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CHAPTER I

                                     INTRODUCTION

                                1.1INDUSTRY PROFILE

Indian auto component industry is robustly driven by the growth in demand for automobiles. The
sector has become a lucrative business proposition for global players, majorly owing to two
factors. First, needless to say, the demand for automobiles is increasing day by day in the
country. India, a market with high potential for the automobiles sector, is expected to witness a
three-fold increase in demand for automobiles by 2020. Secondly, all major global auto-makers
are establishing their bases here due to highly positive business environment, favourable policies
and government support.

According to a study by UK-based global financial advisory firm-Rothschild, India would
become the third largest auto industry by volumes after China and the US by 2015. This would
give immense support to the growth of ancillary sector as well.

According to a recent study by the Automotive Component Manufacturers’ Association of India
(ACMA), original equipment manufacturers (OEMs) account for 41 per cent of the auto
components consumed in the Indian aftermarket.

The study estimated current size of Indian components business at Rs 24,800 crore (US$ 4.87
billion), 49.7 per cent of which is formed by two-wheeler segment. Passenger vehicles,
commercial vehicles and three-wheelers follow with 24.7 per cent, 23.1 per cent and 2.5 per cent
of the share respectively.

CARBURETOR MANUFACTURING INDUSTRY

Most of the modern vehicles make use of a carburetor that is used for blending accurate amount
of vaporized fuel with air so that the internal combustion engine works efficiently. The
carburetors available in the market accentuate several features such as highest quality standards,
lifetime warranty, engine tested, improved performance, economical, excellent drivability,
versatility, better fuel economy, greater throttle response, quick installation, highly modifiable

                                                1
and easy to maintain. Carburetors supplied in the market provide greater calibration capabilities
and comprise of central float chamber and a unique throttle body that comprises of throttle body
spacers, throttle cables and more. The carburetor manufacturing industry presently sizes around
US $ 2.4 billion. Its major manufacturers are AML Carburetor Company, Edelbrock AVS
Carburetor, LectronCarburetors, Walbro and TillotsonCarburetors, Zenith UK, Holley, Keihin
and Rochester Products Division.

FUEL SYSTEMS

The function of the fuel system is to store and supply fuel to the cylinder chamber where it can
be mixed with air, vaporized, and burned to produce energy. The fuel, which can be either
gasoline or diesel is stored in a fuel tank. A fuel pump draws the fuel from the tank through fuel
lines and delivers it through a fuel filter to either a carburetor or fuel injector, then delivered to
the cylinder chamber for combustion.




                                                  2
1.2 COMPANY PROFILE

UCAL FUEL SYSTEMS LTD. (UFSL) was established in 1985 by Carburetors Limited,
pioneers In India in the manufacturing of Carburetors and mechanical fuel pumps. In 1987
UCAL entered into a joint venture with Mikuni Corporation of Japan, an internationally
renowned company for Fuel Management System and products. UCAL became public limited
in 1989. With the factories in MaraimalaiNagar, Pondicherry and Gurgaon commissioned and
the product range enlarged, UCAL witnessed a quantum leap in the last decade of the century.
UCAL started to manufacture world class Carburetors and mechanical fuel pumps using
advanced technology in the state of the art facilities and began supplying as OEM to Maruti-
Suzuki, Premier 118 NE, and HM. The Pondicherry plant started to manufacture Carburetors
and Secondary Air Valves for two wheelers and Multi point fuel injection hardware products for
passenger cars 1996

A Vignette given below explains UFSL’s growth towards becoming truly an internationally
respected Brand and becoming a proud supplier to some of the globally acclaimed companies
such as Maruti-Suzuki, Hero Honda, TVS, Bajaj, Yamaha, Piaggio, Fiat, Tata Motors, Cummins
and many more.

   2003 - Collaboration with Orbital Inc, Australia for development of Direct Injection
   systems.

   2004 - Krishnamurthy centre for Technology a R&D centre,

   2005 - Acquired Amtec Precision Products Inc in US.

   2006 - Started development of products for Diesel applications.

   2008 - Close of JV agreement with Mikuni Corporation. Supply of full volume of pumps
   for Suzuki power train

   2009 - Supply of Fuel Pump to Visteon started




                                              3
1.2.1 LIST 0F MANUFACTURING PLANTS-UCAL


                               Production Capability                  Certification



      Maraimalai Nagar, TN    Pressure Die Casting for Zn & Al,      TS 16949
 P1   May 1990                Machining & Assembly for               ISO 9001
      Total Area 20200 sq m   MPFI &Carburetors, Gasoline Test       ISO 14001

      650 employees           High precision Jet Section & plating   OSHAS 18001


      Puducherry              Machining & Assembly ASV,              TS 16949
 P2
      September 1996          Carburetor (2W & 4W) , Gasoline ISO 9001
      Total Area 5700 sq m    Test                                   ISO 14001

      474 employees           High Precision Jet Section             OSHAS 18001




      Gurgaon, Haryana        Machining & Assembly for 4W TS 16949
 P3
      April 2000              MPFI parts                             ISO 9001
      Total Area1800 sq m                                            ISO 14001
                              Assembly unit for oil and vacuum
      200 employees           pumps                                  OSHAS 18001


      Ambattur,TN
 P4                           R&D                                    TS 16949
      2003

      Total Area 8900 sq m




                                        4
1.2.2SUBSIDIARIES-UCAL


List of Subsidiary Plant



                                 Production Capability                 Customers


          Pondicherry           Rubber to metal bonding              UCAL,
UPIL
          December 1999         Plastic to Plastic welding           Mikuni,
          Total Area 1965       Metal to Plastic welding
                                                                     Lucas TVS
          sq m
                                Precision Assemblies
          80 employees

          Elgin, Rockford –     Precision component,                 GM, Cummins,
AMTEC
          Ilinois               Air Conditioning compressor          Sensata, Ford,
          Acquired : 2005       components
                                                                     Continental
          Employees : 200       Plastic Injection Molding parts




CERTIFICATIONS

It is the right synergy that we are able to create by our incisive knowledge of the industry; the
key processes and our worldwide resources that enabled us to get the right Human resources and
the advanced technologies helped us to achieve exceptional results for our customers. We have
been able to build differentiated leadership and cutting edge operations through integration of
knowledge and expertise shared from across our entire worldwide network. All our units are
certified to pertinent ISO standards which validate the existence and working of effective
system. The processes are monitored and controlled through stringent Internal and External
Audits for their effective functioning.




                                                5
Various Certifications obtained by Company

       ISO9001:2000 – Quality Management system for other industries
       ISO14001:2004 – Environmental Management system
       TS16949:2002 – Quality Management system for Automotive industries
       OHSAS18001:2007 – Safety Health Management System



AWARDS

Over a period of time, UCAL has been consistently able to receive a series of awards and
recognitions for the excellence in customer service, technology, quality and industrial relations.

 Awards for Customer Service

    2004 - Direct On Line award from Hero Honda

    2004 - 100PPM Commendation certificate from HMIL

    2005 - Award from MUL for superior performance in Quality

    2005 - Award from MUL for overall excellence

    2008 - Best Vendor award from Sona Koyo Steering Systems

    2009 - BOSCH Supplier Award for maximizing value to the customer



Awards for Technology



    2004 - Frost & Sullivan Special Award for India Manufacturing Excellence

    2006 - Silver Award to Gurgaon Plant in the Automotive Ancillary by F & S

    2006 - ACMA Bronze to Gurgaon Plant for manufacturing excellence

    2007 - Frost & Sullivan Golden Certificate of Merit for Manufacturing Excellence




                                                6
1.2.1 VISION AND MISSION OF THE COMPANY

    To strive for continuous growth in Fuel Management Systems to meet the ever-exacting
    Market Demands through Research & Development and Excellence in Operations
    Management.
    To be a Key Global Player in Fuel Management Systems.




                                          7
1.3 PRODUCT PROFILE

UCAL today spans a wide spectrum of products for the automotive sector and is a perfect
amalgam of people, technology and resources reinforced with the advantage of a thorough
understanding of automotive industry

UCAL is in the business of providing holistic solutions in fuel management systems and is
committed to producing products of consistent quality and timely delivery. This is validated
because UCAL is the most preferred supplier of products to customers such as MarutiUdyog,
Hyundai, General Motors, Cummins, Bosch, Mikuni, TVS Motor Company, Bajaj Auto, Suzuki,
Yamaha & Hero Honda Motors to name a few.

The company takes pride in being an engineering company that provides solutions to customers.
The company designs products for petrol and diesel engine application and has impeccable
manufacturing process and systems that ensures product quality. Apart from producing parts of
consistent quality and upholding stakeholder satisfaction, UCAL takes it as a duty to be socially
responsible organization and ensure that all products are environmentally friendly.

UCAL product portfolio consists of extensive range of components for two, three and four
wheelers. The product range include carburetors for two wheelers, gasoline fuel injection
system products, engine management systems, products for diesel applications and emission
control, pumps to high pressure die casting and precision manufacturing products.

Their wide range of product portfolio is backed by in-house Design & Development facilities.
Highest level of quality is ensured in all our products through processes governed by Lean,
TPM, SMED, 5S and other best operational practices

Four Wheelers


       Multi Point Fuel Injection (MPFI) Parts
       Carburettors
       Emission Control Products & Others




                                                 8
Two / Three Wheelers


        Carburettors
        Emission Control Products


Gensets


        Carburettors
        Pumps


Pumps


        Oil Pump Assembly
        Vacuum Pump Assembly
        Fuel Pumps
        Water Pump Assembly


Machined Component


        High Pressure Die Casting Products




                                             9
1.4 ORGANISATION CHART



      BOARD OF DIRECTORS




    CHIEF EXECUTIVE OFFICER




      GENERAL MANAGER




         SENIOR DGM




            DGM




       SENIOR EXECUTIVE




         SUPERVISOR




           10
1.5 DEPARTMENTS IN UCAL FUEL SYSTEM LIMITED

In Pondicherry plant UCAL has the machining & assembly of ASV (Air Suction Valve),
Carburetor (2W & 4W), Gasoline Test and High Precision Jet Section. The plant was established
on September 1996. It has a total area of 5700 sq m and has 474 employees. The company
consists of 12 departments. The combined and trouble free operations of all these departments is
the secret of success of the plant. Various departments are mentioned below.



              Production Department
              Human Resource Department
              Finance Department
              Marketing department




                                               11
CHAPTER II

                             PRODUCTION DEPARTMENT

2.1INTRODUCTION

New products are analysed and report regarding production method, design, average time taken
to finish single product, rough expense etc. are prepared by this department. First Time Through
method is adopted in the development procedure. Trial and error method is not adopted here.
Department also recommend new tools, designing facilities and other requirements in the
production.

All the activities related to the production are handled by this department.

       Preparing process flowchart
       Preparing control facilities
       Giving instructions to workers regarding the methodology
       Displaying the operations in front of workers in local language
       Giving awareness about safety and convenience



2.2 MANUFACTURING PROCESS

     They provide a total solution from product design to analysis, prototyping, and testing and
validation services to our customer and ensure a cutting edge technology and know-how in our
manufacturing facilities. Adhering to strict disciplines of quality and precision our manufacturing
process ranges as follows:

       Die and tool manufacturing
       High pressure die casting
       Vacuum die casting
       Precision Machining
       Surface treatments
       Machining, Assembly and end of line testing


                                                 12
These processes are supported by well-equipped and modern Tool Room, Standard Room,
Design &Process facilities. Their process design ranging from layout design, die design, tool
engineering, designing & building Special purpose machines. Further our rigorous inspection
and testing facilities takes our manufacturing standards to levels of excellence.

2.3 MANUFACTURING FACILITIES

The company has five manufacturing facilities across 3 locations - 3 in Tamil Nadu, 1 in
Pondicherry and one in Haryana. The facilities are equipped with automated die casting
machines, vacuum die casting, Sophisticated CNC machining centers, CNC lathe, in-house built
special purpose machines, etc.

Full control of the manufacturing process is handled by this department. Structuring of
Production planning and control department is given below.


                2.3.1 ORGANIZATION CHART (PPC)

                                      Plant Head




                                    Senior Engineer




              Diploma Trainee - 1                  Diploma Trainee - 2




              Diploma apprentice                      Diploma apprentice




                                                 13
2.4 PRODUCTION PROCESS

         Daily production plan made by various departments finally reaches this department
and will execute the plan. As the condition and availability of workers are known by this
department cycle time and the number of workers are planned here. Supervisors are allotted for
all the lines (4 wheeler, 3 wheeler, 2wheeler and ASV). Monitoring of production is done here.



                           2.4.1 Production process of carburetor

                                         DESIGN




                      MATERIALS                         DIE CASTING




                     INSPECTION                      BODY MACHINING




                      MACHINING                           ASSEMBLY




               ULRASONIC CLEANING                         FLOW TEST




                                                           DELIVERY




                                               14
2.5 PRODUCTION FACILITIES



2.5.1Design & tool room
They presently use PRO E & Solid works for designing. Casting dies moulds, precision jigs &
fixtures, critical press tools are developed in house. Our tool room possesses the sophisticated
machinery cad, EDM, universal milling machines etc. Sophisticated imported measuring
instruments are being used by highly trained & dedicated engineers.


2.5.2Die –Casting
They are having their own pressure die-casting machines120 & 250Tonneproducing carburettor
body & other parts.


2.5.3Auto Shop
       They are fully equipped with various required automatic machines such as traubs, sliding
head (Swiss type automatic machines), CNC turning centres for the manufacturing of precision
turned components such as jets, throttle needles, valves, atomizers, air control screws etc. We
have tremendous additional capacity to produce in quantity all types of turned components.


2.5.4Machining Carburettors Body & Other Casting Parts
Fully equipped with the Special purpose machines (SPM): for reaming & boring operations of
different castings.


2.5.5Assembly and Testing
In order to fulfil the performance of the carburettor, a great stress in the dust free air-conditioned
assembly section is given to ensure the high quality at every stage.




                                                  15
2.6PURCHASE FUNCTIONS

           Purchase of materials is an important function of an industry.
The procedure of purchase is as follows

2.6.1 Purchase request

The department or officer in need of material has to place his request in a purchase requisition
form. In case of raw materials, it is done by the inventory control section. The purchase
requisition is prepared in the triplicate. The original copy of it is kept by storekeeper and the
other is send to the authorized executive. The purchase request must be approved by the
concerned department head.

2.6.2Stockverification

On receiving the purchase request the storekeeper checks whether the materials required is
available through the store. If the materials are out of stock, the storekeeper informs the purchase
section through and indents form.

2.6.3 Selectionofsuppliers

The next function is to select the supplier to whom the order is to be sent. The company places a
public tender notice for the procurement of raw materials .On the basis of the vendor submits the
tenders.

Tenders have two parts
Technical bid and commercial bid

The tender committee opens the tender and verifies the technical bid and if they are satisfied with
the technical bid i.e. , with the quality of materials, they opens the commercial bid, the tender
committee than prepares a comparative statement and accept the lowest price quoted Quotation.
Usually, a contract for one year is made for the supply of raw materials. To avoid risk of the
irregularities of the supply, the company appoints more than one vendor. In case of spare parts
the enquiry is send to the vendor for, the vendors list of company and the apt vendor is selected
on the basis of tenders. The vendor list contains the name and address of vendors and with
specific items

                                                  16
2.6.4 Purchase order

After deciding the supplier, the purchase officer of UCAL has to place a purchase order. The
purchase order is written authorization to the supplier to supply the particular materials. The
materials are to be supplied according to the terms and conditions of the purchase order. In
UCAL five copies of purchase order is prepared.

The original is send to the supplier.
Second copy is send to the material receiving section
The third copy is send to the person who has placed the purchase requisition
The fourth copy is send to the Finance department for future reference for payment the last copy
is kept in the department itself.

2.6.5Inspection of goods and quotation reception
        on receiving the materials from the vendor, a visual inspection is conduced. If there is
any discrepancy between the party advice copy and received copy, a discrepancy is prepared and
if there is any damage report is prepared.


2.7STORE SECTION

     Store section deal with the following

                             Receiving the materials
                             Inspection of materials
                             Storage and presentation
                             Proper classification and codification of materials
                             Materials handling
                             issue and dispatch
                             Stock records
                             Store accounting
                             Stock taking




                                                  17
2.7.1STORAGE FUNCTIONS
Various documents are prepared by the store section for the proper functioning of the
department. The documents maintained are as follow:-

2.7.1.1 Stores inwards book
on receiving any materials to the store, it is entered in a document called stores inward book
(SIB)

2.7.1.2Inspection of goods
On receiving any materials and preparation of SIB inspection request is send to the concerned
technical officer for technical evaluation and prepared on this basis.

2.7.1.3Store received note

After the preparation of SIB and inspection of goods or materials, Store Received Note (SRN) is
prepared. This is the document showing that the, materials received is accepted and payment can
be made for it. The SRN is sent to the Finance department for payment.

2.7.1.4Material issue notes

Any material is issued from the store only after receiving a material requisition or Material Issue
Note (MIN). MIN contains all the details regarding the material as well as the indenter.

2.7.1.5 Stock transfer note

For transfer of materials between store or section or contractors, for transfer of materials between
store and section prepared, it contains details such as material code, cost center, material
description, Unit and quality. It should be mentioned that material description, unit and quality. It
should be mentioned that from which section and to which section is the transfer-taking place.

2.7.1.6Material return note
sometimes materials issued from the store may be returned. In that case Material Return Note
(MRN) is prepared. It contains details such as the name of department from which the material is
returned, value, quality, code, unit, present balance and reason for return.

2.7.1.7 BINCARD
BINCARD is a document attached to bin and it contains the quantities details of the materials
                                                 18
received, issued and closing balance. In addition to this, it indicates information regarding
different stock levels like minimum level, maximum level, reorder level, etc coded number and
name of materials.



2.8 INVENTORY CONTROL SECTION

Proper inventory management is necessary to provide and maintain good customer service. It
enables smooth flow of goods through the production process. It is important as it provides
protection against the uncertainties of demand and supply and also performing the various
production operations economically and independently. Materials purchased for month is
analyzed and an issue price is fixed for the month. The company follows weighted average
method.


       2.8.1Inventory Control Techniques

                  1. ABC Analysis
                  2.VSN Analysis
                  3. FSN Analysis
                  4. EOQ


2.9QUALITY POLICY

          UCAL are committed to serve our Customers with Consistent quality products and
services as per mutually agreed terms. This is achieved by implementing quality management
system as per ISO / TS 16949: 2002 standard involving all employees through training and
motivation to create quality culture for continual improvement in the organization

2.9.1 Quality Control / Research and Development
To ensure the quality and performance, we have a team of highly qualified and experienced
personals to achieve the high standards of the functioning of the products. In order to further
ensure the reliability of the product, rigid quality control measures are established at all stages of
production.



                                                 19
2.9.2Supplier Quality Assurance

SQA deals with the quality issues of the materials which are supplied by the supplier to the plant.
Quality of the product includes various dimensions of the materials, quality of the materials etc.
Imported Machines are used to check the quality. Working of SQA department and additional
operations done by the department is given below.


                        Received material PGN at gate and generate RR tag



                     Verify the quantity at store and keeps in temporary location

                               Self certified parts        Not self certified parts



           Directly moved to
            store inventory


                                                                 OK
                                  Accept the tag and                     Inspected as per RIS
                                    move to store

                                                                                      Not ok

                                                                Hand over RTV paper to store
                     Material return to supplier



                                      2.9.2.1 PROCESS IN SQA




                                                      20
2.10 MACHINERY MAINTENANCE

      Ultimate aim of the department is the trouble free running of machines. Mainly 3 type of
maintenance methods are adopted by the department.

              Reactive maintenance
              Proactive maintenance
              Condition checking
   Apart from these methods time based maintenance is also adopted. It is applied basically the
case of changing lubricants for machines. Reactive maintenance refers to the solving of a
problem after its occurrence. In proactive method the problem is attacked before it occurs and
condition checking includes the inspection of machine parts once in a month. Machines used in
SQA are not maintained by maintenance department. The machines used in production and
assembly are handled by the department

2.10.1Machine Shop

Machine shop is mainly functioning to achieve cost reduction. For achieving this department
follows various steps

       Tool cost reduction
       Consumable cost reduction
       Scrap cost reduction
       Productivity improvement in ASV line
       Setup time reduction in 2wheeler mixing body.
       WIP(Work In Progress) reduction
       10% reduction in all other process

Machine shop has the spares of all cutting tools in separate boxes. The length is measured and
arranged in specific areas. This is done mainly to reduce the time taken to change the damaged
tool. Additional spare parts are there in the assembly line also. Based on the budget given by the
top management plans are prepared by machine shop. Every year top management will give a
target in reducing the cost. Machine shop will take various measures to achieve this go



                                               21
2.11NEW PRODUCT DEVELOPMENT

New product development is done by a separate department. This department starts their work
after getting approval and drawing from R & D centre situated at Ambathoor. This department
studies the requirements and additional resources which should be implemented in the
production cycle and gives detailed report to other departments. If a new order for product is
given to the plant, the department will prepare a rough idea about the product and inform the
management about the additional cost which should be raised by the management. New
machines will not purchase, but changes in existing machine will be done it is done by adding
fixtures and tooling. As a result with existing machines new products can be made in a lower
cost. Sample product will be developed by the department and will send to the customer. After
getting the feedback from customer they will modify the product and after required changes final
product is mass produced. Recently in plant 2 production of carburetor for Piaggio petrol
scooters are developed in plant




2.12 TECHNOLOGIES USED

2.12.1Lean Manufacturing

Adhering to the tenets of Lean Manufacturing we have been able to generate excellent results
that translate into bottom-line profits. They have developed a lean way of thinking by
implementing various lean tools like: TPM, SMED, Value Stream Mapping, Line balancing,
FMEA and 5S.ACT

The goal of Lean Manufacturing at UCAL is to essentially connect the entire value stream and
eliminate all forms of waste.

2.12.2Total preventive maintenance

Producing defect free products from defect free equipment making the manufacturing system
highly reliable and flexible.




                                              22
This strengthens and enhances plant’s ability to produce to the customers’ needs, consistently.
Total Employee Involvement results in cost reduction in overall manufacturing which would in
turn satisfy the customers’ requirements

   Producing defect free products from defect free equipments making the manufacturing
   system highly reliable and flexible

   This would strengthens and enhances plant’s ability to produce to the customer’s needs

   Total Employee Involvement results in cost reduction in overall manufacturing which
   would in turn satisfy the customer’s requirements

                               2.12.2.1 Employee involvement


           S. No                           Parameters                       Targets


             P                     Output per hour per man                  > 30%


                                           Downtime                          Zero


             Q                        In-house Rejection                  80% Down

                                    Customer Complaints                      Zero

                                      Manufacturing cost                  30% Down
             C
                                           Inventory                      30% Down

                                      Kaizen / Employee                    2/Month
             M
                                 Total Employee Involvement                 100%

             S                             Accidents                         Zero


             D                       Delivery Adherence                     100%




                                              23
2.12.3Value Stream Mapping

Value-stream maps are the prototypes for lean transformations. At UCAL, they use VSM
technique to identify and eliminate waste thereby streamlining work processes. The steps that
we follow in implementing the VSM are:

    Identify the products to map

    Draw the “current state” map

    Access and analyse the current state

    Draw the “future state” map with all the improvements

    Create a plan to implement the desired state

    Implement and review the plan



2.12.4Single Minute Exchange of Dies

In this intensely competitive market, there is always a need to provide customers with
diversified products of very high Quality while reducing the manufacturing cost at the same
time. At UCAL, SMED has been consistently proven to be the key to meet this extremely
challenging demand as it reduces waste, time spent between each production runs as well as the
size of production lots and inventory.

2.12.5Other Practices

    Kaizens

    Poka Yoke

    5S




                                               24
CHAPTER III
                          HUMANRESORCE DEPARTMENT
   Personnel Departments concerned with the people’s dimension in organization. The sincerity
   and dedication of the employees in UCAL is a major success factor. With a full-fledged
   Human Resource department, regular training and refresher courses are part of the company
   life. Apart from skill betterment, these courses inculcate quality consciousness, safety and
   awareness contributes to personality development. There are around 200 employees in the
   company

   Structuring of HR department in UCAL plant 2 is as follows



    3.1 STRUCTURE OF HR DEPARTMENT


                                       HR Manager




                                       HR Executive




                   Assistant 1                           Assistant 2




Human resource (HR) department deals with wide range of activities from strategic planning
level to the day to day operations level. Therefore defining roles and responsibilities of HR
department is a quite complex task. Some of the functions carried are summarized below.




                                              25
3.2STRATEGIC PLANNING PROCESS

HR department gets involved in the strategic planning process of the organization and identifies
HR as a core competency of the organization. When HR is assumed as a core competency HR
becomes a. competitive advantage for the organization.

3.3 FORECASTING THE LABOUR REQUIREMENT

The HR manager holds the responsibility of forecasting the labour requirement of the
organization in the future based on the future level of sales/production level of the organization.
The labour forecast may identify the need for need for hiring or firing employees.

3.4 RECRUITMENT

Once the labour forecast is done organization can identify the need for more labour in the
organization if the existing workforce is not sufficient to handle the future workload. In such a
situation HR manager has to recruit new potential candidates to fill the vacancies. Recruitment is
the process of creating a pool of potential candidates who can be employed to fill the vacancies.

3.5SELECTION

Selection is the process by which the most suitable candidate is selected from the recruited pool
of candidates. Selection is done by carrying out various types of tests and interviews. HR
department/manager is responsible of selecting the most suitable employees to fill existing
vacancies.

3.6 TRAINING

  Once the employees are done with the induction they become an employee of the organization
but the skills they possess may not be adequate to carry out required tasks. The need for training
arises when the there is a gap between expected level of skills and the current level of skills of an
employee. If a there is a training need HR department has to design training programs and
execute them.



                                                 26
3.7 INDUCTION

Induction is the process by which new employees are made familiarized with the organizational
environment. Once the employees are selected they need to be introduced to other staff of the
organization and they should be given necessary guidelines about the organizational culture and
the procedures.

3.8 MOTIVATION

HR manager is responsible of motivating employees to carry out their duties of a timely and
accurate basis.

3.9 PERFORMANCE APPRAISAL

This is where the employee’s performance is evaluated based on expected level and the actual
level of the performance. HR department needs to design performance appraisal systems to
appraise the employee performance on a fairly manner.

3.10 REWARDING EMPLOYEES

Once the employee performance evaluation is done HR department needs to design good
employee rewarding packages to reward well performing employees. These rewards could be
of monetary or non-monetary in nature.

3.11PROMOTION

Promotion is the movement of an employee from a lower position to another position with a
better pay, and responsibility. Every organization chances of promotion chances of promotion
came up occasionally. Employees will consider for promotion only if they have qualification and
experience in the respective field. Grade II worker in the MS unit who completes 8 years of
continues service will be automatically promoted to grade I. Promotion posts will be notified
with the plant and the officer of the unit, giving educational qualifications and experience. The
application received will be screened by the personnel department. Every employee promoted to
a higher post will be on probation in that post for a period of one year


                                                 27
Four factors are considered for promoting an employee
1) Seniority (25 marks)
2) Test/Interview(0 marks)
3) Attendance(20 mark)
4) Performance(15 marks)

Employee who secure less than 50% score of marks in tests and interview are not considered for
promotion. All vacancies in the post, in the level of shift in charge equivalent and below in the
pigment until shall be filled up by promotion subject to availability of suitable workman. Actual
promotion shall be drawn up by the promotion committee and he is empowered or delegated
with power to the effect.

3.12TRANSFER

    There is only inter departmental transfer in the company.


3.13MANAGING EMPLOYEE GRIEVANCE

HR department needs to accept the grievance and complaints submitted by the employees about
their problems. HR department need to listen to grievance and should come up with solutions to
solve problems.

3.13.1 Managing complains about employees

There can be complaints about employees regarding poor performance, bribery, misbehaviour
and so on. HR department needs to hear that complains and make necessary steps
(advising/punishing employees) to solve those issues.

Recruitment is done both in the plant and from the top management. Workers who deal with the
assembly and manufacturing process are selected by plant itself. Temporary trainees are selected
here. Minimum qualification required for these staffs is 12th and ITI or diploma. Other staffs are
selected and recruited from head office. Campus recruitment, job melaas, off campus selection,
walk in interviews are the various methods to select employees. On the basis of salary employees
are categorized into 3.


                                               28
1. Temporary apprentice
           2. Technicians
           3. Staffs and executives

Salary structure is finalized from head office and increase in salary occurs as the experience
become more.

Training given to the staffs is also based on the categories mentioned above. Temporary
apprentice are given training for 1 hour and on the job training is given to them. For technicians
period of training is 2 months and for staffs that is 3 months. Statutory returns additional to the
salary is given to the employees in monthly, 6monthly and annually. Provident funds are also
provided to the employees.

Workers are provided with breakfast, lunch and snacks at appropriate time. A small amount is
deducted from the salary and good food is provided in the canteen by HR department. All
administrative activities are managed by HR department it includes security management,
transportation facility, canteen and welfare for workers, room booking for visitors, checking bills
etc.

Department conducts an annual tour for all the staff along with their family working in the firm.
Family day celebration is conducted by the department once in a year. Employees who worked
for more than 10 years are awarded 2gm gold coin on this ceremony. Games are conducted for
employees and their family members. Food is supplied to all. All these expenses are undertaken
by the company. This motivates the employees and gives them affection towards the company.



3.14WORKMEN CLASSIFICATION

        Permanent Employees:
                 There are about 200 Technical and 20 non technical staffs working in the UCAL
       plant 2 as permanent employees.


        Employees Engaged On Contract Basis:
       These employees work n contract for a limited period of time say one year or six months

                                                29
on specific terms and condition fixed by the company. They have no preference for future
        employment in the company.


        Temporary or seasonal worker:
                These workers are employed when the work load is more. On certain season due
        to the increase in demand, more work forces are needed to meet the production. In such
        cases temporary workers are engaged. The services of such employees are dispensed with
        as and when the need is satisfied


        Apprentices:
              Apprentices work for a period of one year as part of their training programmed as
        per apprenticeship Act



3.15 WAGE STRUCTURE

Basic wages for each category of workers are fixed as per agreement the management and the
workers representative. The items covering under wages are follows;

            Basic pay
            Dearness Allowance
            Variable Dearness Allowance

The worker are given specified amount as basic wage as per the agreement. The agreement is
valid for four years.

3.16WELFARE ACTIVITIES

Bonus
Employees who are drawing more than Rs.3500/- per mount are eligible for bonus almost all the
employees working here are eligible for bonus irrespective or casual worker.




                                               30
Provident fund

Introduced in 1956 and administered by a trust. Here both the employer and the employee have
to continue 12% each of the basic pay, where eight and one third percent is transferred to pension
fund.

Gratuity
Minimum amount payment payable as gratuity is Rs.3500 Employees having continues service
of the year is eligible for gratuity.

Employees State Insurance
All the employees working here come under Employees State insurances Scheme.


3.16.1 Labour Welfare Activities

The allowances provided by the company for its employees are as follow

     House pent Allowances
         Workmen of the company shall be entitled to house rent allowance @ 10% of the basic
        pay effective from 1. 1. 1997.
     Conveyance Allowances
        Up to Rs.100 is given as conveyance allowance as per Memorandum of Agreement.
     Shift Allowances
        Employees working A, B and C shift are paid Rs 200 per month as shift allowances.
     Cash Handling Allowances
        Rs.40 per month is paid as cash handling allowance to employees who look after the
        duties of the cashier.
     Attendance Bonus:-
        Employees who attain attendance of:
        A) 80 to 90% are given a bonus of Rs. 100/-
        B) Greater than 90% are given a bonus of Rs.110/-
        C) 100% are given one wage and DA




                                               31
 Housing Loan
             For small works of residential building such as extension are repair works loans
      are given to Rs. 1.5 lakes and a maximum amount of Rs.3 lakes can be given for
      construction of new residential buildings.


   Vehicle Loan
             For two wheelers amount Rs.40000 are given as vehicle loan and for officer loan
      amounts to Rs.1 lakhs.

3.17FRINGE BENEFITS

   Retirement Benefits
   Death Relief Fund
   Medical Facility
   Financial Aid to prolonged Treatment
   Subsidized Canteen facility
   Interest Subsidy for Housing Loan
   Transportation Facility
   Recreation club



3.17 PERSONNEL RECORD KEEPING

   UCAL maintains a personnel record for its employees. It is a file consisting for all the
  details regarding the employee and all the data relevant to him
     Recording Of The Attendance
            The electronic punching system is adopted in UCAL. Every employee had to
     punch the card on entering the work.
     Time Keeping And Time Booking
            A separate wing is concerned with time keeping and time booking in the company.
     With the help of the punch card this section keeps an attendance register. Main function
     of this section is attendance recording of leave, late coming, early going lost hours,
     overtime, shift allowance, loosed wages due to absence, wages due to work holidays.


                                              32
CHAPTER IV
                                      FINANCE DEPARTMENT


4.1 INTRODUCTION
Finance is the life blood of business and hence it requires a lot of effort to manage it well. The
basic functions of the Finance Department are procurement of funds at the right and optimum
utilization of funds. Like every manufacturing company, UCAL also has its own separate finance
department which deals with different financial matters of the company. The finance department
of UCAL is sub divided into various sections and the work flow is divided among these sections
which are consolidated and put together as a whole at the end and the final accounts are prepared
and then the decision making process begins and targets are set for the next financial year.


4.1 VARIOUS SECTIONS IN THE FINANCE DEPARTMENT


4.1.1 Books Section
This section keeps the records of all the matters of finance department and all the other records
that each section keeps with it. They record all the ledgers and vouchers of monthly, quarterly
and yearly accounts. They also maintain records of the inter-unit transactions i.e. the transfers
that take place between this unit and UCAL’s other units. They keep the records of the entire
audit that is done internally as well as the record of the entire statutory and government audit.


4.1.2 Budget Section
This section also deals with the budgeting of the company. The funds are allocated by the
corporate office for each UCAL unit. After receiving this budget they prepare their own budget
of each department with the respective heads and then allocate the funds to each department for
their purposes. They also prepare the budgeted figures and targets of the company for the next
financial year.




                                                 33
4.1.3 Sales Section / Bills Receivable Section
This section deals with all the sales related issues in the company. It keeps all the records and the
data that is necessary while making the records and maintaining the accounts of sales. Eg.,
packing List, clearance letter, lorry receipts, guarantee certificate, etc…It also keeps the record
of all the debtors of the company and the Central and State sales tax that is levied on each item
and the terms and conditions related to them. The debtor’s management is also dealt with this
department. They have to prepare an MIR (Manual Information Report) for every month which
is sent to the corporate office as a report of the company.


4.1.4 Bills Payables Section
This section is concerned with the payment of all revenue bills. A revenue bill includes payment
made to suppliers, payment to government agencies. In case of purchasing the materials, the
actual process starts once the order is placed and the materia lis received by stores and it is sent
to quality section. Wherein inspection department will certify and then clear the stores receipt
vouchers. The cleared stores receipt will then come to material management who will value it.
After this, it is forwarded to bills payable section. They will release the payment immediately
when the bill becomes due.


The Records Maintained By This Section Are


· Purchase order book
· Supplier’s invoices
· Store requisition voucher, etc.,


4.1.5Cash Section
The main function is to account the cash and bank balance. Other than this function the
actualPayment of money is done through this section. The employee’s salary, contract labourers’
wages, supplier’s amount and receipt of customer’s payment all are done through this section.




                                                 34
4.1.6 Costing and material account section
          Costing section in UCAL is an part integral section which co-ordinates various other
departments like production, marketing, etc.. The main task of this department is to classify the
various types of costs, accumulation of assignment and control of cost. The information supplied
by this department has a great deal of importance to the management in decision making. By cost
splits the management will be in a position to know where exactly wastages are more, or which
method is causing runoff profits etc,.It also prepares the cost estimates, based on which the
marketing department will make the bidding. Another important function of this section is
preparing the price stock ledger and major task of this section is that it looks after the capital
payments.


4.1.6.1 Types of Software for Accounting Procedure

The software which is used for the purpose of accounts they use Tally software of 7.1 version which
covers all recent updates accounting standards and also tally software of 7.1 version covers VAT concept
which marks very easy for company to fill the tax according rules and regulation.


4.1.7 Works Bill Section
This section keeps a record of all the infrastructure related issues. They keep a record of the
building, roads, furniture and the township related matters. It also keeps a record of the work that
is needed to be done for the company as well as for the township and other areas.


4.1.8 Pay-Roll Section
This section is concerned with the computation and payment of wages / salaries, medical
reimbursement, conveyance reimbursement, tour advance settlement, air fare settlement,
payment of medical expenses of retired employees, provident fund and gratuity, etc,. Hence for
this purpose, this section maintains Master Records which consists details of each and every
employee regarding their date of joining, leave taken, payment of salary, loan taken, allowances
given, etc., which are monitored and updated every month. This section ensures a pleasant
atmosphere by ensuring accurate payment to the employees in order to




                                                    35
Maintain industrial harmony and employee satisfaction. Apart from these activities, the
department is also concerned with recording and maintaining the attendance, leave taken and
over time work done by each and every employee. Here the department records time in and out
of employee through the medium of automatic time recorders provided at the vantage points
within the factory.


4.1.9 Taxation Section
This section takes care of the tax related issues of the company. All the indirect and direct taxes
thatthey have to deal with is taken care of by this section. They also take care of the excise duties
and customs duty in case of export. They also deal with the service tax related matters. All these
sections of Financial Department collectively function efficiently for the effective and optimum
allocation and utilization of funds of the organization.



4.3 CAPITAL STRUCTURE

A mix of a company's long-term debt, specific short-term debt, common equity and preferred
equity. The capital structure is how a firm finances its overall operations and growth by using
different sources of funds. Debt comes in the form of bond issues or long-term notes payable,
while equity is classified as common stock, preferred stock or retained earnings. Short-term debt
such as working capital requirements is also considered to be part of the capital structure.

4.3.1 Capital Structure Of UCAL


                               Authorized    Issued
Period          Instrument                                 -PAIDUP-
                               Capital       Capital
                                                                                    Capital
                                                           Shares        Face
From To                        (Rs. cr)      (Rs. cr)                               (Rs.
                                                           (nos)         Value
                                                                                    Cr)
2010     2011   Equity Share       75.0          22.1      22113625        10.0      22.1
2009     2010   Equity Share       75.0          22.1      22113625        10.0      22.1
2008     2009   Equity Share       60.0          13.9      13896000        10.0      13.9
2007     2008   Equity Share       60.0          13.9      13896000        10.0      13.9
2006     2007   Equity Share       60.0          13.9      13896000        10.0      13.9



                                                 36
4.4 WORKING CAPITAL MANAGEMENT

Working capital management is concerned with the problem of that arise in attempting to
manage. The current assets and current liabilities are the relationship that exists between them.
The term current assets refers to those assets, which in the ordinary course of business can be or will be
converted into cash within one year without undergoing a diminution in value and without disruption of operation.
The goal of working capital management is to manage the firm’s current assets and liabilities in such a
way a satisfactory that level of working capital is maintained. The company avail the working
capital from the nationalized Bank in the form of over draft account.


4.5 CREDIT POLICY

4.5.1 Trade credit

Trade credit refers to the credit extended by the suppliers of goods and services in the normal course of
transaction/business/ sale of the firm according to trade practices; cash is not paid immediately
for purchases but after an agreed period of time. In case of UCAL credit the suppliers allow period with in
30days.

4.6 ACCCOUNTS RECIVABLE/ RECIVABLE MANAGEMENT

The term receivable is defined as debt owes to the firm by the customers arising from sale of goods
or services on ordinary course of business when a firm makes an ordinary sale of goods or services and does not
receive payment. The firm grants trade credit and create accounts receivable which could be collected in feature.




                                                        37
4.5.1 Balance sheet - UCAL Fuel Systems Ltd.
Particulars                  Mar'12     Mar'11   Mar'10   Mar'09   Mar'08
                             12         12       12       12       12
Liabilities
                             Months     Months   Months   Months   Months
Share Capital               22.11       22.11    22.11    13.90    13.90
Reserves & Surplus          270.96      258.56   246.63   182.36   182.32
Net Worth                   293.07      280.67   268.74   196.26   196.21
Secured Loans               211.42      224.91   237.38   156.02   140.19
Unsecured Loans             20.55       23.83    11.13    26.90    4.81
TOTAL LIABILITIES           525.04      529.41   517.25   379.17   341.22
Assets
Gross Block                 410.00      405.80   373.77   276.05   249.96
(-) Acc. Depreciation       183.91      203.66   181.12   145.59   129.88
Net Block                   226.09      202.14   192.64   130.45   120.08
Capital Work in Progress.   13.45       15.74    7.12     8.74     16.38
Investments.                156.26      156.26   156.26   167.36   115.95
Inventories                 45.75       38.09    30.36    29.72    29.47
Sundry Debtors              104.75      94.96    89.90    47.50    50.48
Cash And Bank               5.66        2.73     2.28     0.81     1.31
Loans And Advances          146.63      125.77   119.91   87.52    107.66

Total Current Assets        302.80      261.55   242.45   165.55   188.93

Current Liabilities         163.60      108.54   94.37    97.22    100.22
Provisions                  15.42       10.28    3.55     17.29    19.02
Total Current Liabilities   179.03      118.82   97.93    114.51   119.24
NET CURRENT ASSETS          123.77      142.73   144.52   51.04    69.69
Misc. Expenses              5.47        12.54    16.71    21.59    19.12
TOTAL ASSETS
                            525.04      529.41   517.25   379.17   341.22
(A+B+C+D+E)




                                          38
CHAPTERV

                             MARKETING DEPARTMENT

5.1 INTRODUCTION

All the working of the plant starts and ends with marketing department. All the suppliers and
customers of the company are handled by marketing department. They collect orders from
customers and to satisfy the customer needs they prepare monthly, weekly and daily production
plans. The information is given to other departments and the production is carried out. Other
departments can work only with the data given by the department. Transportation decisions of
goods through various alternatives are also taken by marketing people. Normal working of this
department ends only when the finished products reach the customer or distributor. Invoice is
finalized by department by analysing the data from dispatch/tax department.

Some important functions of marketing department are mentioned below.

               Focus on the Customer.
               Monitor the Competition.
               Own the Brand.
               Find & Direct Outside Vendors.
               Create New Ideas.
               Communicate Internally.
               Manage a Budget.
               Set the Strategy, Plan the Attack, and Execute.

Focus on the Customer.

Marketers should spend time listening to their customers (and prospective customers) in order to
understand their needs and wants regarding a particular product or service. Soliciting thoughts
and input from internal stakeholders such as Sales and Customer Service is also appropriate, as
these departments are typically closest to the customer.




                                                39
Monitor the Competition.

Learning about, and understanding the competitive landscape is also an important function of the
Marketing Department. Marketers should be the “go to people” within an organization to answer
the following types of questions: Who is the competition (both direct and indirect)? What do
they communicate? Which customers do they serve? Why do customers choose the competitor
versus you?

Own the Brand.

The perceptions and feelings formed about an organization, its products / services, and its
performance is what is known as its “brand.” The Marketing Department is responsible for
creating meaningful messages through words, ideas, images, and names that deliver upon the
promises / benefits an organization wishes to make with its customers. Furthermore, the
Marketing Department is responsible for ensuring that messages and images are delivered
consistently, by every member of the organization.

Find & Direct Outside Vendors.

Internal Marketing Departments do not create magic alone. Therefore, marketing needs to source
and oversee a group of outside resources to make market for the product.

Create New Ideas.

Whether it is customer acquisition campaigns, keep-in-touch programs, new product promotions,
retention efforts, or something in between, the Marketing Department should ultimately be
responsible for developing new ideas that generate revenue for the company. This does not mean
that the Marketers have to come up with every idea on their own; however, they need to identify,
cultivate, and work with others to execute programs that will create revenue.




                                               40
Communicate Internally.

It is important that the Marketing Department communicates with all departments inside an
organization. Since any employee can support a brand, value proposition or even specific
program initiatives, the Marketing Department needs to take responsibility for disseminating
information throughout the organization (this includes internal education and training when
appropriate).

Manage a Budget.

Establishing and communicating messages to the marketplace costs money. Therefore,
Marketing Departments is responsible for estimating the anticipated expenditures associated with
marketing activities. Once set, Marketers should be held responsible for meeting all budget
projections.

Set the Strategy, Plan the Attack, and Execute.

One of the key activities for a Marketing Department is to integrate an organization’s goals,
strengths, and channels of distribution, competitive environment, target markets, pricing, core
messages, and products into one cohesive document known as the Marketing Strategy. As part of
the strategy, the Marketing Department should also develop the list of tactical ideas such as
direct mail, print advertising, and search engine optimization that will enable the organization to
communicate its message to customers and prospects. With a strategy and tactical ideas in hand,
the Marketing Department is now ready to take on the responsibility of executing the programs
and initiatives to drive sales and revenue for the organization.


5.2 MARKETING MIX – THE 4 P’S OF MARKETING

The Marketing mix is a set of four decisions which need to be taken before launching any new
product. These variables are also known as the 4 P’s of marketing. These four variables help the
firm in making strategic decisions necessary for the smooth running of any product /
organization. These variables are



                                                 41
 Product
    Price
    Place
    Promotions



5.2.1PRODUCT

UCAL product portfolio consists of extensive range of components for two, three and four
wheelers. The product range include carburettors for two wheelers, gasoline fuel injection system
products, engine management systems, products for diesel applications and emission control,
pumps to high pressure die casting and precision manufacturing products.

5.2.1.1Four wheeler-carburetors




Applications
2 & 4 Stroke Engines in Motorcycle, Scooters & Three wheelers

Function
To supply proper air-fuel mixture based on the engine requirements Throttle will be directly
operated by the rider. Area of the venturi changes causing a change in the air flow and vacuum

Range
Venturi size: 12 mm – 22 mm, 2 & 4 stroke engines


                                               42
Technology & Special Features
Provision for coasting richer system, throttle switch, solenoid operated auto-starter, electronic
control of air-fuel ratio

Customers
Bajaj, TVS, Mikuni, Suzuki & Yamaha.

5.2.1.2 Multi Point Fuel Injection Parts

Thottle Body Assembly




Applications
Passenger Cars & Vans

Function
Controls the amount of air that goes into the engine depending on engine speed and driving
conditions

Range
Bore Sizes from 32 mm – 80 mm

Technology & Special Features
Provision for mounting idle speed controller, manifold absolute pressure sensor

Customers
Maruti Suzuki, Hyundai, Bosch, Mikuni, Continent



                                                 43
5.2.1.3 High Pressure Fuel Filter




Applications
Gasoline Passenger Cars & Vans

Function
To reduce the particulate impurities

Range
Capable of withstanding pressure from 3.5 to 5 Bar
Provision for accommodating bracket for mounting on to vehicle

Technology & Special Features
Double folded paper element

Customers
Maruti Suzuki and Hyundai.

5.2.1.4 Two /three wheeler-emission control products

Secondary air value




                                              44
Applications
4 Stroke Motorcycles & Scooters

Function
Supply secondary air to oxidize Carbon Monoxide and unburnt Hydrocarbons in the exhaust

Range
Engine capacity from 60cc to 50cc.

    The product is available in Aluminium& Plastic variants.

Technology & Special Features
Air cut valve integrated with Secondary Air Valve to take care of after buring during
deceleration. Product is available in aluminium and plastic variant. Direct Engine mounted
model and chassis mounted model available.

Customers
Hero Honda, Bajaj, Mikuni, TVS, Royal Enfield, Suzuki & Yamaha.




5.2.1.5 Oil Pump Assembly




Applications
Diesel & Gasoline Passenger Cars, Vans, Multi-Utility Vehicles & Trucks



                                               45
Function
To provide oil to all parts of the engine for lubrication

Range
Engine CC: 1litre - 3 litres engines.

Specifications

        Flow rate : 8 - 15 lpm
        Engine RPM : 500-1000 rpm
        Pressure :2-3 bar

Technology & Special Features
Gerotor type oil pumps. Oil Pump assembly available with and without Chain cover

5.2.1.6 Fuel pumps

Piston driven fp




Applications
2 stroke Motorcycles, Scooters and 3 wheelers

Function
Piston fuel pump which can develop up to 10bar pressure at a flow rate of about 7lpm.

    Suitable for gasoline applications More than 1000 hours of functional life




                                                  46
Customers
Bajaj and Other applications

5.2.1.7 High pressure die cast products




Throttle Body Housings

Weight :Approx 0.5- 0.8 kgs
Bore Range : 50mm to 80mm
Customers : Continental

5.2.2PRICE

There are three types of pricing methods. They are Cost based, Demand based, competitive
based. In this company competitor based pricing is followed .The competitor based pricing is
nothing but the name itself indicates the company Fix prices based on the prices of the
competitors. So the rise & fall of price fully depend upon the competitor’s price.

5.2.3PLACE

To reach the products from producer to consumer they use Zero channel and The mode of
distribution is done by the small process shown below.



               Producer                         Distributor                    Consumer

                                               47
5.2.4 PROMOTION

5.2.4.1 Advertisement & sales promotion activities

      The advertisement is done through Seminars, Tradeshows at their work places. The sales
promotion activities are carried out by arranging training programs in their plant and by direct
interaction with their client, agent, they follow PMC(PROJECT MANAGEMENT
CONSULTANT S) to attract all the A, A+ customers.

5.3 COMPETITORS

        Auto line industries ltd
        Banco products (India) ltd
        Bosch ltd
        Federal-mogulGoetze (India) ltd
        IP Rings ltd
        Karmobils ltd



5.4MARKETING RESEARCH

               Marketing researches are conducted to check the flow of products to the customers and
their perception .The Method of conducting this activity is done through the following ways

                              Marketing surveys
                              Case studies
                              Day to day activities likes surveys and feedback carrying different
                                 parameters.




                                                   48
5.5 SWOT ANALYSIS

STRENGTH

   Maintaining internal quality systems
   Good employee relationship
   Certified as AN ISO/TS 16949 : 2009, ISO 14001:2004 &
     OHSAS 18001: 2007 CERTIFIED COMPANY
   Fully computerized
   Ensuring continuous development of human resources
   Good fire & safety department to avoid accidents
   Continuous production system

WEAKNESS

   Marketing department to be strengthen
   Not having sufficient man power
   Over work for employees.
   There is no active employee welfare union for the employees.
   There are more number of apprehends, hence the job security is weakness.

OPPURTUNITIES

      Expansion of plant capacity
      Can capture wide range of market
      New products can be introduced
      The customers are well established in the market, hence the opportunity are wide.

THREATS

      Hence there is a regular importing of products the expense involved is more and
         more.
      Rapid technological changes
      Introduction of various products in the market.
      Perfect competition is there for the commodity.


                                            49
FINDINGS

    360 degree performance appraisal
    The company has certifies as AN ISO/TS 16949 : 2009, ISO 14001:2004 & OHSAS
      18001: 2007 CERTIFIED COMPANY
    The company has plans for further expansion
    Computerization resulted in inter departmental relationship
    Company is in the path of modernization and expansion

SUGGESTIONS

     Product line of the company should improve
     Good communication must be set between employees and the management.
     Marketing department should get more support from other departments to perform
        more effectively.
     Look more into international markets
     Concentrate on expansion and diversification of plant, equipments, products etc.
     Product promotion activity should be introduced by the company




                                           50
6. CONCLUSION

Being the giant in the automobile fuel management business the company has a bright future. All
the functions in the company are going well. According to my opinion employees are given more
work load. Marketing department functions with lots of limitations. Even though there are small
problems in the plant the overall performances of the company is good and have a bright future.
The finance department is doing well in the company. The Production and Administration
department is also doing well and it has a very important role in the performance of the
company. The department provides all help to the employees and settles their grievances. All the
departments are doing well and it is good sign for the company. Name of the company has a
great importance in the automobile fuel management system. Main automobile manufacturers are
depending UCAL to full fill their needs.

     In short the company has a bright future in the coming year and will attain a good position
in the economy and market.




                                              51
BIBLIOGRAPHY


http://www.ucalfuel.com
http://en.wikipedia.org
http://www.google.co.in
Company magazine




                               52

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New project

  • 1. CHAPTER I INTRODUCTION 1.1INDUSTRY PROFILE Indian auto component industry is robustly driven by the growth in demand for automobiles. The sector has become a lucrative business proposition for global players, majorly owing to two factors. First, needless to say, the demand for automobiles is increasing day by day in the country. India, a market with high potential for the automobiles sector, is expected to witness a three-fold increase in demand for automobiles by 2020. Secondly, all major global auto-makers are establishing their bases here due to highly positive business environment, favourable policies and government support. According to a study by UK-based global financial advisory firm-Rothschild, India would become the third largest auto industry by volumes after China and the US by 2015. This would give immense support to the growth of ancillary sector as well. According to a recent study by the Automotive Component Manufacturers’ Association of India (ACMA), original equipment manufacturers (OEMs) account for 41 per cent of the auto components consumed in the Indian aftermarket. The study estimated current size of Indian components business at Rs 24,800 crore (US$ 4.87 billion), 49.7 per cent of which is formed by two-wheeler segment. Passenger vehicles, commercial vehicles and three-wheelers follow with 24.7 per cent, 23.1 per cent and 2.5 per cent of the share respectively. CARBURETOR MANUFACTURING INDUSTRY Most of the modern vehicles make use of a carburetor that is used for blending accurate amount of vaporized fuel with air so that the internal combustion engine works efficiently. The carburetors available in the market accentuate several features such as highest quality standards, lifetime warranty, engine tested, improved performance, economical, excellent drivability, versatility, better fuel economy, greater throttle response, quick installation, highly modifiable 1
  • 2. and easy to maintain. Carburetors supplied in the market provide greater calibration capabilities and comprise of central float chamber and a unique throttle body that comprises of throttle body spacers, throttle cables and more. The carburetor manufacturing industry presently sizes around US $ 2.4 billion. Its major manufacturers are AML Carburetor Company, Edelbrock AVS Carburetor, LectronCarburetors, Walbro and TillotsonCarburetors, Zenith UK, Holley, Keihin and Rochester Products Division. FUEL SYSTEMS The function of the fuel system is to store and supply fuel to the cylinder chamber where it can be mixed with air, vaporized, and burned to produce energy. The fuel, which can be either gasoline or diesel is stored in a fuel tank. A fuel pump draws the fuel from the tank through fuel lines and delivers it through a fuel filter to either a carburetor or fuel injector, then delivered to the cylinder chamber for combustion. 2
  • 3. 1.2 COMPANY PROFILE UCAL FUEL SYSTEMS LTD. (UFSL) was established in 1985 by Carburetors Limited, pioneers In India in the manufacturing of Carburetors and mechanical fuel pumps. In 1987 UCAL entered into a joint venture with Mikuni Corporation of Japan, an internationally renowned company for Fuel Management System and products. UCAL became public limited in 1989. With the factories in MaraimalaiNagar, Pondicherry and Gurgaon commissioned and the product range enlarged, UCAL witnessed a quantum leap in the last decade of the century. UCAL started to manufacture world class Carburetors and mechanical fuel pumps using advanced technology in the state of the art facilities and began supplying as OEM to Maruti- Suzuki, Premier 118 NE, and HM. The Pondicherry plant started to manufacture Carburetors and Secondary Air Valves for two wheelers and Multi point fuel injection hardware products for passenger cars 1996 A Vignette given below explains UFSL’s growth towards becoming truly an internationally respected Brand and becoming a proud supplier to some of the globally acclaimed companies such as Maruti-Suzuki, Hero Honda, TVS, Bajaj, Yamaha, Piaggio, Fiat, Tata Motors, Cummins and many more. 2003 - Collaboration with Orbital Inc, Australia for development of Direct Injection systems. 2004 - Krishnamurthy centre for Technology a R&D centre, 2005 - Acquired Amtec Precision Products Inc in US. 2006 - Started development of products for Diesel applications. 2008 - Close of JV agreement with Mikuni Corporation. Supply of full volume of pumps for Suzuki power train 2009 - Supply of Fuel Pump to Visteon started 3
  • 4. 1.2.1 LIST 0F MANUFACTURING PLANTS-UCAL Production Capability Certification Maraimalai Nagar, TN Pressure Die Casting for Zn & Al, TS 16949 P1 May 1990 Machining & Assembly for ISO 9001 Total Area 20200 sq m MPFI &Carburetors, Gasoline Test ISO 14001 650 employees High precision Jet Section & plating OSHAS 18001 Puducherry Machining & Assembly ASV, TS 16949 P2 September 1996 Carburetor (2W & 4W) , Gasoline ISO 9001 Total Area 5700 sq m Test ISO 14001 474 employees High Precision Jet Section OSHAS 18001 Gurgaon, Haryana Machining & Assembly for 4W TS 16949 P3 April 2000 MPFI parts ISO 9001 Total Area1800 sq m ISO 14001 Assembly unit for oil and vacuum 200 employees pumps OSHAS 18001 Ambattur,TN P4 R&D TS 16949 2003 Total Area 8900 sq m 4
  • 5. 1.2.2SUBSIDIARIES-UCAL List of Subsidiary Plant Production Capability Customers Pondicherry Rubber to metal bonding UCAL, UPIL December 1999 Plastic to Plastic welding Mikuni, Total Area 1965 Metal to Plastic welding Lucas TVS sq m Precision Assemblies 80 employees Elgin, Rockford – Precision component, GM, Cummins, AMTEC Ilinois Air Conditioning compressor Sensata, Ford, Acquired : 2005 components Continental Employees : 200 Plastic Injection Molding parts CERTIFICATIONS It is the right synergy that we are able to create by our incisive knowledge of the industry; the key processes and our worldwide resources that enabled us to get the right Human resources and the advanced technologies helped us to achieve exceptional results for our customers. We have been able to build differentiated leadership and cutting edge operations through integration of knowledge and expertise shared from across our entire worldwide network. All our units are certified to pertinent ISO standards which validate the existence and working of effective system. The processes are monitored and controlled through stringent Internal and External Audits for their effective functioning. 5
  • 6. Various Certifications obtained by Company ISO9001:2000 – Quality Management system for other industries ISO14001:2004 – Environmental Management system TS16949:2002 – Quality Management system for Automotive industries OHSAS18001:2007 – Safety Health Management System AWARDS Over a period of time, UCAL has been consistently able to receive a series of awards and recognitions for the excellence in customer service, technology, quality and industrial relations. Awards for Customer Service 2004 - Direct On Line award from Hero Honda 2004 - 100PPM Commendation certificate from HMIL 2005 - Award from MUL for superior performance in Quality 2005 - Award from MUL for overall excellence 2008 - Best Vendor award from Sona Koyo Steering Systems 2009 - BOSCH Supplier Award for maximizing value to the customer Awards for Technology 2004 - Frost & Sullivan Special Award for India Manufacturing Excellence 2006 - Silver Award to Gurgaon Plant in the Automotive Ancillary by F & S 2006 - ACMA Bronze to Gurgaon Plant for manufacturing excellence 2007 - Frost & Sullivan Golden Certificate of Merit for Manufacturing Excellence 6
  • 7. 1.2.1 VISION AND MISSION OF THE COMPANY To strive for continuous growth in Fuel Management Systems to meet the ever-exacting Market Demands through Research & Development and Excellence in Operations Management. To be a Key Global Player in Fuel Management Systems. 7
  • 8. 1.3 PRODUCT PROFILE UCAL today spans a wide spectrum of products for the automotive sector and is a perfect amalgam of people, technology and resources reinforced with the advantage of a thorough understanding of automotive industry UCAL is in the business of providing holistic solutions in fuel management systems and is committed to producing products of consistent quality and timely delivery. This is validated because UCAL is the most preferred supplier of products to customers such as MarutiUdyog, Hyundai, General Motors, Cummins, Bosch, Mikuni, TVS Motor Company, Bajaj Auto, Suzuki, Yamaha & Hero Honda Motors to name a few. The company takes pride in being an engineering company that provides solutions to customers. The company designs products for petrol and diesel engine application and has impeccable manufacturing process and systems that ensures product quality. Apart from producing parts of consistent quality and upholding stakeholder satisfaction, UCAL takes it as a duty to be socially responsible organization and ensure that all products are environmentally friendly. UCAL product portfolio consists of extensive range of components for two, three and four wheelers. The product range include carburetors for two wheelers, gasoline fuel injection system products, engine management systems, products for diesel applications and emission control, pumps to high pressure die casting and precision manufacturing products. Their wide range of product portfolio is backed by in-house Design & Development facilities. Highest level of quality is ensured in all our products through processes governed by Lean, TPM, SMED, 5S and other best operational practices Four Wheelers Multi Point Fuel Injection (MPFI) Parts Carburettors Emission Control Products & Others 8
  • 9. Two / Three Wheelers Carburettors Emission Control Products Gensets Carburettors Pumps Pumps Oil Pump Assembly Vacuum Pump Assembly Fuel Pumps Water Pump Assembly Machined Component High Pressure Die Casting Products 9
  • 10. 1.4 ORGANISATION CHART BOARD OF DIRECTORS CHIEF EXECUTIVE OFFICER GENERAL MANAGER SENIOR DGM DGM SENIOR EXECUTIVE SUPERVISOR 10
  • 11. 1.5 DEPARTMENTS IN UCAL FUEL SYSTEM LIMITED In Pondicherry plant UCAL has the machining & assembly of ASV (Air Suction Valve), Carburetor (2W & 4W), Gasoline Test and High Precision Jet Section. The plant was established on September 1996. It has a total area of 5700 sq m and has 474 employees. The company consists of 12 departments. The combined and trouble free operations of all these departments is the secret of success of the plant. Various departments are mentioned below.  Production Department  Human Resource Department  Finance Department  Marketing department 11
  • 12. CHAPTER II PRODUCTION DEPARTMENT 2.1INTRODUCTION New products are analysed and report regarding production method, design, average time taken to finish single product, rough expense etc. are prepared by this department. First Time Through method is adopted in the development procedure. Trial and error method is not adopted here. Department also recommend new tools, designing facilities and other requirements in the production. All the activities related to the production are handled by this department. Preparing process flowchart Preparing control facilities Giving instructions to workers regarding the methodology Displaying the operations in front of workers in local language Giving awareness about safety and convenience 2.2 MANUFACTURING PROCESS They provide a total solution from product design to analysis, prototyping, and testing and validation services to our customer and ensure a cutting edge technology and know-how in our manufacturing facilities. Adhering to strict disciplines of quality and precision our manufacturing process ranges as follows: Die and tool manufacturing High pressure die casting Vacuum die casting Precision Machining Surface treatments Machining, Assembly and end of line testing 12
  • 13. These processes are supported by well-equipped and modern Tool Room, Standard Room, Design &Process facilities. Their process design ranging from layout design, die design, tool engineering, designing & building Special purpose machines. Further our rigorous inspection and testing facilities takes our manufacturing standards to levels of excellence. 2.3 MANUFACTURING FACILITIES The company has five manufacturing facilities across 3 locations - 3 in Tamil Nadu, 1 in Pondicherry and one in Haryana. The facilities are equipped with automated die casting machines, vacuum die casting, Sophisticated CNC machining centers, CNC lathe, in-house built special purpose machines, etc. Full control of the manufacturing process is handled by this department. Structuring of Production planning and control department is given below. 2.3.1 ORGANIZATION CHART (PPC) Plant Head Senior Engineer Diploma Trainee - 1 Diploma Trainee - 2 Diploma apprentice Diploma apprentice 13
  • 14. 2.4 PRODUCTION PROCESS Daily production plan made by various departments finally reaches this department and will execute the plan. As the condition and availability of workers are known by this department cycle time and the number of workers are planned here. Supervisors are allotted for all the lines (4 wheeler, 3 wheeler, 2wheeler and ASV). Monitoring of production is done here. 2.4.1 Production process of carburetor DESIGN MATERIALS DIE CASTING INSPECTION BODY MACHINING MACHINING ASSEMBLY ULRASONIC CLEANING FLOW TEST DELIVERY 14
  • 15. 2.5 PRODUCTION FACILITIES 2.5.1Design & tool room They presently use PRO E & Solid works for designing. Casting dies moulds, precision jigs & fixtures, critical press tools are developed in house. Our tool room possesses the sophisticated machinery cad, EDM, universal milling machines etc. Sophisticated imported measuring instruments are being used by highly trained & dedicated engineers. 2.5.2Die –Casting They are having their own pressure die-casting machines120 & 250Tonneproducing carburettor body & other parts. 2.5.3Auto Shop They are fully equipped with various required automatic machines such as traubs, sliding head (Swiss type automatic machines), CNC turning centres for the manufacturing of precision turned components such as jets, throttle needles, valves, atomizers, air control screws etc. We have tremendous additional capacity to produce in quantity all types of turned components. 2.5.4Machining Carburettors Body & Other Casting Parts Fully equipped with the Special purpose machines (SPM): for reaming & boring operations of different castings. 2.5.5Assembly and Testing In order to fulfil the performance of the carburettor, a great stress in the dust free air-conditioned assembly section is given to ensure the high quality at every stage. 15
  • 16. 2.6PURCHASE FUNCTIONS Purchase of materials is an important function of an industry. The procedure of purchase is as follows 2.6.1 Purchase request The department or officer in need of material has to place his request in a purchase requisition form. In case of raw materials, it is done by the inventory control section. The purchase requisition is prepared in the triplicate. The original copy of it is kept by storekeeper and the other is send to the authorized executive. The purchase request must be approved by the concerned department head. 2.6.2Stockverification On receiving the purchase request the storekeeper checks whether the materials required is available through the store. If the materials are out of stock, the storekeeper informs the purchase section through and indents form. 2.6.3 Selectionofsuppliers The next function is to select the supplier to whom the order is to be sent. The company places a public tender notice for the procurement of raw materials .On the basis of the vendor submits the tenders. Tenders have two parts Technical bid and commercial bid The tender committee opens the tender and verifies the technical bid and if they are satisfied with the technical bid i.e. , with the quality of materials, they opens the commercial bid, the tender committee than prepares a comparative statement and accept the lowest price quoted Quotation. Usually, a contract for one year is made for the supply of raw materials. To avoid risk of the irregularities of the supply, the company appoints more than one vendor. In case of spare parts the enquiry is send to the vendor for, the vendors list of company and the apt vendor is selected on the basis of tenders. The vendor list contains the name and address of vendors and with specific items 16
  • 17. 2.6.4 Purchase order After deciding the supplier, the purchase officer of UCAL has to place a purchase order. The purchase order is written authorization to the supplier to supply the particular materials. The materials are to be supplied according to the terms and conditions of the purchase order. In UCAL five copies of purchase order is prepared. The original is send to the supplier. Second copy is send to the material receiving section The third copy is send to the person who has placed the purchase requisition The fourth copy is send to the Finance department for future reference for payment the last copy is kept in the department itself. 2.6.5Inspection of goods and quotation reception on receiving the materials from the vendor, a visual inspection is conduced. If there is any discrepancy between the party advice copy and received copy, a discrepancy is prepared and if there is any damage report is prepared. 2.7STORE SECTION Store section deal with the following Receiving the materials Inspection of materials Storage and presentation Proper classification and codification of materials Materials handling issue and dispatch Stock records Store accounting Stock taking 17
  • 18. 2.7.1STORAGE FUNCTIONS Various documents are prepared by the store section for the proper functioning of the department. The documents maintained are as follow:- 2.7.1.1 Stores inwards book on receiving any materials to the store, it is entered in a document called stores inward book (SIB) 2.7.1.2Inspection of goods On receiving any materials and preparation of SIB inspection request is send to the concerned technical officer for technical evaluation and prepared on this basis. 2.7.1.3Store received note After the preparation of SIB and inspection of goods or materials, Store Received Note (SRN) is prepared. This is the document showing that the, materials received is accepted and payment can be made for it. The SRN is sent to the Finance department for payment. 2.7.1.4Material issue notes Any material is issued from the store only after receiving a material requisition or Material Issue Note (MIN). MIN contains all the details regarding the material as well as the indenter. 2.7.1.5 Stock transfer note For transfer of materials between store or section or contractors, for transfer of materials between store and section prepared, it contains details such as material code, cost center, material description, Unit and quality. It should be mentioned that material description, unit and quality. It should be mentioned that from which section and to which section is the transfer-taking place. 2.7.1.6Material return note sometimes materials issued from the store may be returned. In that case Material Return Note (MRN) is prepared. It contains details such as the name of department from which the material is returned, value, quality, code, unit, present balance and reason for return. 2.7.1.7 BINCARD BINCARD is a document attached to bin and it contains the quantities details of the materials 18
  • 19. received, issued and closing balance. In addition to this, it indicates information regarding different stock levels like minimum level, maximum level, reorder level, etc coded number and name of materials. 2.8 INVENTORY CONTROL SECTION Proper inventory management is necessary to provide and maintain good customer service. It enables smooth flow of goods through the production process. It is important as it provides protection against the uncertainties of demand and supply and also performing the various production operations economically and independently. Materials purchased for month is analyzed and an issue price is fixed for the month. The company follows weighted average method. 2.8.1Inventory Control Techniques 1. ABC Analysis 2.VSN Analysis 3. FSN Analysis 4. EOQ 2.9QUALITY POLICY UCAL are committed to serve our Customers with Consistent quality products and services as per mutually agreed terms. This is achieved by implementing quality management system as per ISO / TS 16949: 2002 standard involving all employees through training and motivation to create quality culture for continual improvement in the organization 2.9.1 Quality Control / Research and Development To ensure the quality and performance, we have a team of highly qualified and experienced personals to achieve the high standards of the functioning of the products. In order to further ensure the reliability of the product, rigid quality control measures are established at all stages of production. 19
  • 20. 2.9.2Supplier Quality Assurance SQA deals with the quality issues of the materials which are supplied by the supplier to the plant. Quality of the product includes various dimensions of the materials, quality of the materials etc. Imported Machines are used to check the quality. Working of SQA department and additional operations done by the department is given below. Received material PGN at gate and generate RR tag Verify the quantity at store and keeps in temporary location Self certified parts Not self certified parts Directly moved to store inventory OK Accept the tag and Inspected as per RIS move to store Not ok Hand over RTV paper to store Material return to supplier 2.9.2.1 PROCESS IN SQA 20
  • 21. 2.10 MACHINERY MAINTENANCE Ultimate aim of the department is the trouble free running of machines. Mainly 3 type of maintenance methods are adopted by the department. Reactive maintenance Proactive maintenance Condition checking Apart from these methods time based maintenance is also adopted. It is applied basically the case of changing lubricants for machines. Reactive maintenance refers to the solving of a problem after its occurrence. In proactive method the problem is attacked before it occurs and condition checking includes the inspection of machine parts once in a month. Machines used in SQA are not maintained by maintenance department. The machines used in production and assembly are handled by the department 2.10.1Machine Shop Machine shop is mainly functioning to achieve cost reduction. For achieving this department follows various steps Tool cost reduction Consumable cost reduction Scrap cost reduction Productivity improvement in ASV line Setup time reduction in 2wheeler mixing body. WIP(Work In Progress) reduction 10% reduction in all other process Machine shop has the spares of all cutting tools in separate boxes. The length is measured and arranged in specific areas. This is done mainly to reduce the time taken to change the damaged tool. Additional spare parts are there in the assembly line also. Based on the budget given by the top management plans are prepared by machine shop. Every year top management will give a target in reducing the cost. Machine shop will take various measures to achieve this go 21
  • 22. 2.11NEW PRODUCT DEVELOPMENT New product development is done by a separate department. This department starts their work after getting approval and drawing from R & D centre situated at Ambathoor. This department studies the requirements and additional resources which should be implemented in the production cycle and gives detailed report to other departments. If a new order for product is given to the plant, the department will prepare a rough idea about the product and inform the management about the additional cost which should be raised by the management. New machines will not purchase, but changes in existing machine will be done it is done by adding fixtures and tooling. As a result with existing machines new products can be made in a lower cost. Sample product will be developed by the department and will send to the customer. After getting the feedback from customer they will modify the product and after required changes final product is mass produced. Recently in plant 2 production of carburetor for Piaggio petrol scooters are developed in plant 2.12 TECHNOLOGIES USED 2.12.1Lean Manufacturing Adhering to the tenets of Lean Manufacturing we have been able to generate excellent results that translate into bottom-line profits. They have developed a lean way of thinking by implementing various lean tools like: TPM, SMED, Value Stream Mapping, Line balancing, FMEA and 5S.ACT The goal of Lean Manufacturing at UCAL is to essentially connect the entire value stream and eliminate all forms of waste. 2.12.2Total preventive maintenance Producing defect free products from defect free equipment making the manufacturing system highly reliable and flexible. 22
  • 23. This strengthens and enhances plant’s ability to produce to the customers’ needs, consistently. Total Employee Involvement results in cost reduction in overall manufacturing which would in turn satisfy the customers’ requirements Producing defect free products from defect free equipments making the manufacturing system highly reliable and flexible This would strengthens and enhances plant’s ability to produce to the customer’s needs Total Employee Involvement results in cost reduction in overall manufacturing which would in turn satisfy the customer’s requirements 2.12.2.1 Employee involvement S. No Parameters Targets P Output per hour per man > 30% Downtime Zero Q In-house Rejection 80% Down Customer Complaints Zero Manufacturing cost 30% Down C Inventory 30% Down Kaizen / Employee 2/Month M Total Employee Involvement 100% S Accidents Zero D Delivery Adherence 100% 23
  • 24. 2.12.3Value Stream Mapping Value-stream maps are the prototypes for lean transformations. At UCAL, they use VSM technique to identify and eliminate waste thereby streamlining work processes. The steps that we follow in implementing the VSM are: Identify the products to map Draw the “current state” map Access and analyse the current state Draw the “future state” map with all the improvements Create a plan to implement the desired state Implement and review the plan 2.12.4Single Minute Exchange of Dies In this intensely competitive market, there is always a need to provide customers with diversified products of very high Quality while reducing the manufacturing cost at the same time. At UCAL, SMED has been consistently proven to be the key to meet this extremely challenging demand as it reduces waste, time spent between each production runs as well as the size of production lots and inventory. 2.12.5Other Practices Kaizens Poka Yoke 5S 24
  • 25. CHAPTER III HUMANRESORCE DEPARTMENT Personnel Departments concerned with the people’s dimension in organization. The sincerity and dedication of the employees in UCAL is a major success factor. With a full-fledged Human Resource department, regular training and refresher courses are part of the company life. Apart from skill betterment, these courses inculcate quality consciousness, safety and awareness contributes to personality development. There are around 200 employees in the company Structuring of HR department in UCAL plant 2 is as follows 3.1 STRUCTURE OF HR DEPARTMENT HR Manager HR Executive Assistant 1 Assistant 2 Human resource (HR) department deals with wide range of activities from strategic planning level to the day to day operations level. Therefore defining roles and responsibilities of HR department is a quite complex task. Some of the functions carried are summarized below. 25
  • 26. 3.2STRATEGIC PLANNING PROCESS HR department gets involved in the strategic planning process of the organization and identifies HR as a core competency of the organization. When HR is assumed as a core competency HR becomes a. competitive advantage for the organization. 3.3 FORECASTING THE LABOUR REQUIREMENT The HR manager holds the responsibility of forecasting the labour requirement of the organization in the future based on the future level of sales/production level of the organization. The labour forecast may identify the need for need for hiring or firing employees. 3.4 RECRUITMENT Once the labour forecast is done organization can identify the need for more labour in the organization if the existing workforce is not sufficient to handle the future workload. In such a situation HR manager has to recruit new potential candidates to fill the vacancies. Recruitment is the process of creating a pool of potential candidates who can be employed to fill the vacancies. 3.5SELECTION Selection is the process by which the most suitable candidate is selected from the recruited pool of candidates. Selection is done by carrying out various types of tests and interviews. HR department/manager is responsible of selecting the most suitable employees to fill existing vacancies. 3.6 TRAINING Once the employees are done with the induction they become an employee of the organization but the skills they possess may not be adequate to carry out required tasks. The need for training arises when the there is a gap between expected level of skills and the current level of skills of an employee. If a there is a training need HR department has to design training programs and execute them. 26
  • 27. 3.7 INDUCTION Induction is the process by which new employees are made familiarized with the organizational environment. Once the employees are selected they need to be introduced to other staff of the organization and they should be given necessary guidelines about the organizational culture and the procedures. 3.8 MOTIVATION HR manager is responsible of motivating employees to carry out their duties of a timely and accurate basis. 3.9 PERFORMANCE APPRAISAL This is where the employee’s performance is evaluated based on expected level and the actual level of the performance. HR department needs to design performance appraisal systems to appraise the employee performance on a fairly manner. 3.10 REWARDING EMPLOYEES Once the employee performance evaluation is done HR department needs to design good employee rewarding packages to reward well performing employees. These rewards could be of monetary or non-monetary in nature. 3.11PROMOTION Promotion is the movement of an employee from a lower position to another position with a better pay, and responsibility. Every organization chances of promotion chances of promotion came up occasionally. Employees will consider for promotion only if they have qualification and experience in the respective field. Grade II worker in the MS unit who completes 8 years of continues service will be automatically promoted to grade I. Promotion posts will be notified with the plant and the officer of the unit, giving educational qualifications and experience. The application received will be screened by the personnel department. Every employee promoted to a higher post will be on probation in that post for a period of one year 27
  • 28. Four factors are considered for promoting an employee 1) Seniority (25 marks) 2) Test/Interview(0 marks) 3) Attendance(20 mark) 4) Performance(15 marks) Employee who secure less than 50% score of marks in tests and interview are not considered for promotion. All vacancies in the post, in the level of shift in charge equivalent and below in the pigment until shall be filled up by promotion subject to availability of suitable workman. Actual promotion shall be drawn up by the promotion committee and he is empowered or delegated with power to the effect. 3.12TRANSFER There is only inter departmental transfer in the company. 3.13MANAGING EMPLOYEE GRIEVANCE HR department needs to accept the grievance and complaints submitted by the employees about their problems. HR department need to listen to grievance and should come up with solutions to solve problems. 3.13.1 Managing complains about employees There can be complaints about employees regarding poor performance, bribery, misbehaviour and so on. HR department needs to hear that complains and make necessary steps (advising/punishing employees) to solve those issues. Recruitment is done both in the plant and from the top management. Workers who deal with the assembly and manufacturing process are selected by plant itself. Temporary trainees are selected here. Minimum qualification required for these staffs is 12th and ITI or diploma. Other staffs are selected and recruited from head office. Campus recruitment, job melaas, off campus selection, walk in interviews are the various methods to select employees. On the basis of salary employees are categorized into 3. 28
  • 29. 1. Temporary apprentice 2. Technicians 3. Staffs and executives Salary structure is finalized from head office and increase in salary occurs as the experience become more. Training given to the staffs is also based on the categories mentioned above. Temporary apprentice are given training for 1 hour and on the job training is given to them. For technicians period of training is 2 months and for staffs that is 3 months. Statutory returns additional to the salary is given to the employees in monthly, 6monthly and annually. Provident funds are also provided to the employees. Workers are provided with breakfast, lunch and snacks at appropriate time. A small amount is deducted from the salary and good food is provided in the canteen by HR department. All administrative activities are managed by HR department it includes security management, transportation facility, canteen and welfare for workers, room booking for visitors, checking bills etc. Department conducts an annual tour for all the staff along with their family working in the firm. Family day celebration is conducted by the department once in a year. Employees who worked for more than 10 years are awarded 2gm gold coin on this ceremony. Games are conducted for employees and their family members. Food is supplied to all. All these expenses are undertaken by the company. This motivates the employees and gives them affection towards the company. 3.14WORKMEN CLASSIFICATION Permanent Employees: There are about 200 Technical and 20 non technical staffs working in the UCAL plant 2 as permanent employees. Employees Engaged On Contract Basis: These employees work n contract for a limited period of time say one year or six months 29
  • 30. on specific terms and condition fixed by the company. They have no preference for future employment in the company. Temporary or seasonal worker: These workers are employed when the work load is more. On certain season due to the increase in demand, more work forces are needed to meet the production. In such cases temporary workers are engaged. The services of such employees are dispensed with as and when the need is satisfied Apprentices: Apprentices work for a period of one year as part of their training programmed as per apprenticeship Act 3.15 WAGE STRUCTURE Basic wages for each category of workers are fixed as per agreement the management and the workers representative. The items covering under wages are follows;  Basic pay  Dearness Allowance  Variable Dearness Allowance The worker are given specified amount as basic wage as per the agreement. The agreement is valid for four years. 3.16WELFARE ACTIVITIES Bonus Employees who are drawing more than Rs.3500/- per mount are eligible for bonus almost all the employees working here are eligible for bonus irrespective or casual worker. 30
  • 31. Provident fund Introduced in 1956 and administered by a trust. Here both the employer and the employee have to continue 12% each of the basic pay, where eight and one third percent is transferred to pension fund. Gratuity Minimum amount payment payable as gratuity is Rs.3500 Employees having continues service of the year is eligible for gratuity. Employees State Insurance All the employees working here come under Employees State insurances Scheme. 3.16.1 Labour Welfare Activities The allowances provided by the company for its employees are as follow  House pent Allowances Workmen of the company shall be entitled to house rent allowance @ 10% of the basic pay effective from 1. 1. 1997.  Conveyance Allowances Up to Rs.100 is given as conveyance allowance as per Memorandum of Agreement.  Shift Allowances Employees working A, B and C shift are paid Rs 200 per month as shift allowances.  Cash Handling Allowances Rs.40 per month is paid as cash handling allowance to employees who look after the duties of the cashier.  Attendance Bonus:- Employees who attain attendance of: A) 80 to 90% are given a bonus of Rs. 100/- B) Greater than 90% are given a bonus of Rs.110/- C) 100% are given one wage and DA 31
  • 32.  Housing Loan For small works of residential building such as extension are repair works loans are given to Rs. 1.5 lakes and a maximum amount of Rs.3 lakes can be given for construction of new residential buildings.  Vehicle Loan For two wheelers amount Rs.40000 are given as vehicle loan and for officer loan amounts to Rs.1 lakhs. 3.17FRINGE BENEFITS  Retirement Benefits  Death Relief Fund  Medical Facility  Financial Aid to prolonged Treatment  Subsidized Canteen facility  Interest Subsidy for Housing Loan  Transportation Facility  Recreation club 3.17 PERSONNEL RECORD KEEPING UCAL maintains a personnel record for its employees. It is a file consisting for all the details regarding the employee and all the data relevant to him Recording Of The Attendance The electronic punching system is adopted in UCAL. Every employee had to punch the card on entering the work. Time Keeping And Time Booking A separate wing is concerned with time keeping and time booking in the company. With the help of the punch card this section keeps an attendance register. Main function of this section is attendance recording of leave, late coming, early going lost hours, overtime, shift allowance, loosed wages due to absence, wages due to work holidays. 32
  • 33. CHAPTER IV FINANCE DEPARTMENT 4.1 INTRODUCTION Finance is the life blood of business and hence it requires a lot of effort to manage it well. The basic functions of the Finance Department are procurement of funds at the right and optimum utilization of funds. Like every manufacturing company, UCAL also has its own separate finance department which deals with different financial matters of the company. The finance department of UCAL is sub divided into various sections and the work flow is divided among these sections which are consolidated and put together as a whole at the end and the final accounts are prepared and then the decision making process begins and targets are set for the next financial year. 4.1 VARIOUS SECTIONS IN THE FINANCE DEPARTMENT 4.1.1 Books Section This section keeps the records of all the matters of finance department and all the other records that each section keeps with it. They record all the ledgers and vouchers of monthly, quarterly and yearly accounts. They also maintain records of the inter-unit transactions i.e. the transfers that take place between this unit and UCAL’s other units. They keep the records of the entire audit that is done internally as well as the record of the entire statutory and government audit. 4.1.2 Budget Section This section also deals with the budgeting of the company. The funds are allocated by the corporate office for each UCAL unit. After receiving this budget they prepare their own budget of each department with the respective heads and then allocate the funds to each department for their purposes. They also prepare the budgeted figures and targets of the company for the next financial year. 33
  • 34. 4.1.3 Sales Section / Bills Receivable Section This section deals with all the sales related issues in the company. It keeps all the records and the data that is necessary while making the records and maintaining the accounts of sales. Eg., packing List, clearance letter, lorry receipts, guarantee certificate, etc…It also keeps the record of all the debtors of the company and the Central and State sales tax that is levied on each item and the terms and conditions related to them. The debtor’s management is also dealt with this department. They have to prepare an MIR (Manual Information Report) for every month which is sent to the corporate office as a report of the company. 4.1.4 Bills Payables Section This section is concerned with the payment of all revenue bills. A revenue bill includes payment made to suppliers, payment to government agencies. In case of purchasing the materials, the actual process starts once the order is placed and the materia lis received by stores and it is sent to quality section. Wherein inspection department will certify and then clear the stores receipt vouchers. The cleared stores receipt will then come to material management who will value it. After this, it is forwarded to bills payable section. They will release the payment immediately when the bill becomes due. The Records Maintained By This Section Are · Purchase order book · Supplier’s invoices · Store requisition voucher, etc., 4.1.5Cash Section The main function is to account the cash and bank balance. Other than this function the actualPayment of money is done through this section. The employee’s salary, contract labourers’ wages, supplier’s amount and receipt of customer’s payment all are done through this section. 34
  • 35. 4.1.6 Costing and material account section Costing section in UCAL is an part integral section which co-ordinates various other departments like production, marketing, etc.. The main task of this department is to classify the various types of costs, accumulation of assignment and control of cost. The information supplied by this department has a great deal of importance to the management in decision making. By cost splits the management will be in a position to know where exactly wastages are more, or which method is causing runoff profits etc,.It also prepares the cost estimates, based on which the marketing department will make the bidding. Another important function of this section is preparing the price stock ledger and major task of this section is that it looks after the capital payments. 4.1.6.1 Types of Software for Accounting Procedure The software which is used for the purpose of accounts they use Tally software of 7.1 version which covers all recent updates accounting standards and also tally software of 7.1 version covers VAT concept which marks very easy for company to fill the tax according rules and regulation. 4.1.7 Works Bill Section This section keeps a record of all the infrastructure related issues. They keep a record of the building, roads, furniture and the township related matters. It also keeps a record of the work that is needed to be done for the company as well as for the township and other areas. 4.1.8 Pay-Roll Section This section is concerned with the computation and payment of wages / salaries, medical reimbursement, conveyance reimbursement, tour advance settlement, air fare settlement, payment of medical expenses of retired employees, provident fund and gratuity, etc,. Hence for this purpose, this section maintains Master Records which consists details of each and every employee regarding their date of joining, leave taken, payment of salary, loan taken, allowances given, etc., which are monitored and updated every month. This section ensures a pleasant atmosphere by ensuring accurate payment to the employees in order to 35
  • 36. Maintain industrial harmony and employee satisfaction. Apart from these activities, the department is also concerned with recording and maintaining the attendance, leave taken and over time work done by each and every employee. Here the department records time in and out of employee through the medium of automatic time recorders provided at the vantage points within the factory. 4.1.9 Taxation Section This section takes care of the tax related issues of the company. All the indirect and direct taxes thatthey have to deal with is taken care of by this section. They also take care of the excise duties and customs duty in case of export. They also deal with the service tax related matters. All these sections of Financial Department collectively function efficiently for the effective and optimum allocation and utilization of funds of the organization. 4.3 CAPITAL STRUCTURE A mix of a company's long-term debt, specific short-term debt, common equity and preferred equity. The capital structure is how a firm finances its overall operations and growth by using different sources of funds. Debt comes in the form of bond issues or long-term notes payable, while equity is classified as common stock, preferred stock or retained earnings. Short-term debt such as working capital requirements is also considered to be part of the capital structure. 4.3.1 Capital Structure Of UCAL Authorized Issued Period Instrument -PAIDUP- Capital Capital Capital Shares Face From To (Rs. cr) (Rs. cr) (Rs. (nos) Value Cr) 2010 2011 Equity Share 75.0 22.1 22113625 10.0 22.1 2009 2010 Equity Share 75.0 22.1 22113625 10.0 22.1 2008 2009 Equity Share 60.0 13.9 13896000 10.0 13.9 2007 2008 Equity Share 60.0 13.9 13896000 10.0 13.9 2006 2007 Equity Share 60.0 13.9 13896000 10.0 13.9 36
  • 37. 4.4 WORKING CAPITAL MANAGEMENT Working capital management is concerned with the problem of that arise in attempting to manage. The current assets and current liabilities are the relationship that exists between them. The term current assets refers to those assets, which in the ordinary course of business can be or will be converted into cash within one year without undergoing a diminution in value and without disruption of operation. The goal of working capital management is to manage the firm’s current assets and liabilities in such a way a satisfactory that level of working capital is maintained. The company avail the working capital from the nationalized Bank in the form of over draft account. 4.5 CREDIT POLICY 4.5.1 Trade credit Trade credit refers to the credit extended by the suppliers of goods and services in the normal course of transaction/business/ sale of the firm according to trade practices; cash is not paid immediately for purchases but after an agreed period of time. In case of UCAL credit the suppliers allow period with in 30days. 4.6 ACCCOUNTS RECIVABLE/ RECIVABLE MANAGEMENT The term receivable is defined as debt owes to the firm by the customers arising from sale of goods or services on ordinary course of business when a firm makes an ordinary sale of goods or services and does not receive payment. The firm grants trade credit and create accounts receivable which could be collected in feature. 37
  • 38. 4.5.1 Balance sheet - UCAL Fuel Systems Ltd. Particulars Mar'12 Mar'11 Mar'10 Mar'09 Mar'08 12 12 12 12 12 Liabilities Months Months Months Months Months Share Capital 22.11 22.11 22.11 13.90 13.90 Reserves & Surplus 270.96 258.56 246.63 182.36 182.32 Net Worth 293.07 280.67 268.74 196.26 196.21 Secured Loans 211.42 224.91 237.38 156.02 140.19 Unsecured Loans 20.55 23.83 11.13 26.90 4.81 TOTAL LIABILITIES 525.04 529.41 517.25 379.17 341.22 Assets Gross Block 410.00 405.80 373.77 276.05 249.96 (-) Acc. Depreciation 183.91 203.66 181.12 145.59 129.88 Net Block 226.09 202.14 192.64 130.45 120.08 Capital Work in Progress. 13.45 15.74 7.12 8.74 16.38 Investments. 156.26 156.26 156.26 167.36 115.95 Inventories 45.75 38.09 30.36 29.72 29.47 Sundry Debtors 104.75 94.96 89.90 47.50 50.48 Cash And Bank 5.66 2.73 2.28 0.81 1.31 Loans And Advances 146.63 125.77 119.91 87.52 107.66 Total Current Assets 302.80 261.55 242.45 165.55 188.93 Current Liabilities 163.60 108.54 94.37 97.22 100.22 Provisions 15.42 10.28 3.55 17.29 19.02 Total Current Liabilities 179.03 118.82 97.93 114.51 119.24 NET CURRENT ASSETS 123.77 142.73 144.52 51.04 69.69 Misc. Expenses 5.47 12.54 16.71 21.59 19.12 TOTAL ASSETS 525.04 529.41 517.25 379.17 341.22 (A+B+C+D+E) 38
  • 39. CHAPTERV MARKETING DEPARTMENT 5.1 INTRODUCTION All the working of the plant starts and ends with marketing department. All the suppliers and customers of the company are handled by marketing department. They collect orders from customers and to satisfy the customer needs they prepare monthly, weekly and daily production plans. The information is given to other departments and the production is carried out. Other departments can work only with the data given by the department. Transportation decisions of goods through various alternatives are also taken by marketing people. Normal working of this department ends only when the finished products reach the customer or distributor. Invoice is finalized by department by analysing the data from dispatch/tax department. Some important functions of marketing department are mentioned below. Focus on the Customer. Monitor the Competition. Own the Brand. Find & Direct Outside Vendors. Create New Ideas. Communicate Internally. Manage a Budget. Set the Strategy, Plan the Attack, and Execute. Focus on the Customer. Marketers should spend time listening to their customers (and prospective customers) in order to understand their needs and wants regarding a particular product or service. Soliciting thoughts and input from internal stakeholders such as Sales and Customer Service is also appropriate, as these departments are typically closest to the customer. 39
  • 40. Monitor the Competition. Learning about, and understanding the competitive landscape is also an important function of the Marketing Department. Marketers should be the “go to people” within an organization to answer the following types of questions: Who is the competition (both direct and indirect)? What do they communicate? Which customers do they serve? Why do customers choose the competitor versus you? Own the Brand. The perceptions and feelings formed about an organization, its products / services, and its performance is what is known as its “brand.” The Marketing Department is responsible for creating meaningful messages through words, ideas, images, and names that deliver upon the promises / benefits an organization wishes to make with its customers. Furthermore, the Marketing Department is responsible for ensuring that messages and images are delivered consistently, by every member of the organization. Find & Direct Outside Vendors. Internal Marketing Departments do not create magic alone. Therefore, marketing needs to source and oversee a group of outside resources to make market for the product. Create New Ideas. Whether it is customer acquisition campaigns, keep-in-touch programs, new product promotions, retention efforts, or something in between, the Marketing Department should ultimately be responsible for developing new ideas that generate revenue for the company. This does not mean that the Marketers have to come up with every idea on their own; however, they need to identify, cultivate, and work with others to execute programs that will create revenue. 40
  • 41. Communicate Internally. It is important that the Marketing Department communicates with all departments inside an organization. Since any employee can support a brand, value proposition or even specific program initiatives, the Marketing Department needs to take responsibility for disseminating information throughout the organization (this includes internal education and training when appropriate). Manage a Budget. Establishing and communicating messages to the marketplace costs money. Therefore, Marketing Departments is responsible for estimating the anticipated expenditures associated with marketing activities. Once set, Marketers should be held responsible for meeting all budget projections. Set the Strategy, Plan the Attack, and Execute. One of the key activities for a Marketing Department is to integrate an organization’s goals, strengths, and channels of distribution, competitive environment, target markets, pricing, core messages, and products into one cohesive document known as the Marketing Strategy. As part of the strategy, the Marketing Department should also develop the list of tactical ideas such as direct mail, print advertising, and search engine optimization that will enable the organization to communicate its message to customers and prospects. With a strategy and tactical ideas in hand, the Marketing Department is now ready to take on the responsibility of executing the programs and initiatives to drive sales and revenue for the organization. 5.2 MARKETING MIX – THE 4 P’S OF MARKETING The Marketing mix is a set of four decisions which need to be taken before launching any new product. These variables are also known as the 4 P’s of marketing. These four variables help the firm in making strategic decisions necessary for the smooth running of any product / organization. These variables are 41
  • 42.  Product  Price  Place  Promotions 5.2.1PRODUCT UCAL product portfolio consists of extensive range of components for two, three and four wheelers. The product range include carburettors for two wheelers, gasoline fuel injection system products, engine management systems, products for diesel applications and emission control, pumps to high pressure die casting and precision manufacturing products. 5.2.1.1Four wheeler-carburetors Applications 2 & 4 Stroke Engines in Motorcycle, Scooters & Three wheelers Function To supply proper air-fuel mixture based on the engine requirements Throttle will be directly operated by the rider. Area of the venturi changes causing a change in the air flow and vacuum Range Venturi size: 12 mm – 22 mm, 2 & 4 stroke engines 42
  • 43. Technology & Special Features Provision for coasting richer system, throttle switch, solenoid operated auto-starter, electronic control of air-fuel ratio Customers Bajaj, TVS, Mikuni, Suzuki & Yamaha. 5.2.1.2 Multi Point Fuel Injection Parts Thottle Body Assembly Applications Passenger Cars & Vans Function Controls the amount of air that goes into the engine depending on engine speed and driving conditions Range Bore Sizes from 32 mm – 80 mm Technology & Special Features Provision for mounting idle speed controller, manifold absolute pressure sensor Customers Maruti Suzuki, Hyundai, Bosch, Mikuni, Continent 43
  • 44. 5.2.1.3 High Pressure Fuel Filter Applications Gasoline Passenger Cars & Vans Function To reduce the particulate impurities Range Capable of withstanding pressure from 3.5 to 5 Bar Provision for accommodating bracket for mounting on to vehicle Technology & Special Features Double folded paper element Customers Maruti Suzuki and Hyundai. 5.2.1.4 Two /three wheeler-emission control products Secondary air value 44
  • 45. Applications 4 Stroke Motorcycles & Scooters Function Supply secondary air to oxidize Carbon Monoxide and unburnt Hydrocarbons in the exhaust Range Engine capacity from 60cc to 50cc. The product is available in Aluminium& Plastic variants. Technology & Special Features Air cut valve integrated with Secondary Air Valve to take care of after buring during deceleration. Product is available in aluminium and plastic variant. Direct Engine mounted model and chassis mounted model available. Customers Hero Honda, Bajaj, Mikuni, TVS, Royal Enfield, Suzuki & Yamaha. 5.2.1.5 Oil Pump Assembly Applications Diesel & Gasoline Passenger Cars, Vans, Multi-Utility Vehicles & Trucks 45
  • 46. Function To provide oil to all parts of the engine for lubrication Range Engine CC: 1litre - 3 litres engines. Specifications Flow rate : 8 - 15 lpm Engine RPM : 500-1000 rpm Pressure :2-3 bar Technology & Special Features Gerotor type oil pumps. Oil Pump assembly available with and without Chain cover 5.2.1.6 Fuel pumps Piston driven fp Applications 2 stroke Motorcycles, Scooters and 3 wheelers Function Piston fuel pump which can develop up to 10bar pressure at a flow rate of about 7lpm. Suitable for gasoline applications More than 1000 hours of functional life 46
  • 47. Customers Bajaj and Other applications 5.2.1.7 High pressure die cast products Throttle Body Housings Weight :Approx 0.5- 0.8 kgs Bore Range : 50mm to 80mm Customers : Continental 5.2.2PRICE There are three types of pricing methods. They are Cost based, Demand based, competitive based. In this company competitor based pricing is followed .The competitor based pricing is nothing but the name itself indicates the company Fix prices based on the prices of the competitors. So the rise & fall of price fully depend upon the competitor’s price. 5.2.3PLACE To reach the products from producer to consumer they use Zero channel and The mode of distribution is done by the small process shown below. Producer Distributor Consumer 47
  • 48. 5.2.4 PROMOTION 5.2.4.1 Advertisement & sales promotion activities The advertisement is done through Seminars, Tradeshows at their work places. The sales promotion activities are carried out by arranging training programs in their plant and by direct interaction with their client, agent, they follow PMC(PROJECT MANAGEMENT CONSULTANT S) to attract all the A, A+ customers. 5.3 COMPETITORS Auto line industries ltd Banco products (India) ltd Bosch ltd Federal-mogulGoetze (India) ltd IP Rings ltd Karmobils ltd 5.4MARKETING RESEARCH Marketing researches are conducted to check the flow of products to the customers and their perception .The Method of conducting this activity is done through the following ways  Marketing surveys  Case studies  Day to day activities likes surveys and feedback carrying different parameters. 48
  • 49. 5.5 SWOT ANALYSIS STRENGTH  Maintaining internal quality systems  Good employee relationship  Certified as AN ISO/TS 16949 : 2009, ISO 14001:2004 & OHSAS 18001: 2007 CERTIFIED COMPANY  Fully computerized  Ensuring continuous development of human resources  Good fire & safety department to avoid accidents  Continuous production system WEAKNESS  Marketing department to be strengthen  Not having sufficient man power  Over work for employees.  There is no active employee welfare union for the employees.  There are more number of apprehends, hence the job security is weakness. OPPURTUNITIES  Expansion of plant capacity  Can capture wide range of market  New products can be introduced  The customers are well established in the market, hence the opportunity are wide. THREATS  Hence there is a regular importing of products the expense involved is more and more.  Rapid technological changes  Introduction of various products in the market.  Perfect competition is there for the commodity. 49
  • 50. FINDINGS  360 degree performance appraisal  The company has certifies as AN ISO/TS 16949 : 2009, ISO 14001:2004 & OHSAS 18001: 2007 CERTIFIED COMPANY  The company has plans for further expansion  Computerization resulted in inter departmental relationship  Company is in the path of modernization and expansion SUGGESTIONS  Product line of the company should improve  Good communication must be set between employees and the management.  Marketing department should get more support from other departments to perform more effectively.  Look more into international markets  Concentrate on expansion and diversification of plant, equipments, products etc.  Product promotion activity should be introduced by the company 50
  • 51. 6. CONCLUSION Being the giant in the automobile fuel management business the company has a bright future. All the functions in the company are going well. According to my opinion employees are given more work load. Marketing department functions with lots of limitations. Even though there are small problems in the plant the overall performances of the company is good and have a bright future. The finance department is doing well in the company. The Production and Administration department is also doing well and it has a very important role in the performance of the company. The department provides all help to the employees and settles their grievances. All the departments are doing well and it is good sign for the company. Name of the company has a great importance in the automobile fuel management system. Main automobile manufacturers are depending UCAL to full fill their needs. In short the company has a bright future in the coming year and will attain a good position in the economy and market. 51