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MAHARAJA AGRASEN INSTITUTE OF MANAGEMENT STUDIES
SUMMER TRAINING REPORT
ON
MARKETING OF STEEL PRODUCTS
CARRIED OUT AT
NEW DELHI
Submitted in partial fulfillment of the requirement for the award of degree
BACHELOR OF BUSINESS ADMINISTRATION
SESSION :- 2011-2014 Submitted by :-
SARVDAMAN PRASHAR ENROLLMENT NO :- 09761101711
CONTENTS
Topic Page No.
Declaration
Preface
Acknowledgement
Chapter-1
Introduction to MULTI COLOR STEELS
Chapter-2
Various Departments
Chapter-3
Research & Development
List of Major Plant & Machinery
Chapter-4
Production of Steel roofs and claddings
Bibliography
2
STUDENT UNDERTAKING
This is to certify that I have completed the Project titled "MARKETING OF STEEL
PRODUCTS " in MARKETING DEPARTMENT of MULTI COLOR STEELS INDIA PVT.
LTD " under the guidance of Mr. Ravi Jain" in partial fulfillment of the requirement for the
award of degree of Bachelor of Business Administration at Maharaja Agrasen Institute of
Management Studies, Delhi. This is an original piece of work & I have not submitted it
earlier elsewhere.
Sarvdaman Prashar
3
CERTIFICATE
This is to certify that the project titled "MARKETING OF STEEL PRODUCTS
in MARKETING DEPARTMENT of MULTI COLOR STEELS INDIA PVT.
LTD" is an academic work done by " SARVDAMAN PRASHAR " submitted
in the partial fulfillment of the requirement for the award of the degree of
Bachelor Of Business Administration from Maharaja Agrasen Institute of
Management Studies, Delhi, under my guidance & direction. To the best of my
knowledge and belief the data & information presented by him/her in the project
has not been submitted earlier.
Mr. Jatin Vaid (Assistant Professor)
4
ACKNOWLEDGEMENT
Apart from the efforts of me, the success of any project depends largely on the
encouragement and guidelines of many others. I take this opportunity to express my gratitude
to the people who have been instrumental in the successful completion of this project.
I would like to show my greatest appreciation to Mr. Jatin Vaid. Thank you won't be enough
for him tremendous support and help. I feel motivated and encouraged every time I attend his
meeting. Without his encouragement and guidance this project would not have been
materialized.
The guidance and support received from all the members who contributed to this project, was
vital for the success of the project. I am grateful for their constant support and help.
SARVDAMAN PRASHAR
5
EXECUTIVE SUMMARY
Practical training imbibes an integral part of management studies. One cannot merely rely upon the theoretical knowledge. It is to be coupled with practical for it to be fruitful.
Classroom lectures made the fundamental concepts of management clear. They also facilitate
the learning of subject in a comprehensive manner. Practical training in a company has a
significant role to play in the subject of. To develop leadership skills in future managers
and enhance their analysis skills , it is necessary that they combine their class room learning
with the practical knowledge of manufacturing and other operations.
I consider myself lucky to get my summer training in India's respected organization and
the leader in Indian metal buildings business in quality, productivity and customer
satisfaction MULTI COLOR STEELS INDIA PVT. Ltd. I under went six weeks of
practical training at M.C.S. It helped me to get a practical insight into the actual industrial
environment and provide me opportunity to make my management concept more clear .
It is difficult to elaborate everything which I have learned during the training. However, I have endeavoured many comprehensive pictures of details about working in the following
pages. I have accumulated the desire information through personal observation, self practice
over machines and discussion held with officer at different levels.
6
CHAPTER - 1INTRODUCTION TO M.C.S.
INTRODUCTIONOF M.C.S.
HISTORY
MEMBERS OF MCS GROUP
DIRECTORS OF THE COMPANY
COMPANY ORGANISTION
FUTURE PLAN
EXPANSION PLAN
QUALITY MANAGEMENT
VISION & MISSION
7
INTRODUCTION
Founded in March 1972, MULTI COLOR STEEL INDIA PVT. LTD. is one the leading manufacturers and suppliers of high tensile fasteners such as Bolts , Screws,
Nuts and similar parts for Automobile and other Industrial Sectors.
LPS have grown steadily over the past 31 years on the strength of our in house technological developments innovations coupled with our reputation as the company with
strong commitment to customer satisfaction and quality improvement.
LPS understand what we have to do for our customers. We assure that we will do our best to make our products safe and reliable for our customer's assembly line.
LPS promise to improve our products to meet the ever increasing expectations of our customers and are always obliged for their continued guidance and patronage.
LOCATION OF PLANT
The company is situated on PLOT NO.4, SECTOR-6 IMT MANESAR, GURGAON, (HARYANA). The company has got excellent manufacturing facilities and conditions.
Manufacturing plant exceeds over a space of about 25 - 30 acres .
8
RESEARCH METHODOLOGY
A) Primary Data
B) Secondary Data
Primary Data- Primary data is that kind of data which is collected by the investigator
himself for a specific study. The data search collected is original in character. The
advantage of this method of collection is the authentic. Primary data is collected from
women entrepreneur. Questionnaire as a tool is used as primary data in this research.
Questionnaire contains:
1. Self prepared questions and size of questionnaire is appropriately taken so as to
avoid any adverse affect on response rate.
2. Instructions which make it simple and easy to understand.
Secondary Data- When an investigator uses the data that has been already collected by
others is called secondary data. It may be official or unofficial. The secondary data is
collected from Website, Journals, Reports and various publications. The advantages of
secondary data can be –It is economical in terms of money and time spent.
BOTH PRIMARY AND SECONDARY DATA ARE USED.
SAMPLING DESIGN
In the theory of finite population sampling, a sampling design specifies for every possible sample its probability of being drawn.
Mathematically, a sampling design is denoted by the function which gives the probability of drawing a sample
Descriptive Research=Descriptive research, also known as statistical research,
describes data and characteristics about the population or phenomenon being
studied. However, it does not answer questions about.
eg: how/when/why the characteristics occurred, which is done under analytic research.
Although the data description is factual, accurate and systematic, the research
cannot describe what caused a situation. Thus, Descriptive research cannot be used
to create a causal relationship, where one variable affects another.
The description is used for frequencies, averages and other statistical calculations.
Often the best approach, prior to writing descriptive research, is to conduct a
survey investigation. Qualitative research often has the aim of description and
researchers may follow-up with examinations of why the observations
SAMPLING TECHNIQUE
Probability Sampling = A probability sampling method is any method of
sampling that utilizes some form of random selection. In order to have a random
selection method, you must set up some process or procedure that assures that the
different units in your population have equal probabilities of being chosen.
Humans have long practiced various forms of random selection, such as picking a
name out of a hat, or choosing the short straw. These days, we tend to use
computers as the mechanism for generating random numbers as the basis for
random selection
Probability sampling is a sampling technique wherein the samples are gathered in a
process that gives all the individuals in the population equal chances of being
select
A Simple random sample is a subset of individuals (a sample) chosen from a
larger set (a population). Each individual is chosen randomly and entirely by
chance, such that each individual has the same probability of being chosen at
any stage during the sampling process, and each subset of k individuals has
the same probability of being chosen for the sample as any other subset of k
individuals. This process and technique is known as simple random sampling,
and should not be confused with systematic random sampling. A simple
random sample is an unbiased surveying technique
MEMBERS OF MCS GROUP .
NAV BHARAT INDUSTRIES
LAKSHMI PRECISION SCREWS LTD.
LPS FASTENERS AND WIRES PVT. LTD
UNIVERSAL ENTERPRIES.
LAKSHAMI PRECISION SCREWS LTD. (PLANT II).
JC FASTNERS LTD.
LAKSHMI PRECISION SCREWS LTD. (PLANT III)
SWADESH ENGINEERING INDUSTRIES
DIRECTORS OF THE COMPANY
MR. DEEP GUPTA
MR. DIPANE GUPTA
MR. ASHISH GUPTA
11
CHAPTER-2:COMPANY PROFILE
BOARD OF DIRECTORS
CHAIRMAN AND MANAGING DIRECTOR
QUALITY MANAGEMENT CORPORATE STRATEGY
MARKETING R&D PLANNING PRODUCTION FINANCE GENERAL D E V E L O P ME
NT
SALES
DEVELOPMENT
LABORATORY
CPP ERL NOA TDN RUN ACI LTN - IG -O- -N-
PLANT
-I
PLANT-II
PURCHASE
FINANCE
HRD
EDP
12
FUTURE PLAN
Its future plan includes :-
Continuous investment in R&D.
More concentration on hard currency market of USA , UK, Japan and Europe
with the objective of doubling the exports and to bring invaluable foreign exchange
for the country.
On the corporate agenda is a massive expansion program which include
diversification into chemicals and engineering.
To improve quality in design and manufacture through implementation of ISO-9002
system.
EXPANSION PLANS
To meet the challenges is an open economy and competitive edge, the company had undertaken and expansion scheme with a total capital out of Rs.1655 lakhs.
13
QUALITY MANAGEMENT
The company has embarked upon the ambitious plan of furthering the cause of quality through total customer satisfaction after achieving the ISO
GUIDE 25 & ISO 9002 . Towards this end the company has initiated steps for
obtaining QS:9000 . In addition fastener quality act. 1996 of USA is now under
implementation which is a mandatory requirement for exporting to USA after May
1998.
14
MISSION & VISION
VISION :- Be recognized as the best and preferred supplier of National / International standard.
MISSION :- To be a growth oriented professional company
promoting high standards of business ethics and
producing best quality products thereby achieving
international standards of excellence.
To establish a strong R&D facility to fulfill the
demands of the automotive industry as comprehensively as
possible.
To make each member of the company feel proud and
empowered by fostering a culture of participation and
innovation.
To strive for reduction in defects and achieve 6
Sigma and beyond so as to make quality a way of life
To reduce cycle time in all processes as a step
towards over-all improvement.
To provide prompt and excellent service to customers
anywhere in the world.
To maximize shareholder's wealth.
Their motto:- Total customer satisfaction and leadership.
Their target:- Annual growth rate of 30% of which export contributed up
to 50%
Their people:- To diversify after 100 crores.
Their function:- System oriented .
Their people:- The main force behind it.
16
VARIOUS DEPARTEMENTS
PRODUCTION DEPARTEMENT
PRODUCTION PLANNING AND CONTROL
INSPECTION AND QUALITY CONTROL
TOOL ROOM DEPARTMENT
PURCHASE DEPARTEMENT
PERSONEL DEPARTEMENT
MARKETING DEPARTEMENT
17
PRODUCTION DEPARTMENT
The function of production department is to effectively plan and regulate the operations of that part of enterprise which is responsible for actual transformation of raw material
into finished products. The production activities in L.P.S. are looked after by Works
manager who is responsible to report the general manager.
For efficient production, the department has being divided into various units such as PPC department , Quality Control department , Heat Treatment department etc. All the
departments are part of production department and responsible for regulating all the
workers of production department.
The production system is a part of a longer system of a business firm.
The production system can be viewed as a frame work or skeleton of activities within which the creation of values can occur.At one end of the production system are the input and
the other end are outputs. Connecting the outputs and inputs are a series of operation
or processes storages and inspections.
The production system is applicable for both production of components and production of services also.
The production of any component can be viewed in terms of a production system. For example, the manufacture of Fasteners in values such as inputs, wire, machines, workers,
tool, etc. After these inputs are acquired, the several operations are performed which are
necessary for the formation of bolts. By these operations the inputs are converted into
outputs such bolts, screws, nuts etc. After finishing operations, a final inspection occurs. Then
outputs are held in the stock rooms until they are supplied to the customers.
18
Factors affecting scheduling
Customer's demand.
Customer's delivery date
Stock already lying with dealers
.
Stock already lying with the firm.
How much time available and how much time is required for manufacture.
Availability of machinery and other facilities.
Availability of raw materials.
Availability of manpower.
Feasibility of economic production/batch size.
19
PRODUCTION PLANNING AND CONTROL
FUNCTIONS :-
Production planning and control has following functions: 1. Planning 2.
Routing
3. Scheduling 4.
Dispatching
5. Inspection
Following chart can show these functions:
FORECASTINGPRODUCT DESIGN
AND
PRODUCTION PLANNDEVELOPMEN ING
AND CONTROL
PRODUCTION CONTROL
T
INVENTORY PRODUCTION PLANNING
CONTROL
20
OBJECTIVES OF P.P.C :- Objectives of production planning and
control department are closely linked with the objectives of the enterprise whole.
Keeping in view, the main aim of the customer's satisfaction, objectives of P.P.C
can be summarized as follows :-
To deliver the product the customer when he wants it.
To follow-up production schedule to ensure that delivery promises are
maintained.
To maintain quality at desired level, i.e. same as that of approved sample.
To maintain adequate level of inventories, as excess or shortage both are
harmful.
To utilise optimum plant capacities
To maintain flexiblities in manufacturing operation, so that emergency rush
can be accomodated.
Production planning and control system which converts the objectives into
action is shown on the chart below.
21
pPRODUCTION PLANNING
AND CONTROL
PRODUCTION
LANNING
INVENTORY CONTROL
PRODUCTI ON P
TRAFFIC
MANONTRO UFAC RECEIVING PRODUCTION BUDGET
MANUFACTU- RING METHODS
MATERIAL BUDGET
STORES RECORD
TURIL&NG SUBSIDIA RY ORDER ROUTING
SHIPPING
INTERNAL KPROCESS
MACHINERY &
EQUIPMENT
PLANT LAYOUT
TOOL DESIGN
OPERATION SHEET
EEPIN G
MATERIL REQUIRE
STORE KEPING
SOLVEGIN G
SCHEDULING & MACHINE LOADING
DESPATCHING
EXPEDITING FOLLOW-UP
TOOL KEEPING
TRANSPORTATION
INSTRUCTION CARDS
MOTION AND TIME STUDY
M/C AND MANPOWER REQUIREMENT
MASTER SCHEDULE
22
Objective
AAnalyses
Plan PRODUCTION PLANNING
FURTHER ACTION
COMPARE
IMPLEMENT
MEASURE AND
OBSERVE
PRODUCTION CONTROL
23
INSPECTION AND QUALITY CONTROL
FUNCTIONS OF INSPECTION :- Inspection of raw material.
Inspection during manufacturing.
Metallurgical and metallographic inspection. Purchase and inspection. Finish
goods inspection. Tool
inspection.
TYPES OF INSPECTION :- Dimensional inspection.
Testing of mechanical properties.
Surface finish inspection.
Performance testing.
The inspection is done commonly at two places, stage inspection and final inspection, but sometimes patrol inspection is also done to check the effectiveness and efficiency of
machines. Thus patrol type of inspection is done to manufacturing of components.
24
INSPECTION METHOD :- In a repetitve type of manufacturing inspection should be done at several placed.
Process inspection
Sampling inspection
Batch sampling inspection
Final inspection
PROCESS INSPECTION :- Process inspections the inspection of the components during the manufacturing. It is also
reffered as inspection is to prevent scrap, rework, reduce operation levels and detect hidden
defects and to attain a higher quality of finished products.
SAMPLING INSPECTION :- In sampling sample is taken and analyzed for machine and tolling faults. This type of
inspection is performed by stage inspector. This inspection helps in detecting only fault
which may be in machine as tooling. Thus report also benefits the operator by letting him
know his quality of work.
BATCH INSPECTION :- This type of sampling generally concerns parts there have been removed from the sho door
and sampled according to statistical methods based on the past experience.
FINAL INSPECTION :- Final inspection is done at the end of all the operations being performed.All the parameter are
checked again. Thus inpection is very critical and all the parts are screened and combed to
detect any faults which might have crept in during manufacturing.
25
STORAGE INSPECTION :- In storage inspection components come in lot are checked by stage inspectors. The
components are checked functionally and dimensionally. Different guages for different
dimensions are used to reduce the inspection time.
PARTIAL INSPECTION :- In the partial inspection, the components are inspected in the machine itself during their
manufacturing. This type of inspection helps as follows :
Reduce scrap.
Better control and dimensions.
Time saving.
Man power saving.
QUALITY CONTROL :- Quality control means degree of perfection achieved. It is not absolute but it can be judged
and realized by comparing with some standards.
OBJECTIVES :- To see that the products being manufactured are in tolerance limits. To Take necessary steps,
so that products which are not up to the standard don't reach the consumers.
ADVANTAGES :- Quality of the products is improved and thus the consumers attracted with the effect quality
control, scrap, rejection and re-working are minimized and thus avoiding wastage, which
reduces the cost of production.
Reputation of the company is enhanced by good quality of its products.
26
RESPONSIBILITIES OF Q.C.DEPT. :- To allow sale of product of uniform and required specification.
To reject the defective goods and shield the consumer from defective items.
To correct the rejected goods if possible.
27
TOOL-ROOM DEPARTMENT
Tool Room is a very important department of a company. All the repairs in dies and manufacturing of new dies are performed in the Tool Room. The main function of the tool
room is to deal with the dies used in the Production Department. To maintain & repair the
dies used in power press, equipped with various punches, is an important function of Tool
Room. Without the help of tool room, the functioning of production department seems
impossible. Production Department can't work without the existence of Tool Room, even for a
single day. For efficient working of any company, or Production Department, in particular a
Tool Room with efficient workmanship is must. Tool Room consists of two section.
Turning Section
Grinding Section
In Turning section soft material is used for work then hardening is done for attaining its required hardness , after this material is transferred to grinding section for its required surface
finish .
Various Machine Used in Turning Section:
Lathe Machine
Milling Machine
E. D. M(Electric Discharge Machine )
Engraving & Marking Machine(Pentograph )
Various operation on Lathe Machine are :-
Centering
Thread cutting
Drilling
Turning
28
Various operation on Milling Machine are :-
Keyway cutting
Gear cutting
Slotting
Tapering
Drilling
Facing
Various machine used in Grinding section are:-
Surface Grinding Machine
Cylindrical Grinding Machine
Lathe Machine
Various operations on Grinding Machine are :- Internal Grinding
Surface Grinding
Hex./Pent. Grinding
Outer Diameter (cylindrical grinding)
Some of the grinding machines used in grinding operation in tool room are :- Grinders Maker's Name
1) Universal Tool & Cutter Grinder 0200* 500 Stanlaso, US
2) Surface Grinder Paraga, India
3) Internal Grinder Fort VNA, USA
4) Cylindrical Grinder HMT, USA
Rectification is done on lathe in grinding section .
Power Hex Saw is used in tool room store for cutting of material of required size
(length wise).
Drilling Machine is also used in tool room .
29
After turning section and grinding section final inspection is done whether
required tool or m/c part or die is according to required specification.
Material used in tool room is basically High Carbon High Chromium, Hot die Steel,
High Speed steel ,Mild Steel etc.
PURCHASE DEPARTMENT
The purchase department is that section of an organization, which deals with the arrangements of various physical inputs used, in actual production, maintenance and
establishment. The purpose of purchase department is to purchase the selected material
at minimum cost. The organization hierarchy of purchase department is shown as:-
PURCHASE MANAGER
PURCHASE OFFICER
PURCHASE ASSISTANT
30
Firstly the purchase department bought the raw material from the
market, which is passed to the laboratory for inspection. The laboratory test
involves which type of material is that, what's its composition and what's its
strength. After this test the report is supplied to general manager of production
department. If material is o.k. then order is placed by the purchase department. The
purchase process to buy a raw material can be shown as:-
INDENT
QUOTATION (TO BE SOUGHT WITHIN 15 DAYS AND FOR
CAPITAL ITEM-1 MONTH)
COMPARATIVE STATEMENT
PURCHASE APPROVAL BY G.M.
PURCHASE ORDER(4 COPIES)
31
PERSONNEL DEPARTMENT
The activities of personal department are :
Recruitment
Training/Placement
Welfare Activities
Welfare Action
Industrial Relation
RECRUITMENT :-
It is based upon the work load for a predetermined target and with the consent of the Managing Director.The qualification standard for each job is laid down as approved by the
M.D. of the company.
GENERAL POLICY :-
According to the company all the promotion vacancies are fulfilled through internal recruitment . Usually recruitment from outside is for workmen grade category administration
department and trainee in the technical department.
TRAINING/PLACEMENT :-
The company has different types of training programs.Trainees are trained to improve the basic skill and work knowledge on the basic machine . After completion of the two Years
training, Specialists trainees,Engineer trainees, Technician trainees and Trade trainees are
posted as Forman with two increments.
32
WELFARE ACTIVITIES :-
As per factories act following are the welfare activities for worker and staff :
A) STATUTORY ACTIVITIES Provision of toilets
Provision of drinking water
Separate washing facilities
Sitting facilities in side the factory
First-Aid and Medical facilities
Subsidized Canteen facilities
Rest room and lunch rooms
Apartment of welfare officer
For every 200 employees there will be one welfare officer . For every additional 500 ,one additional officer is posted .
b) NON-STATUTORY ACTIVITIES
Transport facility
Quarters/Housing
House building allowance scheme
Uniform
Recreation activities
Death Relief
33
M.C.S. MARKETING
The company has established its various sales representatives in various parts of India ; Mainly in Industrial cities of India like Chennai , Bangalore ,Coimbatore, Kanpur etc. Their
main test is to find out market or customers for their product.
The marketing division has been divide into 2 parts
Export Marketing
Domestic Marketing
The Domestic marketing then divides the customer into two parts
OEM (Original Equipment Manufactures )
Dealers
OEMs are the ones who are designers of the product themselves . They are the ones who can supply the design and we have to make the fastener according to the design given . Similarly
the OEM are divided into future 2 Sub-Categories:
New Customer
Existing Customers
WORKING WITH NEW OEM :-
Company gets the purchase order from the new customer through our sale personnel and the customer provides the Drawing . Then the drawing is taken to the Research &
Development as the feasibility report about the product .Whether we can make it or not
and if we can make what are the requirements?
34
The R&D Then prepares the feasibility report about . After the feasibility report the
report the sent to the Finance Department for the costing . The Finance Department then
prepares the unit price of the product and then this is forward to the marketing
department ,who gives the quotation to the customer.
If the customer approves the quotation then sample of some pieces is made and given to the customer for the approval . If the customer approves the sample then pilot lot is
prepared and given to the customer and . The size of the pilot lot can be 50,100,or 200 also.
If the is again approved then we get purchase order (PO) from the Customer and a CC is
sent to the production , planning and control department(PPC).
After completion of the manufacturing of the product , the material is to given to the finished . Goods stores who dispatches it to the customer .
WORKING WITH EXISTING OEM :-
If the customer is existing then purchase order is directly given to the PPC department then Engineering department releases the drawing and the product is made . The format of
dispatching is same in every case.
WORKING WITH DEALERS :- Sometimes our the customer is the manufacturer but the dealer and instead of quoting
the price we have the price list for our products and we give them the price. After that it the
same working procedures as the rest.
35
MAIN MARKETS
DOMESTIC (USER INDUSTRIES)
Automotive
Aviation
Heavy & Light Machinery
Hydraulics/Pneumatics Pumps
Machine Tools ,Jigs & Fixtures
Railways
Refrigeration & Air Conditioning
INTERNATIONAL (COUNTRIES) Australia
Germany
Holland
Japan
Singapore
South Africa
South Korea
Sweden
Switzerland
United Kingdom
United States of America
36
MAJOR CLIENTS :-
Berwick PTY Ltd. (Australia)
Muller & Wilde (Austria)
Hussaini Brothers (Austria)
Bossard France (South Africa)
Berner France Sarl (France)
Nestinox B.V (Holland)
China Crystal Metalware Limited (Hong Kong)
Nuova Ferro and Acciaio SRI (Italy)
National Socket Screw Company (South Africa)
L & W fasteners Co. (USA)
Heads and Threads Company (USA)
Lindstrom Metric. Inc (USA)
Bangkok Salakphon Ltd. (Australia)
RESEARCH & DEVELOPMENT
The company's R & D efforts continue to be dictated by the need for market orientation.
In the face of stiff competition , in order to maintain the profit margin , the focus is on developing products of increased value addition. Accordingly manufactures of sems, track
bolts, automotive nonfasteners components like steering knuckles , gudgeon pins,
startermotor, pin ions are being planned. The fully computerized five station part former and
boltwasher assembly machine presently under installation and commissioning/ordered would
facititates this. Stainless-steel fasteners & fasteners which are percolated with micro
encapsulated anaerobic thread cocking adhesive are also being considered as value
added products.
Special purpose machines and CNC turning centers are being added to the manufacturing facilities to increase productivity and consistency in quality of SPECIAL FASTENER,
especially for the automotive application.
Since the tools form considerable parts of the manufacturing cost, in house heat treatment of the tools has already started. Plans are being drawn up to introduce vacuum hardening,
organic treatment and
other tribiological coatings to improve the tool life.
In order to cut down development cycle time for SPECIAL FASTENER in the automotive industry which is the largest consumer for company's products technical collaboration is
being entered into a leading manufacturer of automotive fasteners in the world . The
company's effort on the whole should meet the today's customer's requirements, namely,
zero defects, low cost, just in time delivery and short development cycle time.
39
LIST OF MAJOR PLANT AND MACHINERIES
Sl. no.
1
2
3
4
5
6
7
8
9
Plant and Machinery
CNC Machines
Flat Rolling
Circular Rolling
Nut Tapping
Drilling
Single Spindle Secondary
Operation Machines
Centreless Grinding
Pointing
Turning
No. Off
1
12
16
3
5
9
6
6
1
40
PRODUCT PROFILE
LPS has a capacity to produce over 10,000 MT of precision engineered fasteners.
LPS offers over 6000 / 8000 kinds fasteners with diameter ranging from 3mm to 24mm and in grade of 8.8 , 10.9 , 12.9 45H , R , S , T , V , Grade 5 & Grade 8etc. for
almost all product category . High - grade alloy steel goes into LPS high tensile
precision fasteners for superior fatigue resistance and closer tolerance level.
The company produces two types of items :
Standard fasteners
Specialized fasteners
42
The standard fasteners confirms to international and national standards. These are as follows:
Socket head cap screw (allen bolt)
Socket shoulder screws
Low head socket cap screws
Button head socket screws
Socket set screws
High tensile hex head wrenches
High tensile hex head bolts
High tensile friction grip bolts and nuts
High tensile hex nuts
Dowell pins
Hexagonal wrenches (allen keys)
43
A very comprehensive range of special high tensile bolts/screws, studs, nuts, and special cold
forged components in the size range of 3 mm to 30 mm are manufactured . These special
products are made to satisfy a very exacting Engineering standards.
LPS Range of Special Products cover the automobile, tractor, heavy earth moving equipments, textile machinery and machine building industries. To name a few of the special
products in which LPS is the undisputed leaders are:-
Durlock Bolts
WheelHub Bolt
Flange Bolt
Connecting Rod Bolt
Gear Shaft
Axles
Stud
The special fasteners are made to customers specification of size, grade and finish to the point of precision. Specials currently being manufactured.
Wheel bolts/ hub bolts and nuts
Connecting rod bolts
Cylinder studs
Axle bolts
Flange bolts
Counter weight bolts
Round head bolts
44
PRODUCTS DETAIL'S
SOCKET HEAD CAP SCREWS:-
One can get the extra strength and fatigue resistance that is needed for total reliability. In high strength fastening from L.P.S Socket Head Caps Screws. L.P.S Socket Head Cap Screws
have cold forged head, which ensures stronger heads. Due to uniform grain flow of the
material. Threads are rolled and kept uniform with closer tolerances, smoother surface and
better size controls. Socket head cap screws are made out of high-grade alloy steals and heat-
treated in atmosphere controlled furnaces which surface carburisation and decarburisation.
COUNTERSUNK SOCKET HEAD SCREWS :- L.P.S countersunk socket head screws are manufactured out of high grade alloy steels to suit
the specifications of every lot. One can achieve smooth flush mounting with reliable and
dependable fastening. They also provide increased fatigue. L.P.S-CSK screws assures flush
seating and close all round head contained due to closely controlled head angles in cold
forging closely controlled rolled threads ensure tighter fit And stronger assemblies. Non-slip
wrench engagement for full tightening is achieved with deep socket.
BUTTON HEAD SOCKET SCREWS :- These are manufactured from grade alloy steel and forged head provide greater strength. Non
slip wrench engagement for full tightening is achieved with deep sockets, which prevents the
surface in which they are installed from getting marred. Threads are rolled with close
controlled tolerances which ensures greater strength and superior fatigue resistance.
LOW HEAD SOCKET CAP SCREWS :- Socket low head cap screws are used in applications where the clearances are limited. They
are manufactured out of high-grade alloy steels for precision fastening. Rolled threads with
45
root radius increase fatigue life of threads and reduce the stress conservation. Uniform
concentric socket depth helps in full engagement of wrench in for proper fastening.
SOCKET SET SCREWS :- L.P.S SOCKET SET SCREWS are available in knurled cap point, cone point, flat point and
dog point. They are manufactured from special grade alloy steel and heat treated in
atmosphere controlled furnaces which ensures uniform hardened and higher strength without
decarburisation rolled threads provide strength. Deep socket and reduced corners gives more
key engagement and distributed stress which eliminates points of weakness where cracks may
starts.
HIGH TENSILE HEX. HEAD BOLTS :- LPS high tensile hex head bolts are manufactured in strength levels 80 kg/mm to 120 kg/mm
and it offers several benefits to the economy minded, such as reduction in the size and
number of fasteners required compared to conventional mid-steel fasteners there providing
valuable savings in the cost and space. There are manufactured in the size range M3 to M24
and length from 6mm to 210mm.
HIGH TENSILE HEX. NUTS:- L.P.S high tensile nuts are cold forged using quality steel on high-speed nut former. Heat
treatment is done in atmosphere-controlled furnaces to suit the chemistry of every lot of steel
and to ensure correct mechanical properties and tightening fatigues to fulfill standard
requirements. Dimensions finish are costly and controlled to ensure smooth assembly with
L.P.S high tensile Hex head bolts.
HIGH STRENGTH FRICTION GRIP BOLTS AND NUTS:- L.P.S high strength friction grip bolts are mainly developed to have bolted with higher fatigue
strength, than riveted or welded joints. They help in having fastener assembly and fewer
number of bolts thus economizing the cost and main power requirements.
46
SPECIAL FASTENER :- L.P.S special fasteners are tailor made to meet the specific requirements of customers in
range of 3mm to 24mm and in property grades 4.8 to 12.9. L.P.S special fasteners include
wheel bolts and nuts, connecting rod bolts, counter weight bolts, cylinder studs, flange screws,
axel bolts, shock absorber-mounting paints etc.
Dimensions, finish and mechanical properties requirements are closely controlled to satisfy
very exactly engineering needs of the customers. L.P.S special fasteners are very widely
acknowledged and are in greater demand.
47
PROCESS CHART
The process of manufacturing NUT & BOLTS are explained below with the help of flow chart :-
RAW MATERIAL FROM STORE
SAMPLE OF RAW MATERAIL FOR APPROVAL
WIRE DRAWING
FORGING
ROLLING
HEAT TREATMENT
GRINDING
PLATING/PHOSPHATING
FINISHING
OILING
LABORATORY
48
PACKING
STORING
MARKETING
49
RAW MATERIAL :- The Raw Material for production, comes in form of coil/wire bend. The basic raw material
used in the production of these screws are CHQ carbon boron /alloy steel. The source of raw
material is both INDIAN MARKET and FOREIGN COUNTRIES .
The Indian Market from where L.P.S purchase are :- Mukund Limited Bombay.
Bihar alloy Limited.
Main Foregin countries from where L.P.S imports raw material are : Dongbou cooperation South Korea .
Komorowaski company West Germany.
Mitsui company ltd. Japan.
Indian raw material is used in the production of HEX. NUTS and imported raw material is used
in the production of high tensile screw and nuts.
VARIOUS DEFECTS IN RAW MATERIAL ARE :- Loose scale
Crack
Seams
Blow holes
Decarburisation
Hardness
Pitting
Chemistry
FORGING :- This is an important step in making the product . There are two types of forging that are being
done .
Hot Forging
Cold Forging
50
M.C.S is mainly concerned for the cold forging operations. Cold Forging is another form of
swaging operation and is used for the manufacture of bolts ,rivets ,hexagonal Sockets
screws ,screws and similar headed item. The importance of cold heading operation lies
principally in the saving of material, very little or no scrap being produced . A header being
a high speed automatic production machine, it result in low labour cost with proper cost
with proper production runs . Because of the method flowing the material ,it often result in
the better structure of the metal and hence stronger parts. The machine produces parts to
close tolerance and fairly smooth finishes. Cold heading can be done on a wide variety of
materials(capable of being cold worked without hardening too rapidly e.g steel having
0.45% carbon or lees and alloys which work rapidly).
A typical examples for manufacturing the bolt from cold headed operation is described
below. A ductile material in the form of rod is fed on to the machine , where it is cut in
standard pairs of jaws , and subjected to two or three blows to form the head roughly . It is
then repositioned in the another die for final shaping and sizing and then thread rolling is
done on automatic machine whose output rages from 50 to 150 pieces per minute .
Some of the machines used in cold forging are:-
Bolt Maker 5L4
3/8 100LS Quarter B.M 6L4 5/8 S-325 S-340
CHD 82 CH16 SSSM
Nut Former 124 CLF
Maker's Name National Kayser, Germany
-do- -do- -do- -do-
SakaMuRa Co Ltd Japan -do- -do-
Chun-Zu Taiwan -do-
Davenport , U.S.A
Maker's Name National Kayser, Germany
51
ROLLING :-
The rolling of the bolt depends upon the requirement of the customers. It is very important step in manufacturing process. Rolling is the only thing which differentiate the screws and
bolt . If the threading is on the whole cylindrical surface , then it is called screw, otherwise it is
called bolt.
There are two types of Rolling machines:-
FLAT ROLLING MACHINE :-
In this machine the die are flat and the bolt is fed through the 2 rolled dies .There are 4 flat rolling machine available. We can have different dies for different pitch diameters.
CIRCULAR ROLLING MACHINE :-
There are 2 rolling dies between which the bolt is kept and the threads are formed on the bolts or screws. In this machine there are two division:-
In Feed (Automated)
Through Feed (Manually)
HEAT TREATMENT :- Heat treatment is an important operation in the manufacturing process of machine parts and
tools . It may be defined as an operation of heating and cooling of metals in the solid state to
induce certain desired properties into them . Heat treatment can alter the mechanical properties
of steel by changing the size and shape of the grain of which it is composed , or by changing its
micro constituents. It is generally employed for the following purpose:
To improve machinability .
To change or refine grain size.
To relieve the stresses of the metal induced during cold or hot working.
To improve mechanical properties e.g tensile strenth, hardness, ductility , shock
resistance to corrosion etc.
To improve magnetic and electrical properties.
52
To increase resistance to wear, heat and corrosion.
To produce a hard surface of ductile interior.
The heat treatment of the product is divide mainly into 2 portions:
HARDENING
TEMPERING
HARDENING :-
Hardening is done to increase the strength of the material. There 3 furnaces and each furnace has 2 zones with it . The first zone is for pre heating the material and the second zone is to used
for soaking the product till the required temperature is attained in the product .
The furnace is called the shaker hearth furnace . It is electrically heated and the atmosphere
inside it is ENDO GAS(AIR +LPG, 1O:1). There are 12 heating elements in the first chamber
and 6 in the second chamber . The soak in time in each chamber depends on the diameter of
the products .
TEMPERING :-
There are 2 furnaces . The furnaces is vertically tempering furnaces .There are heating elements on the chamber and hot air is continuously circulated inside the chamber .
In High Temp furnace hardening and tempering is done simultaneously . Hardening chamber has three zones and Tempering chamber has four zones.
GRINDING :- Grinding is mainly done for finishing the shininess of the product . Grinding eliminates tiny
cracks due to hardening and tearing is always present to some extent in any material
removal method .
Centerless grinders ( CLG ) are used for grinding purpose .
These are semiautomatic and manually.
53
PLATING AND FINISHING :-
Finishing and plating is done to remove the impurities in the product and to increase its corrosive resistance and to give it a better look. This operation is done after the material has
been heat treated . The plating department receives the work order from the PPC department
as to what type of finishing is required for the product . The type of finishing required for the
product is given by the customer , alongwith the design .
The plating and finishing is divided into 3 main portion
Pre treatment
Plating (electro plating)
Post treatment
PRE TREATMENT :-
This is basically the clearing and activation of the products so as to get an adherent deposits (i,e. Oil removal etc.) on the products.
PLATING :-
The product are mainly zinc plated , depending upon the requirement of the customer . This is done to improve the corrosive resistance of the material . Electrolyte used during plating is a
combination of (Zinc metal +Zinc Chloride +Boric Acid).
Zinc Metal = (25 gms to 35 gms )/litre.
Zinc Chloride = (100gms to 120gms)/litre.
Boric Acid = ( 30 gms to 35 gms )/litre.
During plating Zn plate is positive charge and material to be plated is negatively charged.
Plating tank is combination of two electrodes one of which is consumable i.e. Anode and
electrolyte.
54
POST TREATMENT :-
This is done to increase the corrosive resistance of the steel. The process is called passivation. According to the requirement Zn plated or phosphated (black finishing) products are dipped
into the respective passivation solution . The product is kept for 1 minute in the solution and
dried after wards .
Different colours imparted during Passivation
Colours Solution
Yellow Nitric Acid + Sulphuric Acid + Sodium Dicromate
(8ml to10ml)/lts. (55ml to 60ml)/lts. (330gms.)/lts
White Nitric Acid + Ginthon Oil 550
( 4gms to 6gms)/lts ( 8ml to10ml)/lts.
Green Olive 862 (120ml to 140ml)/lts
Black Kempass 66A+Kempass 66B (90ml)/lts. (90ml)/lts
.
55
SECONDARY OPERATION
The operations, which are done after first operation that is forging are known as secondary operation.
Following are the secondary operations and machines used for those operations.
Sl. No.
1
2
3
4
5
6
7
8
Operation
Thread Rolling
Grinding
Pointing
Bend Removing
Drilling Machine
Nut Tapper
Facing
Undercutting
Name of machine used
Thread Rolling Machine
Thread Rolling Machine
Center less Grinding Machine
Adda / Drilling machine
Center less Grinding Machine
Adda / Drilling machine
Traub
Traub
56
Product Name
Material
Grade
Hardness Required
Finish
Tolerances Allowed :-
Linear
Angular
Part No.
PRACTICAL EXAMPLE
M12 x 1.75 x 42 Hex Collar Bolt
4140/4037
10.9
32 - 38HRC
Blackened & Ground
0 - 6±0.1 6 - 30 ±0.2 30 - 120±0.3
0- 30 ̀
14 - 2913
Let us consider an example of HEX. Collar Bolt from Raw Material to the finished product.
As required material of product is 4140\4037, so the wire from the Raw material ,of size M12 is brought on to the forging machine. The colour code & any defect of material is
inspected on the machine by operator Quality Control Supervisor.
Then the wire is loaded on the forging machine and the forging of the bolt is started . There are four steps in forging of the bolt i.e. there are a set of four dies in which the formation of
bolt takes places.
After forging the supervisor of Q.C Deptt. check all the dimension of bolt according to the
given dimensions in the drawing . The main dimension ,which are kept in mind , are Body
Dia. , Thread Rolling dia. ,Collar dia ,across flat Stamp, under head Radius head height etc.
After completion of forging , the bolt is transferred to Automatic lathe / Traub for
pointing ,undercutting Grooving and Collar dia Turing.
57
After the completion of process on auto lathe the floor inspection is done by Q.C Supervisor .
The under cut angle , radius and pointing angle are checked on the profile projector.
After the completion of the process, the bolt is sent to the grinding machine for the thread rolling dia grinding. The final size of T.R.D is maintained at this machine.
After finalizing the T.R.D. dia ,the bolt is sifted to the rolling deptt. Where ,thread are formed on the rolling machine . The die no. is given in the drawing so that same die is used
for rolling . There are two gauges for the checking of threads one is GO & another NOT GO.
One of gauges should satisfy the conditions. The major dia. is checked by simple
micrometer where as pitch dia. is checked by the pitch micrometer. The minor dia. is checked
on the profile projector.
After thread rolling ,bolt is transferred to heat treatment section required hardness is obtained their, hardness is checked on Rockwell Hardener Tester .
After heat treatment, finishing is done for required surface finish. If required oiling is according to customer requirement. Final inspection is done in laboratory for approval of
finished product. Then product is send to packaging dept.
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CLASSIFICATION OF DEFECTS
Sl.no Types of Major Defects Minor Defects
fasteners fastners
( 1.) Hexagonal Width across flat Thread length,screw length,
socket ,Head pitch dia. Thread shank dia., height of head
Cap Screw major dia. concentricity, fillet radius,
depth of socket
( 2.) Hexagonal Thread major Thread pitch dia. under size,
Bolts and dia. Thread picth thread length, bolt length.
Screws dia. Oversize, Height of head,end of screws
width across Perpendicular of head to
flats shank
Black Thread major dia Thread picth dia. under size, ( 3.)
Hexagoanl thread picth dia. thread length, bolt length. bolt Oversize, width Height of head,end of screws
across flats Perpendicular of head to
shank
( 4.) Socket head Thread major Minor dia., thread length, bolt
Cap
scre
w
dia. Thread pitch length.
dia.
Oversize,depth
of socket
key ,head height
( 5.) Coach bolts Thread major dia Thread picth dia under size, thread
thread picth dia. length, bolt length.
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Oversize,width Shank dia of square neck, -
of square necks. height of head ,head dia., end
of screw
( 6.) Slotted Thread major dia Head dia, slot width, slot
counter sunk thread picth dia. depth ,screw length, thread
head machine Oversize. length,thread picth dia under
screws size, end of screw
perpendicular head to shank
( 7.) Grub screws Thread major dia Head dia, slot width, slot
thread picth dia. depth ,screw length,head
Oversize. length, thread picth dia.
( 8.) Slotted Thread major dia Head dia, slot width, slot
cheese head thread picth dia. depth ,screw length,head
screws Oversize. length, thread picth dia
METHODOLOGY
Primary Data:
For obtaining the primary data for my project, I used two research instruments:
Questionnaire
Structured Interviews
1.For Questionnaire:
Sample size: 10
CHAPTER-3:DATA ANALYSIS & DATA INTERPETATION
Q1.Can you describe steel company's overall approach to maintaining its competitive position ?
Chart showing steel companies overall approach
Product Oriented
Price Oriented
Brand Oriented
61
Q2.What have been the main challenges that the company has had to face and how has it
dealt with these challenges?
62
Q3.Does the company have specific plans for growth in the next few years?
63
Q4.What do you think which growth strategies is most effective?
64
Q5.Is the Government supporting the steel industry?
65
Q6.Is the growth and expansion strategies of the company are effective?
66
Q7.What are people experiences about the steel company product ?
67
Q8.Does Steel industry has good impact on the Indian economy ?
68
Q9.What type(s) of machinery do you use?
69
Q10.What type of facilities you get fom your suppliers ?
70
CHAPTER-4:Suggestions
1. Key Challenges for Retail Managers: A retail manager's goal is to maximize
productivity. This is tough. Store staffs likely include inexperienced, part-time or seasonal
employees. Retail hours are long. Sales targets may seem unreachable. Yet, in this setting,
good retail managers thrive. They are skilled in four primary areas which are:
Managing time.
Recruiting and supervising staff.
Building skilled and motivated sales and service teams.
Managing change.
2. Time -- a Fixed Resource: Tight budgets. Lean staff. Information overload. It's never
been harder for retail managers. Those who manage time well can do these things:
Know when to solve a problem immediately, when to put something off and when to
delegate.
Eliminate time wasters.
Handle interruptions.
Say "no" to unreasonable demands.
3. Teamwork Lightens the Load: For retail managers to have any personal life, they must
be able to trust staff to work and solve problems on their own. Skilled managers continually
work at:
Delegating responsibility.
Establishing group goals.
Aligning staff people and their roles so that cross-training and cooperation can thrive.
Identifying and securing resources so people can do their jobs well.
Motivating the team to work together and support each other even in stressful times.
4. In Retail, Change Is a Given: Change in retailing is what drives success. Styles change.
Customer needs and wants evolve. Competitors jockey for market leadership. Retail
management means managing change by:
Anticipating change.
Leading group problem solving.
Managing transition.
Championing innovation.
Reducing resistance to change.
5. Retailers Value Training: According to a study released at the National Retail
Federation's 90th Annual Convention, management skills are the most frequently addressed
training subject of US retail companies.
"As retailers expand, acquire properties, reposition or rebrand, managers become the critical
players in communicating and instilling change throughout the organization," stressed Michael
Patrick, CEO of MOHR Learning, the company that conducted the study. "Clearly retailers want
to make sure their managers have the skills needed to do this
CHAPTER-5:LIMITATIONS AND CONCLUSIONS
I have noticed that the most commonly talked about disadvantage of the fast fashion model in
retail business is the cost of production due to the short production runs. What are the other
likely disadvantages? I seem to find this model to assume or rather target people with readily
disposable incomes which may make it difficult to plough money back if this group is small.
In this context, can lack of disposable income on the part of customers be a disadvantage?
What does the group think about this line of thought and what could other disadvantages be
Lack of disposable income is inevitably a disadvantage in retail, but when customers leave
one market segment in favour of another there is a benefit to those operating in that
segment - fast fashion retailers targeting the value market achieve large volume through their
low pricing. By providing close copies at a fraction of the cost of the originals they appeal
both to low incomes and also higher income groups, who purchase more frequently.
Other disadvantages include sustainability issues - short product lifecycle - more frequent
purchases linked with more clothing going to landfill - more transportation - more
natural resource
Ability to offer personal service
A small retailer may know all his clients personally due to constant interaction with them. He
would know the tastes and preferences of his clients to be able to offer them a better
personalized service, catering for their unique needs. A large retailer would not be able to do
this as its aim is to sell, sell and sell. Time is money is such a large business and the more
rapidly it sells, the higher the profit. Special small orders from customers are rarely accepted,
especially if these do not generate enough cash to generate the required rate of return for the
business. The customer may be considered nothing more than a number in a large superstore,
but he would be a treasured regular customer for the small retail store.
Labour problems
The fact that it is constrained by time, pressure is transferred to the large retail store’s staff,
which is expected to do more in less time. Most of the work is repetitive and they can hardly
engage in conversations with the client or with colleagues. This leads to lower morale on the
place of work and more costs of recruitment and retraining if workers regularly resign from
their work.
Less control over pilfering
With a huge surface area full of thousands of items, it is difficult to have eyes all over the
place to control pilfering. Large retailers are faced with the problem of people stealing small
amounts from the shelves while no one is looking. Installation of closed-circuit cameras is
essential but having someone to go over all the tapes in real-time to check that no one is
slipping items into their handbag or clothing comes at a large cost. The temptation to steal is
higher in a large shop than it is in a smaller shop where it is easier to be spotted by someone.
Thieves may also think that it is less likely for larger retailers to notice occasional pilfered
items due to the large quantities of material. Shoplifters are regularly convicted by large
retailers than they are by the smaller ones. The business is faced with a loss-loss situation
where it either invests in security or else it suffers the loss of pilferage.
On the other hand, the retail inventory method is only accurate if all pricing across the board
is the same and all pricing changes occur at the same rate. In most cases, this is not realistic in
retail because of the many variations that exist in merchandise pricing. For example,
depreciation, markdowns, product damage and theft can affect the price of the retail
inventory. For this reason, any calculations made using the retail inventory method should
serve only as an estimate.
CONCLUSIONS
The Retail Sector in India can be split up into two, the organised and the unorganized. The
organized sector whose size is expected to triple by 2010 can be further split up into
departmental stores, supermarkets, shopping malls etc.
In terms of value the size of the retail sector in India is $300 billion. The organised sector
contributes about 4.6% to the total trade.
The retail sector in India contributes 10% to the Gross Domestic Product and 8% to the
employment of the country.
In terms of growth the FMCG retail sector is the fastest growing unit and the retail relating to
household care, confectionery etc, have lagged behind.
The foreign retail giants were initially restricted from making investments in India. But now
FDI of 51% is permitted in India only through single branded retail outlets. Multi brand
outlets are still beyond their reach. Again they can only enter the market through
franchisees,. This was how Wal-Mart had entered joining hands with Bharti Enterprises.
On line retailing is still to leave a mark on the customers due to lacunae that we have already
mentioned.
In a nutshell we may conclude that the retail industry in India has a very bright future
prospect. It is expected to enrich the Indian Economy in terms of income and employment
generation.
BIBLIOGRAPHY
To make this project, I took help from some secondary sources and these are :-
The Books: Business Organization, T.N Chabra, 3Rd edition , 2010, Srijain publishing. Marketing Management, T.R Jain , 2nd edition, 2005, oxford publisher. Marketing Research, Naresh Malhotra, 3rd edition,2011, Pearson publishers.
Marketing Strategies, Michael porter, 8th edition, 2012, Tata MacGraw Hill.
WEBSITE www.multicolorsteels.com www.wikipedia.com/marketingofsteels.html
