMITTED TO

THE DIRECTOR

SCHOOL OF DISTANCE EDUCATION

SUBMITTED TO THE UNIVERSITY OF CALICUT IN PARTIAL

FULLFILLMENT OF THE AWARD OF BACHELOR DEGREE
OF BUSINESS ADMINISTRATION

2010-2011
UNIVERSITY OF CALICUT

SUBMITTED BY
ASWATHI.P
ENROLMENT NO: 820051
REG.NO: FKAIBBA086
 ACKNOWLEDGEMENT

I would like to express my sincere thank to THE

DIRECTOR SCHOOL OF DISTANCE EDUCATION, CALICUT
UNIVERSITY for allotting me this placement training.

I honestly express my gratitude to the chairman and

director of THE MALABER TILE WORK for allowing me to
undergo training in their institution.
I am especially thankful to sir BALAKRISHNAN, general manager
of THE MALABAR TILE WORKS for this guidance and assistance
in completing the placement works in the specified time frame.

Further also thankful to all staff and workers of THE

MALABAR TILE WORKS for the selfless support in the above
venture.

At last I express my thanks to god, my parents,

teachers, and friends who have been given help to me during
the training and completing the placement report

Aswathi. P
 DECLARATION

I Aswathi here-by declare that the placement work

entitled A STUDY OF OVERALL FUNCTION AND PERFORMANCE
OF MALABAR TILE WORK in the partial fulfillment of the
requirement for the completion of the BBA of my original work
and not submitted for the award of any other degree or
diploma.

Aswathi p
 INTRODUCTION

Be highly sophisticated office building or a lovely

living room where you spend most of your time, for everywhere
in your surroundings where style and quality contribute CROWN
BRAND terracotta is all conquering, available in the most verity
designs and colour of tile can be produced in natural and
comfortable way. Terracotta is a porous material which absorbs
water and hence is highly suitable for indoor use particularly in
place with high clay hallow blocks for roof slab construction
walls and partitions are now fast replacing monolithic concrete
forms. Because of huge expenses of concrete your roof CROWN
BRAND terracotta to any other roofs in its place, quality and
also durability.

The internationally standardised tile developed by

THE MALABAR TILE company are unique in their application to
different culture, climate, and architectural around the world.
 OBJETIVES

• To evaluate the overall performance of THE MALABAR TILE

WORKS

• To understand the structure of the organization

• To know the profitability of the company

• To understand the financial position of the company

• TO evaluate the functions of THE MALABAR TILES WORKS

• To analyse the marketing aspect of the company

• To analyse the activity and effectiveness of the company

• To know the demand of the product

HISTORY OF MALABAR TILE WORKS

THE MALABAR TILE WORKS has got a trusted

tradition spanning 90 tears in manufacturing and marketing
quality terracotta products. The unit was setup in 1920 as a
partnership firm at Feroke on the bank of river chaliyar and 12
km away from Calicut city.

The unit manufacture terracotta roofing tile.

Most of the equipment and machineries were procuired from
Germany. The CROWN BRAND building products are well known
of their superior quality.

Providing a profitable as well as beautiful

alternative to concrete roofing, the company redefined the
aesthetic concept about building with its high quality CROWN
BRAND terracotta products. Leveraging the expertise earned
through legacy of more than 100 years of experience is having
feltched by shares.

The most accept eco-friendly, cost effective and

aesthetically pleasing solution to home roofing and flooring,
these products have by now earned international fame and
recognition. THE MALABAR TILE WORKS offer an eco-friendly
relationship to the nature and CROWN BRAND tile products
promise you a world of endless imagination.

Terracotta tiles appear in a wide range of

models in flooring, roofing and ceiling and also in ventilator
breaks and building blocks. Roofing tile has different models
like roofing tile ventilator and building blocks are appear in a
range of models. THE MALABAR TILE Company has been the
aim of producing tile with quality and confirms to set the
standard.

Terracotta has been used since prehistoric

times, because of its features plasticity or elasticity when wet,
its ability to retain any form given when dried and finally
burning into a strong body with a beautiful colour terracotta
has been used widely by suipolaters and artisans to express
their creative imagination over a period of time creative
contribution from successive generation of gifted artisans have
not only enriched the cultural heritage but also provided a wide
variety of terracotta craft, both visually enticing and
intellectually entertaining. The heritage of terracotta craft in
India is rich and varied and dates back several centuries. From
the 16th till the end of the 19th century, many terracotta temples
have been built during the rule of mallas, notably in Bengal
which are still intact, bearing testimony to the longevity of the
material.
 In Kerala, centuries ago Christian missionaries
from Germany and Switzerland pioneered the terracotta
revolution by setting up a few factories in Mangalore and
Calicut. The availability of very good alluvial deposits of
common Red clay along the coast of Kerala and South Canara
enthused and encouraged them.

THE MALABAR TILE WORKS

THE MALABAR TILE WORKS HAS got a trusted

tradition spanning 90 years in manufacturing and marketing
quality terracotta building product. The CROWN BRAND
products are well known for their superior quality. The reasons
are superior production technique, the high content of iron and
copper in the clay, superior firing techniques and little water
addition.

CROWN BRAND building products are ideal for both

domestic and commercial use. Whether its a pool surround or
drive away, or the expensive walkways of our civic malls,
plazas, or shopping centers, CROWN BRAND terracotta building
is stunning in its beauty, stylish, elegant without necessary
details or decoration and rewarding in its practicality.
 Professionally qualified and experienced team of
skilled workers, the zed to update and innovate rigorous quality
control, superior German technology used in the fabrication of
kilns, etc are the key factor that has helped as in carving a
niche for ourselves in the building industry.

Recently a laboratory has been setup the factory to

check the quality of the raw material and that of the finished
products. The operations of the lab is being monitored by the
regional research laboratory, Trivandrum, a govt. of India
undertaking which comes under the Council of Scientific and
Industrial Research {CSIR}.

Presently the factory has infracture, experience and

expertise to meet the challenging demands of this highly
quality conscious industry. Safety is one basis of satisfaction
and a satisfied customer is good customer. For us
understanding the customer is an important as understanding
the products.
 7 SCOPE AND IMPORTANCE

The placement training help us for analyzing the

overall functions of THE MALABAR TILE WORKS from the
company the data are collected from many sources
namely primary and secondary.

Primary sources include the direct personal interview,

through observation, and also by interviewing the
employee on the basis of questionnaire. Secondary source
include the financial statement of the company such as
P/L a/c and balance sheet and other recorded document,
made availability of company.

The study is conducted or giving or providing

information about their performance of each department
and giving instruction or guidance and suggestion to
improve the productivity and managerial efficiency of the
company and also this study help the public for knowing
THE MALABAR TILE WORKS deeply. The study helps to
analyse the performance and productivity of the company.
8 LIMITATION

• The study of the company/placement was conducted with in

a two week, which is not enough to study THE MALABAR TILE
WORKS effectively.

• Financial analyse is purely based on financial statement,

some time it have error

• Market analyse is made on the feedback collected by the

company, so it may not be accurate.

• The data are collected by taking sampling technique because

the numbers of staff are in large quantity. Lack of time will
not able to interview the whole staff of the company.

• The details are collected from the staff members of the

concern. Confidential information are not revealed by the
management
 ORGANISATION STRACTURE
PARTNERS

MANAGING
PARTNER

GENERAL FACTORY EXECUTIVE

MANAGER MANAGER MANAGER

FORMAN PURCHASE OF RAW

MATERIAL
FINANC MARKETI HR
E NG M SUPERVISI
MANAG MANAGER ON
FIRE CLA
MECHANIC WOOD Y
AL
DEPARTME
NT

WORKERS
10 MACHINES AND EQUIPMENT

The machineries and equipment are used in the

production process are as follows

• Excavator
• Rail & Trolley
• Box feeder
• Double shaft mixer
• Pug mill
• Crushing ruler
• De-airing machine
• Cutting tool
• Automatic revolving press
• Kiln
• Chain conveyor
• Saw mill
• Racks & pallets
• Conveyor belt
• All mechanical tools
Generator, pump set, other machines.
 11

EMPLOYEES
OF THE
COMPANY

In modern concept employees are the important

asset of the organization. Without the employee the production
will not be continued. Employees are the important factor in an
organization. The success of every business depends upon its
human resources. The principles components of every
organization consider the satisfaction of workers.

There are some factors which have increased the

importance of human recourses such as the labour enactment
and emergence of various labour organizations.

THE MALABAR TILE Company has remarkable good

work force. The company provides good working facilities to
their workers.

There are 225 workers works in THE MALABAR TILE

WORKS. Out of 225, 200 workers are permanent and other 25
are extra workers. These 25 workers get daily wages.

For wages and salary administration workers are in to

5 grades such as A, B, C, D, & E. They are
• GRADE A

1. Burner.
2. Black smith.
3. Carpenter.
4. Masons.

• GRADE B

1. Electricians
2. Lathe operator
3. Mechanic
4. Filter
5. Dye chipper

• GRADE C

1. Ridge tile – frame pulling

2. Ridge tile – cutting
3. Press – purring slabs
4. Kiln – placing tile

• Grade D

1. Loading & unloading

2. Kiln department
3. Searching
4. Pushing trolleys
 • GRAD E
1. Drying section
2. Kiln filling employee
3. Canteen section
4. Releasing workers

For each category have different pay scale. The new

pay scale to the workers of the company is;

CATEGORY NEW SCALE

GRADE A 5210-18-5300-20-5400-22-5510-
24-5630

GRADE B
5910-17-5275-19-5730-21-5475-
21-5745-13-5590
GRADE C

5170-16-5250-18-5340-20-5440-
GRADE D 22-5560

GRADE E 5150-15-5225-17-5310-19-5405-
21-5510

5130-14-5120-16-5280-18-5370-
20-5470
 FACILITIES & INCENTIVES AVAILABLE
TO WORKERS

THE MALABAR TILE WORKS provides many

facilities for their staff & employees. They are

• Extra work payment

The working hours of a day are 8. If an

employee works more than 8 hours a day, he is eligible for
extra payment on a piece rate system. The extra wages is paid
twice in a month and a work register is maintained for this
purpose.

• Salary advance facility

Every worker of a company is paid in

advance an amount of RS 200 before the due date of
the salary on the 7th day of every month and this
amount is deducted from the salary of each employee.
 • ESI facility

All the employee of the company are the

members of the ESI & are eligible to get reimbursement of
hospital charges, fee and medicines.

The workers are eligible for pension in case of

any accident followed by permanent disablement in
capacitating the work.

Each employee contributes 1.75% of the

salary & employee contributes 4.75% of the employee net
salary or eligible amount. The amount has to be remitted in
bank before the 21 of every month.

• pension

All workers are eligible for pension after

completing his service. Minimum period of service required for
the pension year is 10 and the age of retirement is limited to
60.

• Leave Facility

The employee of the company enjoys 2 types

of leave benefits. Such as annual and casual leave. When a
worker has been 180 days of attendance in the previous year,
he is eligible for annual leave of 14 days in addition to 20 days
casual leave.
 • Gratuity

If a worker completes a minimum 5 years of

service then he is eligible for getting

Gratuity. It is calculated by the formula;

Salary * length of service * 15

Gratuity = 26

• Provident fund { P F}

As required under provision for provident

fund act employee and employer, contribute 12% of the net
salary to the provident fund, but the employer’s contribution
8.33% of the net salary goes to pension and the balance 3.66%
to PF. Employees contribute is fully credited to PF.

• Bonus

The company pays bonus every year that is in

many which is calculated on the

Basis of total of one year salary and records it in the bonus

reports. The minimum bonus amount is RS 3500/-.

• Overtime allowance
 Workers like kiln burners, have to work
without any holiday. So they are paid

Double charges for working on holidays.

12 LABOUR WELFARE ACTIVITIES

The company has interest in providing all facilities

provided by the management to workers. They are

• Festival allowance

The employees are given festival

allowance like Onam & Bakrid advance. This amount of
allowance are deducted from the monthly salary of workers by
installment.

• Canteen facility

The company provided canteen

facility to the workers. It provides breakfast, lunch, & snacks
with 85% of subsidy. Canteen workers are also the employees
of the organization.

The other essential welfare service are provided

by the company to workers are good working atmosphere,
cleanness of workplace, disposal of wastage, water facility,
ventilation etc.
 RECRUITMENT AND SELECTION OF
EMPLOYEES

In much way can recruit and select the

employee to the company. The company manager is conducted
recruitment and selection process through direct interview. The
company given more important in experience of selecting
workers.

Managerial and technical staffs are selected by advertisement,

in journals and newspapers etc. in managerial post the
company want high qualification.

The company receives application from

the qualified candidates and verifies the received application
thoroughly and invites the appropriate candidates for interview.
There is panel for interview in which the two or three persons
interview the candidates. The members of the panel prepare
questions and on the basis of this questions the interview are
conducted. The final selections of employees are goes to the
hand of director of the company.

After the selection of the employee to the

company, the company provides training to the workers. There
are two types of training method; on the job and off the job
training. On the job training means the training are conducted
within the work place or company. The trainee undergo the
training period by working. During this period the employee
gets minimum wages.
 Off the job training means the training are conducted outside
the company.

THE MALABAR TILE WORKS conducted

on the job training to the workers. On the job training is
provided to the factory workers within the factory. The
managers and staff members are given of the training.

WAGE PAYEMENT

The wage payment is based on the rules

and regulations specified as per the minimum wages act 1948.
The all workers of the factory get minimum wages compulsory.
In company there are two types of workers are employed.
Casual and permanent workers. The casual workers are paid
wages at the end of every week. And the permanent workers
get a fixed rate of salary in every month. In addition they get
leave, travel allowance he rate of 5% of their salary.

PROMOTION AND RETIREMENT OF WORKERS

 Promotion is based on the seniority basis.
The company promotes highly educated and qualified person to
the managerial post. The company considers seniority for the
promotion of the workers and given preference to the internal
promotion. Highly qualified and have the experienced person
get promotion to the high post.

Retirement of employees is the age of 60,

because of the lack of employees. The employee who attain the
age of 50 year is the available the facility of voluntary
retirement. After the retirement the employee get pension and
other benefits.
14 FINANCIAL
DEPARTMENT

Usually finance department handle all the

financial matters of the company. In financial department the
financial manager is essential to control the flow of finance.
Every organization needs finance to carry out its operations.

We know that finance is the life blood of a

business firm. So very careful planning and control are needed
in finance. Absence of proper planning and controlling of
finance may lead to the winding up of the company. Financial
management is concerned with planning and controlling of
firms finance requirement. For effective control of finance
require preparation of trading & profit /loss a/c and balance
sheet.

Profit /loss a/c reveal the profitability of the

concern. And the balance sheet shows the financial position of
the firm.

In finance department there are many

functions. They are

• Planning and control of funds

• Management of cash
• Co-ordination and control
 • Analysis and appraisal of financial
performance
• Record keeping and reporting
• Preparation of financial statements
• Cash managements and credit management
• Debtors and creditors statements
• Running funds
• Sales statements

SOURCE OF CAPITAL

For smooth running of business capital is

essential. Many sources are available in procurement of capital
before deciding to raise funds from a particular source, a cost
benefit analyses of various alternative must be made. The
source of fund must be selected after taking into consideration,
cost of raising fund, risk in financing etc.

THE MALABAR TILE WOERS raise its capital

mainly from owned capital and borrowed fund.

GRAPHIC REPRESENTATION OF SOURCES OF

CAPITAL
 SOURCE OF
SOURCE OF
CAPITAL
CAPITAL

OWNED FUND
OWNED FUND
BORROWED FUND
BORROWED FUND

OTHER FINANCIAL
OTHER FINANCIAL
BANK LOAN
LOAN INSTITUTION
INSTITUTION
BANK
15

PERFORMANCE AND
STATUS

• MANAGERIAL

It was in the year 2009, a change in

partnership took place and proven businessman and an NRI Dr
Krishnan has taken over the unit from the former management
header by Sir P Abdul Hameed as per memorandum of
understanding duly agreed upon and signed on 17-2-2009, in
the presence of representatives of workers union of the unit
and all other officials concerned.

Through most of the factory shed were

dilapidated and few of them collapsed due

To closure for a long period, Dr Krishnan has provided such

wonderful inspire leadership to get those shed repaired on war
footing basis by spending about 50 lakhs

• TECHNICAL

Technical head of the factory is factory

manager, foreman, and supervisors of various sections.
Technical staff and workers carry out their respective duties
under instruction of factory manager. Proper delegation of
powers has been conferred to all levels of hierarchy.
 • FINANCE

For any tile unit, the major raw material is

clay – the clay fields are available on either

sides of the river chaliyar. Unlike other clay it is plastic enriched

and ideal for manufacturing the procurement season i.e. from
December to May. Mining of clay also depends on climatic
conditions. Hence maximum accumulation of clay is necessary
in one season which needs lots of find with in a specified period
of time.

PRICE OF RAW MATERIALS

MATERIAL QUATITY REQUIREMENT

2010-2011PRICE 2011-2012
PRICE

A. Clay

per day 80box@rs 300 24000

80box@rs 300 24600

Per year 24000@rs 300 720000 24600@rs

300 792000

B. Fire wood

Per day 600kg@rs200 120000

600@rs200

132000
 Per year 120000@rs200 2400000
132000@rs200 2640000

C. Kerosene

Per month 1350lit@ rs30/l 40500

1350lit@rs30/l 44550

Per year 40500@rs 30/l 486000 44550@rs

30/l 534600

The accounting period starts as usual April 1st and

end with March 31st. At the end of

Accounting period the chief accountant prepare financial

statement and submit to the board of directors. If the report is
accepted it will give the managing partner of the firm

BOOKS OF ACCOUNT

THE MALANBAR TILE WORKS kept the books such

as day book, ledger, special journals, separate ledger for each
item, attendance register for staff and workers etc. At the end
of each accounting period financial statement is prepared.
Financial statement includes Trading & Profit/ Loss A/C and
Balance Sheet.
 Final account

Preparation of final account is the last step in

accounting cycle. It help to achieve the main objectives of
accounting, that is to ascertain profit or loss made by business
and to understand the financial position of the business.

Final accounts consist of Trading Account,

Profit /Loss Account, and Balance Sheet.

•Trading account

Trading Account is a nominal account, prepared

to show the result of buying and

selling of goods. The result of trading account may be gross

profit or gross loss.

Trading Accounts help to determine the sale

policy, price policy, and gross profit margin to sale. A
comparative study over the years will pinpoint the defects or
effectiveness of trading policy. It also determines the optimum
level of stock.

•Profit &Loss Account

It also a nominal account. Profit & Loss

Account is prepared to ascertain the net profit or net loss of the
business for an accounting period. It starts with the gross profit
brought down from trading account. The amount of net profit /
net loss is then transferred to Capital Account on the liability
side of the balance sheet.

•Balance Sheet

After having known the net profit /loss of

business, the businessman wants to know the financial position
of his business. For this purpose, prepare a statement of the
assets and liabilities as on a particular date such statement is
known as balance sheet. Hence it is also known as position
statement

A balance sheet has two sides; the assets

are shown on the right side and the liability and capital are
shown on the left hand side.

In a manufacturing concern another

account is prepared namely Manufacturing Account.

A manufacturing concern buys raw material,

process them and produce finished goods for sale. Hence a
manufacturing concern has to find out the cost of goods
manufactured by it during a period before finding out net profit.
In such a case an account called manufacturing account is
prepared to ascertain the cost of manufacturing goods
ACCOUNTING PROCESS

Different stages through which the

transactions travel until the final account are prepared is
collectively called accounting process.

ACCOUNTING PROCESS OF THE MALABAR

TILE WORKS

Transaction

Journals

Ledger

Trail balance

Final Accounts
 Trading Accounts
profit & Loss Acc

Balance Sheet

Cash flow &

fund flow

Repo
rts
ACCOUNTING POLICIES

• Basics of presentation

The structure of the accounts has been

drawn in accordance with the schedule VI of the companies’ act
1956.

• Fixed assets

Fixed assets are recorded in the book

value. Book value means the amount deducted from the value
of fixed assets. Fixed assets are started at less than
accumulated depreciation.

• Depreciation

Depreciation of fixed assets have been

provided on written down value method as per the rates
provided in schedule XIV of Companies Act 1956.

• Inventories

Inventories are valued at cost or market

price which ever is lower
16 PRODUCTION
PROCESS

Production is the basic operating function of

every business enterprises. It is concerned with the supply side
of the business production implies the creation of goods &
services to satisfy the consumers demands. It includes the
transformation of input into output.

Production is the process of transforming raw

materials or purchased components into finished products for
sales. Any process involving the conversation raw material and
components part into finished product is production. The
essence of production is the creation of goods and services by
the conversion of raw material of parts in such conversion of
inputs into finished products adds the value or utility of
products. The utility so created is the difference between the
value of input and the value of output.

Production department is the main

department of THE MALBAR TILE WORKS. The person who is in
charge of this department is known as factory manager. A
foreman is working under the factory manager. The function of
foreman is to coordinate and control all the activities of the
production department. Four supervisors are working under the
foreman. They are clay supervisor, press supervisor, drying
supervisor, and kiln supervisor. The fire wood section is
supervised by the foreman himself. Supervisors of each section
control the activities of workers in the concerned section.

RAW MATERIAL USED FOR PRODUCTION

The production process requires some raw

material. The raw materials used by the company for making
tiles are

• Clay

It is the main raw material used for

manufacturing of tiles, the supervisor who is
capable of identifying the

required quality of clay collects specimen of clay from clay field

and gives it to the company’s laboratory for testing. There are
mainly two types of clay plastic clay and lean clay. The plastics
are sticky on nature with blackish gray colour. It gives rigidity
and condensation of tiles. Lean clay is sticky compared to the
plastic clay. Lean clay is reddish gray in colour and gives bricks
red colour to tiles when burned.

1. sand contend test

 For testing, some sample or type
of clay is collected and washed through the stir in the bucket.
Repeating the washing cycle, still the stand obtained should be
below 30 germs or 30% to be found to be suitable for the
production of tiles.

2. burning test

For burning test prepare a

specimen of clay slab of size 150 mm, 5 mm is required to try
the slab the specimen is the fixed in free electrical test furnace
for 5 or 10 hours. Specimen is taken out after cooling
shrinkage.

3. usual observation

After the test are conducted; and

observation is made to sure that the tested clay is suitable for
tile making. Experienced supervisors for colour and plate of
tested clay carryout this observation very carefully.

4. procurement of clay

Clay is procuired in two ways.

Company made purchase clay from slab- contractors and they
are entrusted to supply clay for the year usually duringthe
months of January to may and this procuired clay both lean and
plastic are loaded in the clay dump. To form layers with equal
proportion, the company has to clay dump, each dump contain
around 3500 loads, in which 75%is used in one year. Loads
around 2000 tiles can be produced by using one load and that
the produced clay is kept at least for one year seasoning. The
clay is mainly obtained from Vengara, Mavoor, Karad,
Cheruvadi, and Edavanna. All are situated at the surrounding
places of the company.

•Water

Water is procuired from the well. The

company has five wells. THE MALABAR TILES WORKS situated
on the bank of the river chaliyar and from the chaliyar the
water requirement for the production process is easily met clay.
Motors and pump set are used for supplying the water to all
section of the factory.

•Oil and kerosene

Rice bran oil and kerosene in the ratio 2:1

are mixed and applied on the plugged slabs to avoid sticking of
slabs each other. Kerosene is also used as fuel in generator.

ELEMENT IN THE PRODUCTION

PROCESS

The production system is composed the

slab system.
 •Inputs

Input consist of raw materials, parts,

capital equipments, human efforts, information etc. inputs
constitute the variable of cost of production.

•Conversion process

Conversion or transformation process

refers to series of operations which are performed on material
and parts. The operation may be mechanical, chemical,
assembling, inspection, receiving, shipping etc.

•Outputs

Outputs are the completed parts resulting

from the conversion process.

•Storage

Storage takes place after the receipts of

the inputs between one operation and the other operations.
After the production process is over the products or inputs are
stored in the store by the store keeper.

•Transportation

Inputs are transported from one operation

to another through the production process.
 •Information

The information interconnects all activities

serves as a effective basis of managerial decision making. It
provides control through comparison, feedback, and corrective
action.

GENERAL MODEL OF
PRODUCTION SYSTEM

Inputs Receiving Operation

Storage Processing Operation

Outputs Information and

controllers
 Shipping
Operation Finished goods
storage

MANUFACTURING
PROCESS

Preparation of clay
 Collection of sliced
clay

Box the feeder

Double shaft mixer

Crushed with single

shaft mixer
 High speed roller

De- airing pug mill

Tile pressing

Drying

Kiln chamber
 Stocking

In manufacturing process there are so many

steps. At least 7 stages are including when the manufacturing
of tile completion. They are;

• Preparation of clay

Clay is an important raw material used in the

production of tiles. The factory manager
inspects in the clay field

and take sample of clay and bring it to the company for testing.

The clay is mixed thoroughly by using

machine called excavator, which takes sufficient quality of
water in the clay dump and sufficient quality of clay. With the
help of excavator the clay is sliced. Slicing is done for
uniformity.

• Collection of sliced clay

After slicing the clay it is collected in trays is

called trolleys
 • Box feeder

For feeding the clay trolleys containing sliced

clay is pushed into the box feeder.

• Double shaft mixer

From the box feeder the sliced clay is put in

to the double shaft mixer for grinding the clay. For this purpose
2 types of clay such as plastic clay and lean clay are mixed
thoroughly and are applied on the dies to avoid the sticking of
clay on the die. These tiles are received on the wooden pallets
and the trimmer, which goes to the de-airing pug mill, cuts the
waste parts of the tile. The pallet containing wet tiles are on the
top of the kiln. The tiles are released from the conveyer and
placed on the shelves arranged in the storing area of drying.

The press supervisor controls the press.

There is a huge revolving press that converts the slabs in to
roofing tiles. Different types of press are used fore producing
different tiles.

• Crashed with single shaft mixer

After grinding the clay thoroughly with

double shaft mixer, the mixer clay is put into the single shaft
mixer for proper grinding. The ingrained clay in the double
shaft mixer can be fully by using single shaft mixer.
 • High speed roller

From the single shaft mixer the clay is carried to

high speed roller through the rubber conveyor
belt. The final

grinding take place here. The processed clay will be free of any
solid substance and homogeneous in nature.

• De-airing pug mill

From the high speed roller the clay is

conveyed to the de-airing pug mill. It is a machine, which
converts the clay in to the required clay slabs by avoiding air in
the clay. The extruded tiles are then piled one above the other.
In the pug mill the labs with are applied with kerosene and rice
bran oil to avoids sticking of slabs witheach other. These slabs
are conveyed to the ridge press for making ridge as and when
required by the company.

Truck pusher push the truck containing the

sliced clay in to the factory, the operator lifts the clay up and
clay feeder, put in to the pug machine. Pug machine is a roller
which mixes the clay thoroughly. The output of pug mill is clay
blocks, which are cut into small pieces.

• Tile pressing

The extruded tile slabs from the de-airing

pug mill are conveyed to the press for making roof tile, with the
help of automatic trimmer by which the tiles are properly
shaped and finished.

• Drying

There are two types of drying implemented

by the company to dry the tiles. they are;

1. Natural drying
2. Artificial drying

Drying with the help of firewood is called

artificial drying otherwise it is called natural drying. Drying
takes around 8- 10 days.

• Kiln chamber

The well dried tile are packed in the

chamber f the hot Mann kiln for backing. For burning wet tiles
in the kiln chamber firewood is used as fuel. A temperature of
800 degree needed for burning the tiles. The kiln’s output is 4
champers per day a kiln run for 24 hours through out and even
on holidays. As the temperature is reached at the required level
in one chamber, the firing will be moved to the next chamber.
After that the chamber is cooled and later empted. The burned
tiles are removed to an open space near the kiln yard. The
grabbled tiles are then carried to stock yard and are stored and
kept separately clash wise.
 THE MALABAR TILE WORKS have two kilns
have 64 chambers with a total capacity of 3000 tiles per
chamber. The factory use chamber system inside the kiln.

• Stocking

In stock yard separately class wise. The

store keeper is responsible to keep the products class wise and
to supply the products when orders are issued from the sales
department. The store keeper arranges to load the goods in the
vehicle and he is responsible for keeping up to date information
about the quantity, classes of tiles in the store.

The store keeper has to maintain a store

ledger account. He should prepare a monthly report containing
details of all transactions made relating to stores and closing
balance of stock.

17
PRODUCTS

Eco-friendly and durable terracotta products

are manufactured and marketed by THE MALABAR TILE WORKS.
The clay works has been considered as the branch mark of
quality. The company uses imported machines and know how
and have won medals at all India exhibitions.

The company is the first manufacture of

ventilator bricks and hallows bricks, used for load bearing in
multi storied floor slabs. THE MALABAR TILE WORKS presents a
widest collection of terracotta products ranging from roofing
tiles it flower pots. The products of THE MALABAR TILE WORKS
are

1. Roofing tile {single grove & double grove}

2. Ridges
3. floorings
4. flat roof tiles
5. jelly blocks
6. sky light
7. Vally tiles
8. flower pots
9. hallow pots
10. floor bricks
11. wire cut bricks
 Types of tiles Sizes

A. Roofing tiles

420*250 [mm]

• Roofing tile double 16.5*9.8 [Inch]

grove
1313 [100sq.m]

122 [100sq.ft]

• Ridge tiles 430*270 [mm]

16.9*10.6 [inch]

262 [running
meter]

• Decorative ridge {A} 80 [running feet]

430*270 [mm]

16.9*10.6 [inch]

262 [running
• Decorative ridge {B} meter]

80 [ running feet]

430*270 [mm]

16.9*10.6 [inch]
• Ceiling tiles {Flower} 262 [running
meter]

80 [running feet]

320*210*15 [mm]
• Taylor tiles
12.6*8.2*0.6
[inch]

1313 [100sq.m]
 18 LIMITATION OF TILE
INDUSTRY

By conducting the placement training,

it reveals that around 20% of tile unit are becoming sick every
year. Many of the tile factories are struggling for existence. This
traditional labour incentive industry facing many problems
today.

• Clay

Clay is an important material used for

making tiles. The non availability or restriction of
digging the clay is

major limitation of tile industry. Though huge deposits of clay

are fount both sides of Chaliyar River and other areas in Calicut
the district administration put certain restriction for digging the
soil for tile industries. Govt. vide notification dated on 10th
march 2010 issued guideline for digging clay meant for tile
industry, in other words known as Kerala minor mineral
concession (amendment) rules 2010 provided that an
application for obtaining permission for digging up of or
renovation of stagnant water bodies in lands in order to store
water for irrigation

• Firewood
 Another limiting factor is the non
availability of firewood. For kiln purpose rubber wood are used.
High costs are incurred for buying and also each hail hour
firewood is feeding to kiln. It is very difficult.

• High cost of raw material

Clay, firewood, and other inputs price are

increased much. As a result of this increase, most of the tiles
factories are finding difficult to cut the cost of production.

• Competition

Till recently there has been a good demand

from the external market. Till 1965, 75% of the output has sold
out side the state. But now the tile factories have been
established in Tamil Nadu, Karnataka, and Andhra Pradesh.

• Power failure

Another problem faced by the tile factory is

the power failure. Especially in Kerala power cuts,
load

shedding etc effect the manufacturing process of the company.

Huge loss is beared by the factories when at the time of power
failure. Non availability of power, the factory has to depend
upon generator. But it is not possible for small scale industries.

• Labour problem
 There are number of employees working in
each and every tile industry. In Kerala trade union is strong and
they are not ready to co operate with the management.
Because of luck of demand the tile factories can not utilize the
labour effectively.

• Scarcity of raw material

Clay is the basic raw material in the tile

industry. Shortage of clay is an important problem faced by the
company. And also the quality of clay is important one.
19 FINDINGS AND SUGGESTION

• From the data provided by the company, it can be

seen that THE MALABAR TILE WORKS has a good
organizational structure.

• This industry did not make any in technology and

quality. Till it is a traditional industry.

• The amenities provided to the workers are limited

and the company faces too many labour
problems.

• The company is not completely computerized and

as such there exit a lot of paper works in the
company.

• Due to continue power failure, the company is not

able to produce goods at his full capacity.

• Non availalibility of raw material also affect the

smooth flow of production and the scale of tiles.
 • The increased demand for concrete building
decrease the demand of roof tiles.

MEASURES TO TAKEN

• Tile factory must apply modern technique and

material handling devices.

• Necessary step shall be taken to provide fuel,

clay, and other inputs as concessional rate.

• Survey regarding the availability of clay may be

conducted.

SUGGESTION

• The company can produce more volume of

products in accordance to the demand of the life
style of the people

• The marketability of the products can be improved

by the introduction of new models to attract
customers.
 • It shall improve the advertisement program and
promotional activities with a view to increase sales

CONCLUSION

From the placement training of THE MALABAR

TILE WORKS it can be understood that the tile companies in
general had been facing a crisis, because of spreading of the
concrete houses. They tries to over come this crisis by
introducing innovative and new product, which can be used
concrete houses for avoiding leakage and making houses more
beautiful.

It include that, the tile companies could

flourish in their business, if they adopt some new product that
are co-product of the concrete houses and also introduced
some means for improving the level of satisfaction of
employee.
20 BIBILOGRAPHY

• Marketing ----
Philip Kotler

• Human resource management ----

Dr. C B Guptha

The data are collected from the staff

members of THE MALABAR TILE WORKS. And
from the records

of the company.