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A SUMMER INTERNSHIP PROJECT REPORT ON
 “TOTAL QUALITY MANAGEMENT PRACTIES
   IN FORGING COMPANY OF RAJKOT CITY
WITH REFERENCE TO KADVANI FORGE LDT”


                      PREPARED BY
                    KOTADIYA VISHAL

Class                                Academic Year
M.B.A. : SEM. 3                       2010-12

Enrollment No.                        Guided By
107440592054                          Mr. Nailesh Libasiya




                        Submitted To
               Gujarat Technological University
                         Ahmadabad

                       College
        R .K. College Of Business Management
            Kasturbadham Rajkot - 360020




                                                             1
2
DECLARATION

I the undersigned here by declare that the project report entitle “RESEARCH ON

TOTAL QUALITY MANAGEMENT” AT KADVANI FORGE LDT. has been prepared

by me during the year 2010-11 under the guidance of Mr. Nailesh Lilbasiya R .k. Collage

of business management Kasturbadham Rajkot – 360020




I also here by declare that this Project Report has not been submitted at any time to any

other university or institute for any degree or diploma.




Date   :


Place : RAJKOT                                        VISHAL KOTADIYA




                                                                                       3
PREFACE
It is said that “Knowledge is power” but “applied knowledge is power” seems to be a

correct statement.


In this modern word, theoretical study has no value without its practical application;

practical knowledge is more powerful than the knowledge of books. In today‟s business

words, practical knowledge plays an important role; course involves industrial training,

which provides practical knowledge and experience to the students in the field of

management.


The project is prepared on kadvani forge Ltd. And include the idea about their production

department, finance department, personnel department, etc. the main thrust of this project

is to acquire information of the unit and to pen it down.


I have acquired a lot of knowledge by doing this study and will always remain thankful to

the college, University and the team of kadvani forge who helped me accomplishing this

task.




                                                                                        4
ACKNOWLEDGEMENT
This is my great pleasure to submit this report. I am thankful to all the persons who have helped

me for arrangement of my practical training and also for getting information which is require for

the preparation of this report.

First of all I am thankful to authorities in KADVANI FORGE LTD., For granting me the permission

for training and their co-operation during the training period. I am also thankful to all the

respondents who have filled the questionnaires which are necessary for the survey.

I am also highly obliged to Mr. Nailesh Limbasiya for their sincere attention valuable guidance

and providing suggestion and thus guiding me all the way in my efforts to prepare this report.

I am heartily thankful to Prof. Dr. Sugan Chand Jain & Dr. Vijay Vyas directly or indirectly

contributed their valuable time and helped me for preparing this report.

I am thankful to HR Manager MR.C.R.NAIR of KADVANI FORGE Ltd. For providing me the

permission to visit this unit and giving me chance to study the company for a particular subject. I

am also thankful to all staff member of KADVANI FORGE Ltd. for sparing their valuable time

inspire of their busy schedule and helping me to collect all such information.

I am also thankful to technical & non-technical staff contributed directly or indirectly their

valuable time and helped me for preparing this report.




                                                                                                 5
EXECUTIVE SUMMARY
In the growing global competion the productivity of any bussiness concern depends on

the behavioral aspects of customers. This topic deals with the customer satisfaction

towards forging components of KFL. This project report contains 5 different chapters.

The report begins with the introduction of the industry, company information, and the

functional area information.


The second chapter is about the literature review which tells about the customer

satisfaction.


The third chapter is about the reseach methodology which was adopted by me in my

topic. It contains research problem, objective, data collection, limitations about the topic.


The fourth chapter is a comprehensive study of forecasting concepts and techniques

which shows analysis and interpretation through graphical representation of the data

collected in survey.


The fifth chapter deals with the findings/conclusions/suggestion/future plans which is

very much important after analysis is made.




                                                                                                6
 TABLE OF CONTENT


SR. NO TOPIC                                      PG. NO
1      INDUSTRY OVERVIEW                          1
2      ORGANIZATION OVERVIEW                      9
            Marketing department                  10
            Production department                 12
            Finance department                    25
            Human resources department            32
            Future plan of KFL                    37
            S.W.O.T. analysis                     37
3      MARKET METHODOLOGY                         39
            Introduction                          40
            Literature review                     40
            Objectives of study                   41
            Sample survey                         42
            Analysis and interpretation of data   47
4      SUGGESTIONS & CANCLUSION                   57
5      LEARNING FROM SIP                          59
6      BIBILOGRAPHY                               60
7      ANNEXURE                                   61




                                                           7
8
Introduction:-

Forging is the process by which metal is heated and is shaped by plastic deformation by
suitably applying compressive force by using hammer or a press. Forging refines the
grain structure and improves physical properties of the mental. Forging changes the size
and shape, but not the volume, of a part. The change is made by force applied to the
material so that it stretches beyond the yield point. The force must not be strong enough
to make the material deform. It must not be so strong; however, that it destroys the
material. The yield point is reached when the material will reform into a new shape.

Normally this results in metallurgical soundness and improved mechanical properties.
Strength, toughness and general durability depend upon the way the grain is placed.
Forging are somewhat stronger and more elastic. The feature of greatest importance is
that there is a greater ability to resist shock, wear and impact than across the grain
material properties also depend on the heat treating process after forging. Good forging
practice makes it possible to control the flow pattern resulting in maximum strength of the
material and the least chances of fatigue failure.

These characteristics of forging, as well as fewer flaws and hidden defects, make it more
desirable than some other operations for products that will undergo high stresses. Physical
properties such as strength, ductility and toughness are much better in a forging than in
the base metal, which has, crystals randomly oriented. Forgings yield parts that have high
strength to weight ratio thus are often used in the design of air-craft frame members.

 Types of Forging:-
                   Hammer Forging,
                   Press Forging.

What is forging?
Forging is manufacturing process where metal is pressed, pounded or squeezed under
great pressure into high strength parts known as forgings. The process is normally (but
not always) performed hot by preheating the metal to a desired temperature before it is
worked. It is important to note that the forging process is entirely different from the



                                                                                          9
casting (or foundry) process, as metal used to make forged parts is never melted and
poured (as in the casting process).

Why use forgings and where are they used?
The forging process can create parts that are stronger than those manufactured by any
other metalworking process. This is why forgings are almost always used where
reliability and human safety are critical. But you'll rarely see forgings, as they are
normally component parts contained inside assembled items such a airplanes,
automobiles, tractors, ships, oil drilling equipment, engines, missiles and all kinds of
capital equipment - to name a few.

Who buys forgings?
Forged parts vary in size, shape and sophistication - from the hammer and wrench in your
toolbox to close tolerance precision components in the Boeing 747 and NASA space
shuttle. In fact, over 18,000 forgings are contained in a 747. Some of the largest customer
markets include: aerospace, national defense, automotive, and agriculture, construction,
mining, material handling, and general industrial equipment. Even the dies themselves
that make forgings (and other metal and plastic parts) are forged.

How big is the forging industry?
The forging industry is composed of those plants that;

a) make parts to order for customers (referred to as custom forgings);
b) make parts for their own company's internal use (referred to as captive forgings); or
c) make standard parts for resale (referred to as catalog forgings).

The largest sector - custom forging - accounts for over $6 billion dollars in sales annually.
These custom forgings are produced by about 250 forging companies in approximately
300 plants across the U.S., Canada and Mexico.

How many people are employed by the forging industry?
Approximately 45,000 people from coast to coast are employed by the forging industry in
the United States and Canada. Because the modern forging process is capital intensive
(requiring an abundance of heavy equipment for manufacture and the people to run and




                                                                                           10
maintain it), most forging plants are small businesses which generally employ between 50
to 500 employees each, with a few larger facilities employing over 1000 people.

What metals are forged?
Just about any metal can be forged. However, some of the most common metals include:
carbon, alloy and stainless steels; very hard tool steels; aluminum; titanium; brass and
copper; and high-temperature alloys which contain cobalt, nickel or molybdenum. Each
metal has distinct strength or weight characteristics that best apply to specific parts as
determined by the customer.

What kind of equipment is used to make forgings?
Although the styles and drive systems vary widely, a forging can be produced on any of
the following pieces of equipment.


Hammers with a driving force of up to 50,000 pounds, pound the metal into shape with
controlled high pressure impact blows.


Presses with a driving force of up to 50,000 tons, squeeze the metal into shape vertically
with controlled high pressure.


Upsetters are basically forging presses used horizontally for a forging process known as
"upsetting".
Ring Rollers turn a hollow round piece of metal under extreme pressure against a rotating
roll, thereby squeezing out a one-piece ring (with no welding required).




History Of Kadvani Forge Ltd

“Every one has a goal to win, but a very few have a strong will to prepare to win. ”

I would like to brief a History of the company which is following the thought mention
above. The company named “KADVANI FORGE LTD.”

After seeing huge potential in the field of forging the company started its career in the
forging with small scale industries. The Kadvani forge ltd. got the certificate of its


                                                                                             11
incorporation on 1st August, 1995 and certificate of its commencement on 20th June,
1995. But it started its commercial production in 1997. It has established its forge-shop in
the area of Gujarat Industrial Development Corporation (G.I.D.C.). And it becomes
popular with the name of “KFL” i.e. Kadvani Forge Ltd.

Its production capacity in the initial stage was 50 tons per month. In the 1 st year of
operation the company faces losses but then after through its sincere efforts it covers all
losses and making profit.

“Success seems to be connected with action.
 Successful people keep moving.
They make mistake, but they don’t quit.”


The company proves its efficiency and move further without any fear of the failure and
results into developing a new 400 components within 6 years. The company exported its
industrial products in the international market in countries like U.S.A., Europe and
Middle East. The company establishes its foot step in the international market by their
hard work and sincerity. All the products are successfully accepted in the international
market.



Vision, Mission & Value

VISION:-

To prepare continuous value through innovation, expertise, excellence & attain highest
level of customer satisfaction.

MISSION:-

To become a global leader by incorporating highest level of quality through a
combination of technology, service, creative, marketing, prizing and cost efficiency. The
vision and mission of KFL is supplied by integrated set of core values.

VALUES:-

integrity & ethics:-



                                                                                         12
KFL is committed to conducting to themselves with non-compromising integrity & ethics
whenever KFL operates.

innovation:-

KFL is committed to fostering innovation through an entrepreneurial spirit team work &
creativity.

costomer satisfaction:-

Customer are at the heart of their strategy & KFL wants to maintained their relationship
to maximize growth and profitability.

Five “S” Systems

KADVANI FORGE LTD. Is implemented 5s system production. This include:-

        1) Self Discipline,
        2) Systematic Arrangements,
        3) Spic and Span,
        4) Standardize,
        5) Sorting,

With the help of 5s System in production, the smooth accurate, speedy production is
possible.




                                                                                           13
ORGANIZATION STRUCTURE OF K.F.L.




                                   14
COMPITITORS

As the demand for Automobiles, Machines are increasing the need for forging
components are also increasing so; this change has attracted many business houses to get
entered into the forging industry.

The KFL has many competitors at state level as well as national level. Some of them
areas bellow:

Bharat Forge

Kalyani Forge

Ajk Forge Pvt Ltd

Silver Forge Pvt Ltd

Super Forge

Crystal Forge

Forge & Forge Pvt Ltd

Echjay Industries Pvt Ltd

Jay Forge




                                                                                     15
16
MARKETING DEPARTMENT
INTRODUCTION

Financial success often depends on marketing ability. Finance operation, accounting and
other business function will not really matter if there is not sufficient demand for products
and services so, the company can make a profit.

Marketing also deals with identifying and meeting human and social needs. One of the
shortest definitions of marketing is

“Meeting needs profitably”

According to American Marketing Association:

“Marketing is an organizational function and a set of process for creating communicating
and delivering value to customer and for managing customer relationships in ways that
benefit the organization and its stake holders.”

Markrting Management At Kfl

KFL is not in a need to practice marketing activities by putting great efforts. That because
the company is not producing components by their own, but it manufactures components
those are demanded by the customers.

So, it is dealing with B to B market and need not do heavy advertisement and other
marketing activities.

The company‟s marketing department is working for getting the orders from the
customers by giving them presentation if they are new to the company.

The KFL is doing marketing in such a way that it is having a membership of many
forging associations.

As well as by participating in various events and fairs related to the industry at national
and international levels.

The starting point of each activity is the customer‟s inquiry. The marketing department in
handles all the inquiries and check the feasibility of the orders and for that the department



                                                                                          17
is preparing APQP and PPC. The prim Moto of the marketing department is „customer
satisfaction‟.

Market

Traditionally, a „Market‟ was a physical place where buyers and sellers gathered to buy
and sell the goods.

But in today‟s modern world there is no as such necessity of physical place due to the
highly technological development i.e. internet and all.

Market can be product market, demographic market, geographic market, labour market,
donor market etc.

The key consumer markets are:

           1. Consumer Market
           2. Business Market
           3. Global Market

The KFL is having business market that the finished components are sold to the another
business houses of automobile, defense, earth movers etc. So, to deal with B to B market
will demand extra specifications of the quality, timely delivery, relation, price etc. aspects
in that.

Target Market

The following are the target markets of KFL:

Mahindra & Mahindra
TATA Motors
RSB
John Dear tractor
Eaton Truck




                                                                                           18
PRODUCTION DEPARTMENT

Product Offering

“A product is a bundle of benefits which are been offered to the consumer”

It is a complex of tangible attributes including material, packaging, colour, price, and
manufacture‟s prestige, retailer‟s service which the buyer may accept as offering
satisfaction of wants or needs.

The products those are offered by KFL on the demand of the customers are:

       Automobile
       Petrochemical
       Earthmoving
       Electric Transmission
       Machine Tools

The KFL only manufactures what customers have given in his drawing so, in this case the
New Product Development activity does not take place.

Distribution Chennel

“Physical distribution comprises the task involved in planning and implementing the
physical flows of material and final goods from the point of origin to points of
consumption to meet the needs of consumers at a profit.”

The distribution of component of KFL differs with the market:

Domestic Market:
The company uses the transportation facilities by roadways as per the demand of
customers.
Foreign Market:

For export order the company‟s components are transported by shipment at seaway from
nearer port.




                                                                                     19
Product Gallery

Kadvani Forge Ltd. Manufactures Closed Die Steel Forged products as per the customer
specification in Carbon & Alloy Steel and supply them in as Forged, Heat
Treated, Partially Machined Condition.

They are producing forged components up to 80kg Weight.

Kfl are Capable of Manufacturing Forging items for Diverse Industries Viz.

       Automobile
       Petrochemicals
       Earthmoving
       Electric Transmission
       Machine Tools

All together 850 type of Components.



Transmission Components.

       Transmission Shaft
       Pinion
       Crown Wheel
       Sliding Gear
       Differential Bevel
       Ring Gear
       Fixed Gear
       Internal Gear. Etc

Engine Components.

       Crank Shaft
       Connecting Rods
       Connecting Rod Cap
       Cam Shaft
       Half Piston
       Rocker Arm. Etc




                                                                                 20
Propeller Assembly Components.

      Flange Yoke
      Tube Yoke
      Long Fork
      UJ Cross
      Short fork, Etc


Earth Moving Components.

      Track Links
      Track Roller Shafts
      Ring Bush Coupling Set
      Worm Gear
      Blanks
      Drill Bits Etc

Machine Tools and Electrical
Components.

      Shafts, Hubs
      Spindles, Etc




Other Components.

      Bell Crank Lever
      Slack Adjuster
      Brackets
      Eye
      Arms
      Stub-Axels
      Wear Pad
      Drop Arms, Etc

Machined

      TC Cover
      Nuts
      Plates. Etc




                                 21
Part Manufactured And Supplied For Tata Nano Car

       Gear Crank Shaft,
       Gear Balancer Shaft,
       1st Gear Lay Shaft,
       2nd Gear Lay Shaft,
       Reverse Gear and Shafter Sleeve 1st / 2nd,
       Lay Shaft 4th Speed,
       Input Shaft 4th Speed,
       Synchronic Ring (1 st / 2nd Speed Lay Shaft),
       3rd Gear Input Shaft,
       4th Gear Input Shaft,
       3rd Gear Lay Shaft,
       4th Gear Lay Shaft,
       Reverse Idle Gear,
       Shafter Sleeve 3rd / 4th Speed,
       Final Drive Gear,




New Product Development

New product means all below six categories of new product:

       A product which is new to the world.
       New product line.
       Addition to the existing product.
       Improvement and revisions of existing products.
       Re-positioning (launch for new target group).
       Cost reduction.

To develop a new product or part directors of technical and marketing KADVANI
FORGE LTD. Consider,

       Its final usage and the user of the parts,
       Its application,

                                                                                22
Quantity to be produced,
       Availability of raw-material, and
       Capability of the company to make the product or part.

As the company is making the parts for automobile companies, it is responsible for the
quality parts manufacturing.

Machinaries

Without adequate machineries production is not possible. Machineries can be parched
from the country or out-side the country.

KADVANI FORGE LTD. Is using different machineries like:

Forge-Shop Equipment :-

                  Pneumatic Hammers,
                  Double Column Trimming Presses,
                  Heating Furnaces,
                  Reduce Roll,

Heat Treatment Equipment :

                  Semi Automatic Continuous Pusher,
                  Brinell Hardness Testing Machine,

Cutting Shop Equipment :

                  Band Saw Machine,
                  Shearing Machine,
                  Hacksaw Machine,
                  Portable Platform Scale,

Die Shop Equipment :

                  Copy milling machine single and double spindle,
                  Vertical Machining Center (Linear),
                  Electric Discharge Machine,
                  Planning Machine,


                                                                                         23
Shaping Machine,
                Tool and Cutter Grinder,
                Heavy Duty Lathe Machine,
                Die Grinder,

Final Inspection Equipment :

                Magana Flax Crack Detector,
                Shot Blasting Machine,
                Double Column Coning Press,
                Flexible Grinder,
                Lathe Machine,
                Portable Platform Scale,

Die And Material Handling Equipment :

                Forklift,
                Cranes,

Design And Software :

                Auto CAD-2000,
                Unigraphics-Nx2,

Laboratory Equipment :

                Poldi Hardness Tester,
                Metallurgical Microscope with Binocular Camera & Screen,
                Balance Digital,
                Balance Manual,
                Single Disc Polishing Machine,
                Water Still,
                Muffle Furnace,
                Spectrometer,




                                                                           24
Stand By Captive Power :

                  Generator Set-1000 KVA,

KADVANI FORGE LTD. Had started its production with only one hummer in 1996.
Presently, it has 6 hummer and 8 press machine including 2 press machines which are
imported from Australia and other equipment as started above to make the production
quick, accurate and smooth.




                                                                                      25
Process Lay Out Of The Company




                                 26
Manufacturing Process

The main products of the company are forging components. The company is passed by
the following procedures while manufacturing the forging components.

First or all the company purchases the raw-material from the various companies in
addition to procurement of raw-material the company also receives the respective data
about the raw-material and it is checked in their own laboratory.

Step:-1         Cutting Process

Here the raw-material which is in billets form is cut into required length according to
cutting slip for this the company is using manual and electrical equipment like band-saw,
sharing machine, heck-saw, for cutting raw-material Smoothly.

Step:-2         Forging Process

In first of all cut metal piece is heated in oil fired furnace, than die forging is done. In
forging first of all die is fixed in hummer with top half impacts in the metal thus the
process of heating the cut metal and to give the shape of heated metal piece is called
forging. In Forging there are three steps:

        Heating,
        Forging,
        Trimming.

Step:-3         Heat Treatment

After the forging process the components are subject to best treatment which remove the
residual stresses that are formed during the forging process and this process is called heat
treatment. The steps in heat treatment are:-

        Normalizing,
        Quenching,
        Trimming,
        ISO Thermal
        Hardening and Tempering,




                                                                                               27
Step:-4        Shot Blasting

For clearing of rods, bars, angles, girdle etc. and make them shining shot blasting
machine are used. These shot blasting machine house powerful and strategically located
blast wheels in up-ward and down-ward position. Blast wheels throw stream of shot on
the job from all side. The job is cleaned perfectly inside work chamber. Number of blast
wheels stations and basis of output requirement and configuration of job.

Step:-5        Coining

Sometime when long and thin component are forged it may possible that the shape goes
somewhat bend. After measurements if the part is bend than it is kept in the coining
machine to make it straight and perfect in shape.

Step:-6        Packing And Dispatching

After final inspection the finished product is packed in a wooden box and dispatched as
per customer order when parts are exported mainly at that time the packing is necessary
and then are sending to the customers.




                                                                                          28
Quality Policy

We shall be customer focused. We shall consistently satisfy customer by providing
products conforming to customer requirements at competitive prices.




                                                                                    29
Drawing & Designs Department

Introduction

Product design is concerned with how the product will be made. Designs that is poor-
quality products. Engineers tend to over design products, with too many features, options
and parts.

When any new part is designed at that time feasibility study is under taken. In that
prototype design is prepared this contains.

    The design review,
    Reliability and maintainability prediction,
    Failure mode effect and critical analysis,
    Safety Analysis,
    Value Engineering, etc. are checked.

Drawing department of Kadvani Forge Ltd. Prepare the sample drawing based on
customer specifications, machine and forging drawing are also prepared by using the
C.A.D. (Computer Aided Design) and this is the process by which a computer assists in
the creation or modification of a design.

Engineering Drawing Specifications:-

                Timely Review,
                Distribution and Implementation of customer engineering specification.
                Master List Cum Distribution Record (M.L.C.D.R.) is prepared.

Process Of Drawing

Forging Drawing:-

              Customer Approve,
              Drawing issue to the customer,
              Data control.




                                                                                         30
Die Designing:-
Dies are prepared by draft man mechanic. Die is designed as per forging. First it is
checked by die shop in charge. Approved by technical person and then issue is possible.
Modification:-
If there is any problem in design or implementation in the parts drawn from the customers
and internal department. The technical director will approve the modification and that
will be followed by the draft man and drawing in charge. And then correction steps are
taken.



Mission And Vision

Vision :-

“Where the vision is one year, cultivate flower.
Where the vision is ten year, cultivate trees.
Where the vision is eternity, cultivate people.”


It is a universal saying. So, keep this I the mind the company wants to increase its
manpower strength not only in quantity but also in the quality. And through that the
company wants to become one of the company wants to become one of the best forgers in
the world by providing quality forged components.
Mission :-

The tags line of the company itself shows mission of the company i.e. “Forging the
Bright Future” and reach M to M i.e. Mahindra to Mercedes reach from national to
international best customer with quality product.




                                                                                          31
FINANCE DEPARTMENT
Introduction

Finance is an important function in any business as money is required to support its
various activities. Finance is defined as the provision of money at the time it is needed.
The term “Business Finance” is composed of two words :-

       Business,
       Finance,

The word business literally means a state of being busy. All creative human activities
relating to the production and distribution of goods and services for satisfying human
wants are known as “Business”. Broadly, the term business includes industry, trade and
commerce.

The word Finance refers to the management of flows of money through an organization.
It concerns with the application of skills in the Manipulation, use and control of money.
Finance is considered as the life blood of any business.

“Business Finance may be said to deal with acquisition of funds, use of funds, and
distribution of profits by a business organization.”

                                                             -   Charles W. Gerstenberg




                                                                                       32
Organisation Chart Of Finance Department


                     C.E.O. & M.D.

                FINANCE IRECTOR

           CHARTED ACCOUNTANT

            ADMINISTRTION STAFF

                        CLEARKS




                                           33
Capital Structure

Capital Structure refers to the makeup of a firm is capitalization. In other words it
represents the mix of different sources of long term funds such as equity share, preference
share the long term loans and retained earning etc.

     PATTERNS OF CAPITAL STRUCTURE :-
        There are four Patterns:-
     Capital Structure with equity shares only,
     Capital Structure with equity and preference share,
     Capital Structure with equity share and Debentures,
     Capital Structure with equity share and preference share and debenture.

The choice of an appropriate capital structure depends on nature of business, earning,
conditions of money market, attitude of investors‟ etc.

Pattern of capital structure of KADVANI FORGE LTD. Consists of share holders fund
and long term liabilities.

In the Year 2009-„10

SHARE HOLDERS FUNDS                                         Rs.
Deferred Tax Liabilities                                          8,146,180
Equity Share                                                  8,00,00,000
Reserves & Surplus                                            2,47,69,952
                    TOTAL:-                                  11,29,16,132



LONG TERM LIABILITIES                                       Rs.
Bank C.C. A/c                                                16,00,00,000
Secured Loans                                                28,48,60,918
Unsecured Loans                                               4,99,14,467
                    TOTAL:-                                  49,47,75,385




                                                                                        34
Working Capital

There are two concept of working Capital.

       Gross Working Capital:-

It refers to the firm is investment in total current or circulating assets.

       Net Working Capital:-

It is the excess of current assets over current liabilities. It also defined as the different
between current assets and current liabilities.

Working Capital

In the Year 2008-„09

Current Assets                                               35,78,10,926
Less:- Current liabilities                                     9,98,36,001
Net working Capital                                          25,79,74,925



In the Year 2009-„10

Current Assets                                                297,788,187
Less:- Current liabilities                                     66,923,855
Net working Capital                                           230,864,332




Cash Management

Cash Management includes:

     Controlling level of cash,
     Controlling inflows of cash,
     Controlling outflows of cash,
     Optimum investment of surplus cash,



                                                                                                35
One of the basic objectives of cash management is to minimize the levels of cash balance
with firm. From controlling the cash inflows Of KADVANI FORGE LTD. Is having a
system of decentralization collection of account receivable. It also makes sure that all the
receipts come on time as decided.

bank and cash a/c.:-

In the Year 2007-„08

Cash on Hand                                                   3,95,314
Add:- Bank a/c                                               86,83,821
                  TOTAL:-                                    90,79,135



In the Year 2008-„09

Cash on Hand                                                   6,92,603
Add:- Bank a/c                                               14,77,800
                  TOTAL:-                                    21,70,403



In the Year 2009-„10

Cash & Bank a/c                                              25,80,893
                  TOTAL:-                                    25,80,893



Sources Of Finance

The business cannot run efficiently if it does not have adequate finance to meet its
requirements of business can be classified into two categories:-

    Short Term Finance Requirement:-

               This required meeting working capital needs. They are usually for a period
               up to one year.




                                                                                          36
 Long Term Finance Requirement :-

These funds are usually for meeting the fixed capital requirements of the business. They
are required for a period exceeding one year.

In KADVANI FORGE LTD. The finance is usually generated form:-

     Bank Loans,
     Term loans or long term Loans,
     Cash Credit,
     Retained Earnings.

Generally, company is generating finance from the internal sources,

       Using depreciation as a source of finance.
       Plugging back of profits.
       From commercial banks etc.

Company cannot generate the finance by external sources like issue of debentures or
preference shares because it has not yet taken the initial public offering.

Inventory Management

Inventories are goods held for eventual sales by a firm. Generally, there are three kinds of
inventories:-

1) Raw-material:-

These are the goods which have not yet been committed to production in manufacturing
firm. It consists of basic raw-material and it is in KADVANI FORGE LTD. Is steel
billets.




                                                                                          37
For the year 2007-„08




  = 3.46
For the year 2008-„09




 = 3.31

Credit Policy

The term credit policy refers to those decision variables that influence the amount of trade
credit means the investment in receivables, the length of credit period to be extended, the
cash discount to be offered depending upon particular circumstances of the company and
the customer. Credit policy of any company determines the amount of risk the company is
willing to undertake in its sales activities.

Terms of Credit :-

The two important components of the credit terms are:-

   i.   Credit Period,
  ii.   Cash Discount.

Credit Policy :-

It refers to the time duration for which credit is extended to the customers. It is generally
expressed in terms of net Days.

[In KADVANI FORGE LTD. The credit of 60 days to the regular customers and 45
days for the other customers is given. When the due date comes at that time through
mail and agent, reminders are given to the customers for the payment.]

Cash Discount :-

                Many companies offer cash discount to their customers for encouraging
        them to pay their dues before the expiry of the credit period.


                                                                                            38
HUMAN RESOURCES DEPARTMENT
Introduction

The management of man is a very important and challenging job; important because it is
job not of managing „men‟, but of administering a social system. No two persons are
similar in mental abilities, tradition, sentiments and behavior. They differ widely also as
group and are subject to many and varied influences.

According to Edward Flippo:

“Human resource Management is the planning, organizing, directing and controlling of
procurement, development, compensation, integration, maintenance and separation of
human resources to the end that individual, organization and societal objectives are
accomplished.”

Recruitment

It is the generation of applications for the specific positions through any source. It makes
possible to acquire the number of people necessary to ensure the continued operation of
the organization.

It has been regarded as the most important function of personnel administration because if
the right type of people is not appointed even the best policies, organization charts and
control system would not do much good.

In KFL the recruitment is done by using the following three sources:

   1.   Advertisement:

The company gives advertisement in the news paper about the vacancy with the
specification required.

   2. Known Source:

In that the company uses the source which is known by the company‟s employees that
may be friend, relative, or from any other reference group. Mainly this source is used for
lower level workers.



                                                                                         39
3.   Placement:

In this type of source the company visits various colleges and takes the interview and
invites application from them.

Selection

Selection is the second step after recruitment in the process of procurement of people. It is
the process of choosing the individuals who possess the necessary skills, ability and
personality to successfully fill specific job in the organization.

The selection process is a number of specific steps taken to decide which recruits should
be hired. The process involves grouping the applications into unsuitable and appearing to
be suitable candidates, conducting tests on suitable candidates, if needed interviewing
them, contacting for references and eliciting their opinion, getting them medically
examined and making final hiring decision. The selection process begins with screening
of applications and ends with hiring decision and placement.

The selection process of KFL for employees and workers are as bellow:

For employee selection all of first the inquiry or information has been gathered whether
he or she as per the job specification eligible or not then after the candidates are being
interviewed and finally out of all, the best one is gone select for the particular job.

For worker‟s selection criteria are as bellow:

        Basic knowledge of language ( i.e. read or write) either Hindi or English.
        He must be having Knowledge and ability to do the work in the production
        department.
        He must be obedient to follow the orders from supervisor or in charge.

Training & Development

Training is the important subsystem of human resource development. Training is a
specialized function and is one of the fundamental operative functions for known resource
management.

It is designed primarily for nonmanagers, it is for a short duration and it is for a specific
job related purpose.

                                                                                          40
According to Dale S Beach:

“Training is the organized procedure by which people learn knowledge and for skill for a
definite purpose.”

The KFL gives training when the employee is selected about the procedures, how to fill
the various forms and all.

Apart from that the company is providing regular training programmes like:

       Operation management
       Attitude development
       First aid
       Production planning and controlling
       Advance process quality plan
       ISO:TS:16949
       Statistical process control
       Six sigma
       Time management
       Document, data and control
       Leadership
       Motivation etc.

So, by all such training programmes are provided for updating and improvement of the
knowledge of the employees and workers to gate the desired level of output.




Salary & Wage Management

Wage and salary administration is the process by which wage and salary levels and
structures are determined in organizational settings.

Wages are payments for labor services rendered frequently, expressed in hourly rates,
while a salary in a similar payment, expressed in weekly, monthly or annual rates.




                                                                                     41
Wage and salary administration is one of the vital areas of HRM, for sound wage and
salary policies and programmes are essential to procure, maintain, develop, promote and
transfer employees and to get effective results from them.

In KFL the wage and salary administration is done very effectively. The wages are paid
on time based as per the government rules and Act. Salary paid monthly basis as per the
rules and regulation of lows.




Welfare Activities

The KFL provides the following welfare facilities to the workers and employees, the
basic purpose of employee welfare is to improve the lot of working class and thereby
make worker the good worker and happy citizen.

        Provident fund to experienced workers

        Insurance Policies

        Bonus

        Transportation facilities

        Housing facilities

        Interest free loans to the employees

        Regular medical checkup camps

Human Resource Audit

In KFL the Human Resource Audit is not done separately but it is included in the overall
internal audit that is been done every four month.

Workers & Time Schedule

 workers :-

In KADVANI FORGE LTD. There are 300 workers and employees (including non-
technical staff).

                                                                                     42
 Time schedule :-

               In KADVANI FORGE LTD. There are three shifts per day for the workers
and eight Hours per shift.

              SHIFT                                      TIME

Shift-1                            8 a.m. To 8 p.m.

Shift-2                            8 p.m. To 8 a.m.

Weekly off Day                     Wednesday




During each shift there is break for half an hour.
Working hour for the Non-technical and Administration Staff employees is:-
9 a.m. To 6 p.m. (With munch and tea break)
In KADVANI FORGE LTD. Time wage system is used for the payment of wages and
salaries.




                                                                                 43
FUTURE PLAN OF K.F.L.

    To increase the production.
    Implementation of performance appraisal system.
    Implement corporate and professional attitude.
    Enhancing technology and scientific technical in all the departments.
    Increase export in more countries.
    To develop each area of quality.

S.W.O.T. ANALYSIS

The overall evaluation of a company is Strength, Weakness, Opportunities and Threat is
called S.W.O.T. Analysis. It involving monitoring the external and internal environment
of the organization. Each business needs to evaluate its internal strengths and weakness.




    strengths:-
            Prestige and goodwill that company has created in the market in the span
               of more than 11 years.
            Strongest production department.
            Skilled and experienced workers and employees of production and
               drawing department.
            Timely delivery of goods.
            ISO/TS-16949 : 2002 certificate for technical specifications and use of 5‟
               “S”
            Employment generation.
            Customized products.
            Lesser in house rejection.




    Weakness:-

       Every business whether big or small can have the weakness. Here I am pointing
       out some weaknesses because “we can get the success if we can change the
       weaknesses into our strength.”


                                                                                            44
 Human Resources department of the company is lagging behind.
        Lack of marketing strategic.
        Business is run in a traditional way to fight with the national and
              international competitors it has to become more professional and should
              have clear corporate strategies.
        Flexibility.
        Poor adaptability of changes.




 Opportunities:-

   Opportunities can take many forms and company has to be a good at spotting
   them some opportunities that I have observed are as given below.

        Company has still its I.P.O. (Initial Public Offering) as reserve. It has not
              yet issued its share to the public.
        Company can get more growth by increasing the exports to reach its goal.
        Capacity can be increased for mass production.
        If company emphasis on marketing than it can grow more.
        More export promotion activates can get a better future.




 Threats:-

   Threat is a challenge posed by an unfavorable trend or development that would
   lead in the absence of action to lower sales or profit. Threats should be classified
   according to its seriousness and probability of occurrence. To deal with threats the
   company needs plans that spell out changers it can make before or during the
   threats.

        Shortage of workers who can work in the forge shop and other process
              department of production.
        Communication Gap.
        High Turnover of Workers.
        Economics conditions like value of rupees price rise in steel which is used
              as a raw-material.

                                                                                        45
MARKET
RESEARCH




           46
INTRODUCTION
According to American Marketing Association “Marketing research is the systematic
gathering, recording and analyzing of data about problems relating to the marketing of
goods and services.”

Management in any organization needs information and in large quantities about potential
markets and environmental forces in order to develop successful strategic marketing plans
and to respond to changes in the market place. A mass of data is available both from
external sources and within the firm. This forms a solid platform for a research to take
place.

Marketing Research includes all the activities that enable an organization, to obtain the
information it needs to make decisions about its environment, its marketing mix and its
present or potential customers and consumers. More specifically, Market Research is the
development, interpretation and communication of decision oriented information to be
used in the strategic marketing process.



LITERATURE REVIEW
This research study seeks to come up with a conceptual framework that investigates the different
dimensions of total quality management (TQM) and its effects on knowledge management (KM).
This is to help build a theoretical framework of TQM and its dimensions, which mainly consists
of leadership, strategic planning, information and analysis, process management, human resource
focus and customer focus. These constructs are rooted in the work of Malcolm Baldrige National
Quality Award (MBNQA). To build the conceptual framework, the background of TQM and
Knowledge Management theory served as a good starting point. The current research study is
based on the complete assessment of present literatures, the six constructs of TQM and the three
elements of knowledge acquisition, knowledge application and knowledge dissemination. This
paper serves as a guide to senior management, who seeks to improve their company‟s
organizational knowledge management activities through the execution of TQM practices, in
which the TQM practices support their company‟s knowledge management efforts. Furthermore,
the conceptual model serves as a benchmark for practitioners to execute their TQM programmes
more effectively and efficiently in their own respective firms. This paper seeks to close the gap on
the existing literature, by giving guidance to the senior management of TQM companies that
aspires to discover the competency of knowledge management. By developing a deeper
understanding of the relationship between TQM practices and knowledge management, senior
management can thus focus their efforts on the practices that ensure the firms‟ ability to establish
a competitive knowledge management capability.



                                                                                                 47
Undeniably, TQM and KM contribute significantly to the improvisation of performance
for any organization. The proposed model in this study seeks to close the gap in the
literature for the assessment of the multidimensionality of TQM and its association with
organizational KM. Furthermore, this model seeks to advance the literature regarding the
relationship between TQM and KM research and at the same time, to provide a means for
both the practitioners and the academicians to better comprehend the link between TQM
practices and KM behaviours. Apart from that, this paper propose this model to be used
for the implementation of TQM practices and also to measure the organizational
processes such as the effectiveness of strategic planning, leadership,process management,
customer service, human resource management and the employment of information
analysis. The initial study on the model, which is to examine the link between TQM
practices and the KM, has led to further studies on the six dimensions of TQM, which are
known to be important attributes to the KM management. As for improvements, further
surveys and research should be done using the multivariate analysis to test, validate and
enhance the model. The results obtained will be reported in afuture article.



Nature Of Research

The Marketing Research is carried out on forging company in rajkoj of appled total
quality managamant. The research where the application of all Marketing Concept and
Strategies have been put into practice. The nature of research is also Syndicate Research,
which can be carried out by anyone, a part from Research Organization. The Research has
been carried out through the universally favoured approach of a personal interview
survey.




OBJECTIVES OF STUDY

The Marketing Research is carried out on the following subject:-

The main objectives kept in mind while selecting the subject and conducting the survey
were as listed below:




                                                                                       48
1. Customer focus

    The first and overriding feature of TQM is the company‟s focus on its customers.
   Quality is defined as meeting or exceeding customer expectations. The goal is to first
   identify and then meet customer needs. TQM recognizes that a perfectly produced
   product has little value if it is not what the customer wants.

   2. Continuous improvement

   Another concept of the TQM philosophy in the focus on continuous improvement.
   Traditional systems operated on the assumption that once a company achieved a
   certain level of quality, it was successful and needed no further improvements.
   Traditionally, change for American managers involves large magnitudes, such as
   major organizational restructuring. The Japanese, on the other hand, believe that the
   best and most lasting changes come from gradual improvements. Continuous
   improvement, called kaizen by the Japanese, requires that the company continually
   strive to be better through learning and problem solving.

   3. Employee Empowerment

    Part of the TQM philosophy is to empower all employees to seek out quality
   problems and correct them. With the old concept of quality, employees were afraid to
   identify problems for fear that they would be reprimanded. Often poor quality was
   passed on to someone else, in order to make it “someone else‟s problem”. The new
   concept of quality, TQM, provides incentives for employees to identify quality
   problems. Employees are rewarded for uncovering quality problems. In TQM, the role
   of employees is very different from what is in traditional systems. Workers are
   empowered to make decisions relative to quality in the production process.




SAMPLE SURVEY

The gathering of primary data through experimentation involves use of sampling, survey
method and observations. The survey conducted on kadvani forge ltd. involved a survey
based on personal interview.

                                                                                      49
The details of the selected samples for the survey is as under:

 City chosen for Sample Survey:-                     Rajkot



 Sample size:-                                       20 Samples



Market Research Methodology


                        Formulation of Research Problem



                        Research Design



                        Determination of Sources of Data



                        Collection of Information



                        Processing and Analysis



                        Present the finding



Formulation Of Research Problem
First step of the marketing research process is the formulation of research problem. Marketing
management must be carefully note to define the problem too broadly or too narrowly for the
marketing researcher. The marketing manager and the researcher must work closely together to
define carefully and agree on the research objectives. The managers best understand marketing
research and how to obtain the information. In order to avoid waste of time and money it is
necessary to define the problem in specific terms.




                                                                                           50
Research Design

The second step of the marketing research process calls for determining the information needed
and developing a plan for gathering it efficiently. A research design can be defined as “The plan,
structure and strategy of investigation conceived so as to obtain answers to research questions and
to control variance.” The marketing manager needs to know the cost of the research plan before
approving it. Designing a research plan calls for decisions on the data sources, research
approaches, research instrument, sampling plan and contact methods. The researcher can gather
secondary data, Primary data or both. Secondary data were collected for another purpose and
already exists some where. Primary data are freshly collected for specific purpose for a specific
research project.

         The Survey Method: -

Surveys are best suited for descriptive research. This method involves learning about people‟s
knowledge, beliefs, preferences and satisfaction and to measure these magnitudes in the general
population. As in observation, survey research can be structured or unstructured. Structured
survey use formal lists of question asked of all respondent the same way where as in unstructured
researcher use an open format that lets the interviewer probe respondents and guide the interview,
depending on their answers. There are three types of surveys namely:




Determination Of Sources Of Data

In marketing research literature, there are two types of data: primary data and secondary data. The
researcher can gather primary data or secondary or both.

1. Primary Data:

The first hand data collected for a specific purpose or for a specific research project constitutes
primary data.

When the needed data do not exist or are inaccurate, incomplete or unreliable the researcher
collects primary data. Most marketing research projects thus involve some primary data
collection. The main primary data sources consist of consumers, dealers, buyers, etc. Consumers
and buyers constitute the main source of information in most researches. A buyer may not be the
user of the product, although in some cases the consumer and the buyer may be the same person.




                                                                                                51
2. Secondary Data:

Information collected by other organization or individuals which might be relevant to the study
constitutes secondary data.

Researchers usually start their investigation by examining secondary data to see whether their
problem can be partly or wholly solved without collecting costly primary data. Secondary data
provides a starting point for research and offer the advantages of low cost and ready availability.

In my study, I have primarily used “Primary Data” obtained through retailer survey with the help
of questionnaire.

Collection Of Information

Marketing researchers have a choice of two main research instruments in collecting primary data:
Questionnaire and mechanical devices.

Questionnaire:

A questionnaire consists of questions presented to the respondents for their answers. Because of
its flexibility, the questionnaire is by for the most common instrument used to collect primary
data.

In preparing a questionnaire, care should be taken in choosing the questions and their form,
wording and sequence. The questions included in the questionnaire can be closed end questions
prosperity all the possible answers and are easier to tabulate and interpret. Open end questions
allow respondents to answer in their own words and they often reveal more as they give an insight
into how people think.

Sampling plan:

After deciding research approach and instruments the marketing researchers must design a sample
plan. This calls for three decisions.

Sampling Unit:

The marketing researcher must define the target population that will be sampled.

Sample Size:

Large samples give more reliable results than small samples. However, it is not necessary to
sample the entire target population or even a substantial portion to achieve reliable results. In my
survey the sample size was 20.


                                                                                                  52
Sampling Procedure:

To obtain a representative sample a probability sample of the population should be drawn.
Probability sampling allows the calculation of confidence limits for sampling errors. When the
time and cost are involved the in probability sampling is excessive, marketing researcher will take
non-probability samples.

Simple random sample

My survey falls under the category of the convenient sample under Non-probability sampling. In
this method the researcher is free to select. The respondents are selected on the basis of the being
available at the time of survey.




                                                                                                 53
ANALYSIS AND INTERPRETATION OF DATA


Q.3:- What is your position?

Top management                      3                   15%
Manager                             5                   25%
Officer                             2                   10%
Supervisor                          4                   20%
General staff                       6                   30%
TOTAL                              20                   100%



                                            position



                                           15%
                                                                                    Top management
                            30%
                                                                                    Manager
                                                                                    Officer
                                                  25%
                                                                                    Supervisor

                               20%                                                  General staff
                                         10%




        From the above analysis and conclusion, we can say that   15% of organization employees is come
        forom top mamagament.
        From the above analysis and conclusion, we can say that   25% of organization employees is come
        forom manager.
        From the above analysis and conclusion, we can say that   10% of organization employees is come
        forom officer.
        From the above analysis and conclusion, we can say that   20% of organization employees is come
        forom supervisor
        From the above analysis and conclusion, we can say that   30% of organization employees is come
        forom general staff.




                                                                                                    54
Q.4:- Is your organization ISO 9000 certified?

NO                                0                                      0%
ISO 9001 Certified                4                                      20%
ISO 9002 Certified                3                                      15%
ISO 9003 Certified                5                                      25%
ISO 9000 Certified                8                                      40%
TOTAL                             20                                     100%



                                            certified?
                                       0%


                                               20%

                                                                                    NO
                     40%
                                                                                    ISO 9001 Certified
                                                                                    ISO 9002 Certified
                                                      15%
                                                                                    ISO 9003 Certified
                                                                                    ISO 9000 Certified


                                        25%




        From the above analysis and conclusion, we can say that 0% of    organization is related with ISO
        NO CERTIFIED.
        From the above analysis and conclusion, we can say that 20% of   organization is related with ISO
        9001 CERTIFIED.
        From the above analysis and conclusion, we can say that 15% of   organization is related with ISO
        9002 CERTIFIED.
        From the above analysis and conclusion, we can say that 25% of   organization is related with ISO
        9003 CERTIFIED.
        From the above analysis and conclusion, we can say that 40% of   organization is related with ISO
        9000 CERTIFIED.




                                                                                                      55
Q.5:- Does your organization apply total quality management?

YES                               14                                  70%
NO                                6                                   30%
TOTAL                             20                                  100%



                                              Sales




                                                      30%
                                                                                                 NO
                                                                                                 YES

                                   70%




        From the above analysis and conclusion, we can say that 70% of organization apply total quality
        management
        From the above analysis and conclusion, we can say that 30% of organization not apply total
        quality management




                                                                                                      56
Q.6:- Does your organization apply statistical process control?

YES                               12                                60%
NO                                8                                 40%
TOTAL                             20                                100%



                                   statistical process




                                                       40%
                                                                                               NO
                                                                                               YES
                                60%




        From the above analysis and conclusion, we can say that 60% of organization apply statistical
        process control.
        From the above analysis and conclusion, we can say that 40% of organization apply statistical
        process control.




                                                                                                    57
Q.7:- What other benefit(s) does your organization gain with ISO/TQM?

Improve Productivity              3                                  15%
Less Waste                        1                                  5%
Less Rework                       4                                  20%
Improve Image                     4                                  20%
Increase Market Share             1                                  5%
Better Teamwork                   3                                  15%
Lower Staff Turnover              2                                  10%
Lower Stock Level                 2                                  10%
TOTAL                             20                                 100%




                                                                              Improve Productivity
                                10%         15%
                                                                              Less Waste
                        10%
                                                  5%                          Less Rework
                                                                              Improve Image
                     15%                                                      Increase Market Share
                                                  20%
                                                                              Better Teamwork
                           5%                                                 Lower Staff Turnover
                                      20%
                                                                              Lower Stock Level




       From the above analysis and conclusion, we can say that 15% of organization gain with Improve
       Productivity.
       From the above analysis and conclusion, we can say that 5% of organization gain with Less Waste.
       From the above analysis and conclusion, we can say that 20% of organization gain with Less
       Rework.
       From the above analysis and conclusion, we can say that 20% of organization gain with Improve
       Image.
       From the above analysis and conclusion, we can say that 20% of organization gain with Improve
       Image.
       From the above analysis and conclusion, we can say that 5% of organization gain with Increase
       Market Share.
       From the above analysis and conclusion, we can say that 10% of organization gain with Better
       Teamwork.
       From the above analysis and conclusion, we can say that 10% of organization gain with Lower
       Stock Level.



                                                                                                     58
Q.8:- What side effect(s) does your organization suffer with ISO/TQM?

Decrease Productivity             2                                  10%
Weaken Morale                     1                                  5%
Higher Costs                      8                                  40%
Higher Stock Level                6                                  30%
Higher Staff Turnover             3                                  15%
TOTAL                             20                                 100%



                                 suffer with ISO/TQM

                                        10%
                           15%
                                                5%
                                                                               Decrease Productivity
                                                                               Weaken Morale
                                                                               Higher Costs

                  30%                                                          Higher Stock Level
                                                                               Higher Staff Turnover
                                                 40%




       From the above analysis and conclusion, we can say that 10% of organization suffer with Decrease
       Productivity.
       From the above analysis and conclusion, we can say that 5% of organization suffer with Weaken
       Morale.
       From the above analysis and conclusion, we can say that 40% of organization suffer with Higher
       Costs.
       From the above analysis and conclusion, we can say that 30% of organization suffer with Higher
       Stock Level.
       From the above analysis and conclusion, we can say that 15% of organization suffer with Higher
       Staff Turnover.




                                                                                                       59
Q.9:- Did your organization use consultant(s) during ISO/TQM?

YES                                14                                  70%
NO                                 6                                   30%
TOTAL                              20                                  100%



                                          consultant



                                                         30%


                                                                                                   NO
                                                                                                   YES


                             70%




        From the above analysis and conclusion, we can say that 70% of organization use consultant(s)
        during ISO/TQM.
        From the above analysis and conclusion, we can say that 30% of organization not use consultant(s)
        during ISO/TQM.




                                                                                                        60
Q.10:- Did your organization employ additional staff since ISO/TQM?

YES                               16                                80%
NO                                4                                 20%
TOTAL                             20                                100%



                                       additional staff



                                                  20%


                                                                                               NO
                                                                                               YES


                                       80%




        From the above analysis and conclusion, we can say that 80% of organization employ additional
        staff since ISO/TQM .
        From the above analysis and conclusion, we can say that 20% of organization employ not
        additional staff since ISO/TQM .




                                                                                                    61
Q.11:- Has your organization structure change since ISO/TQM?

YES                                8                                  40%
NO                                 12                                 60%
TOTAL                              20                                 100



                                    structure change




                                 40%
                                                                                                  NO
                                                                                                  YES
                                                        60%




        From the above analysis and conclusion, we can say that 40% of organization structure change
        since ISO/TQM.
        From the above analysis and conclusion, we can say that 60% of organization structure not change
        since ISO/TQM.




                                                                                                       62
Q.12 Overall, Do you think that ISO/TQM brings positive effect to your organization?

YES                               18                                90%
NO                                2                                 10%
TOTAL                             20                                100%



                                       positive effect



                                               10%


                                                                                               NO
                                                                                               YES


                                        90%




        From the above analysis and conclusion, we can say that 90% of organization is ISO/TQM brings
        positive effect to your organization.
        From the above analysis and conclusion, we can say that 10% of organization is ISO/TQM brings
        not positive effect to your organization.




                                                                                                    63
64
No company is perfect in all ways, so as KADVANI FORGE LTD. During my training
and experience in the company, I have observed some points which I want to mention.

     Professional attitude or professionalism is needed.
     Suggestion Boxes for the staff employees and for workers in plant should be kept to
     know the view of the employees as well as the workers.
     Rest room or canteen facilities, if not for food than for tea and snacks is needed.
     Management should find out different way to motivate employee.
     They should make advertising through television, newspaper and holding etc. for
     increasing their sales and profit.
     Give more information in the web-site therefore person who is interested to know
     about the company.




CONCLUSION

India is a key part of most of the global companies‟ overall growth strategy in auto
components. To utilize the resources provided by the education system and the resources
which are within the company 100% is the success mantra. These industries are also
depending on the growth of OEMs. (Original Equipment Manufacturing) and there is a
bright future of them.




                                                                                           65
Learning From Sip


I have prepared project report on ”total quality management practies in forging company
of rajkot city with reference to kadvani forge ldt”. I learnt so many things like . . .

        I came to know that how company sustain its position during the recession period.
        If sale are increase, it does not means that profit will be increased because of
        operating expenses also increase.
        If you have no proper planning for investing the investment, then you cannot earn
        more return on the investment.
        There is difference between bookish knowledge and real work at company.
        Company‟s planning is not easier at real situation in comparison to the paper
        work.
        If you want to get better work from the company‟s employees and workers then
        company requires proper co-ordination.
        Customers‟ satisfaction is important for any organization. If customers are not
        satisfied then company cannot survive in the market.




                                                                                          66
BIBILIOGRAPHY

BOOKS

 M.Y.KHAN, “INDIAN FINANCIAL SYSYEM”, 3rd edition Publication by TATA
   McGraw hill.
 Ashwathappa, “Personnel Management”, 3rd edition.
 Philip Kotler, “Marketing Management”, 11th edition, Pearson education Asia
   Publication.
 Walker, Boyed, Mullins, Larrenche, “Marketing Strategy”, 4 th edition, Tata McGraw
   hill publications.
 Thompson and Stickland, “Strategic Management” 13 th edition, Tata McGraw-Hill
   publications.
NEWSPAPERS

 Business standard
 Economics times


DOCUMENTS, RECORDS & STATEMENT OF KADVANI FORGE LTD.

 Www.kadvanigroup.com
 www.forgingmagazine.com
 www.forging.org
 Www.indianforging.org




                                                                                 67
CUSTOMERS

Domestic Customers:-

                 NAME                                Component Supplied

Fairfield Atlas Ltd.                 Transmission, Differential and Engine Gear,
(TS-16949)                           Transmission and Bull shaft.
Snderam Fasteners                    Gears
Mahindra Sar Transmission Pvt. Ltd. Engine Gear, Helical Gear, Straight Bevel Gear,
(TS-16949)                           Spleen Shafts, Synchronizers (Gear)
R.B.S. Transmission Ltd.             Flange Yoke, Cross, Forks, Slack, Adjuster,
                                     Brackets, Stub-Axeis etc.
B.E.M.L.                             Flanges and Covers.
V.S.T.                               Multi Throw Crank Shafts.
Fortuna, Garima, Amul.               Connecting Rods, Piston, Rocker Aam.
Overseas Customers (Exports):-

              NAME                                 Component Supplied

G.Elbe and Sohn Gmb,            Fork Flange, Welding Pin, Fork shaft.
Germany
Kampwerk Vieregge, Germany      Balancer Shaft, Eccentric Shaft.
Keystone Bahntechnike,          Druckplatte, Zugmutter, Kronenmutter.
Germany
Defontaine, France              Fly Wheels,
Unique Industrial Company,      Torque Converter Cover, Front Race Cover,
U.S.A.                          Threaded Flange.




                                                                                      68
NAME OF COMPANY SURVEY IS BEING TAKING

1, Patel Steel Forgings

2, Ajk Forge Pvt Ltd

3, Arora Refractories & Forgings

4, Ability Auto Pvt Ltd

5, Advik Hi-Tech Industries

6, Kadvani Forge Ltd ( Registered Office)

7, Kishan Autoparts Ltd

8, Silver Forge Pvt Ltd

9, Super Forge

10, Forge & Forge Pvt Ltd

11, Advik Hitech Industries

12,Crystal Forge

13, Echjay Industries Pvt Ltd

14, Mehta Forgings

15, Sakhiya Industries

16, A K International

17, Jay Forge

18,Ability Auto Pvt Ltd

19. Leo Tech Pvt Ltd

20. Akshar Industries




                                                69
“TOTAL QUALITY MANAGEMENT
      PRACTIES IN FORGING COMPANY OF
       RAJKOT CITY WITH REFERENCE TO
                       KADVANI FORGE LDT”
Q1: Name of the company?

________________________________________________________________________

Q2. Name of employee?

________________________________________________________________________

Q3:What is your position?

       Top management

       Manager

       Officer

       Supervisor

       General staff

Q4: Is your organization ISO 9000 certified?
  NO           ISO 9001 Certified          ISO 9002 Certified   ISO 9003 Certified

    ISO 9000 Certified

Q5: Does your organization apply total quality management?

      NO

      YES

Q6: Does your organization apply statistical process control?

       NO

       YES




                                                                                     70
Q7:What other benefit(s) does your organization gain with ISO/TQM?

       Improve Productivity

       Less Waste

       Less Rework

       Improve Image

       Increase Market Share

       Better Teamwork

       Lower Staff Turnover

       Lower Stock Level

Q8:What side effect(s) does your organization suffer with ISO/TQM?

       Decrease Productivity

       Weaken Morale

       Higher Costs

       Higher Stock Level

       Higher Staff Turnover

Q9: Did your organization use consultant(s) during ISO/TQM?

       YES

       NO

Q10: Did your organization employ additional staff since ISO/TQM?

       YES

       NO

Q11: Has your organization structure change since ISO/TQM?

       YES

       NO

Q12: Overall, Do you think that ISO/TQM brings positive effect to your organization?

       YES

       NO

                                                                                       71

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Vish al r kotadiya.en. no.107440592054

  • 1. A SUMMER INTERNSHIP PROJECT REPORT ON “TOTAL QUALITY MANAGEMENT PRACTIES IN FORGING COMPANY OF RAJKOT CITY WITH REFERENCE TO KADVANI FORGE LDT” PREPARED BY KOTADIYA VISHAL Class Academic Year M.B.A. : SEM. 3 2010-12 Enrollment No. Guided By 107440592054 Mr. Nailesh Libasiya Submitted To Gujarat Technological University Ahmadabad College R .K. College Of Business Management Kasturbadham Rajkot - 360020 1
  • 2. 2
  • 3. DECLARATION I the undersigned here by declare that the project report entitle “RESEARCH ON TOTAL QUALITY MANAGEMENT” AT KADVANI FORGE LDT. has been prepared by me during the year 2010-11 under the guidance of Mr. Nailesh Lilbasiya R .k. Collage of business management Kasturbadham Rajkot – 360020 I also here by declare that this Project Report has not been submitted at any time to any other university or institute for any degree or diploma. Date : Place : RAJKOT VISHAL KOTADIYA 3
  • 4. PREFACE It is said that “Knowledge is power” but “applied knowledge is power” seems to be a correct statement. In this modern word, theoretical study has no value without its practical application; practical knowledge is more powerful than the knowledge of books. In today‟s business words, practical knowledge plays an important role; course involves industrial training, which provides practical knowledge and experience to the students in the field of management. The project is prepared on kadvani forge Ltd. And include the idea about their production department, finance department, personnel department, etc. the main thrust of this project is to acquire information of the unit and to pen it down. I have acquired a lot of knowledge by doing this study and will always remain thankful to the college, University and the team of kadvani forge who helped me accomplishing this task. 4
  • 5. ACKNOWLEDGEMENT This is my great pleasure to submit this report. I am thankful to all the persons who have helped me for arrangement of my practical training and also for getting information which is require for the preparation of this report. First of all I am thankful to authorities in KADVANI FORGE LTD., For granting me the permission for training and their co-operation during the training period. I am also thankful to all the respondents who have filled the questionnaires which are necessary for the survey. I am also highly obliged to Mr. Nailesh Limbasiya for their sincere attention valuable guidance and providing suggestion and thus guiding me all the way in my efforts to prepare this report. I am heartily thankful to Prof. Dr. Sugan Chand Jain & Dr. Vijay Vyas directly or indirectly contributed their valuable time and helped me for preparing this report. I am thankful to HR Manager MR.C.R.NAIR of KADVANI FORGE Ltd. For providing me the permission to visit this unit and giving me chance to study the company for a particular subject. I am also thankful to all staff member of KADVANI FORGE Ltd. for sparing their valuable time inspire of their busy schedule and helping me to collect all such information. I am also thankful to technical & non-technical staff contributed directly or indirectly their valuable time and helped me for preparing this report. 5
  • 6. EXECUTIVE SUMMARY In the growing global competion the productivity of any bussiness concern depends on the behavioral aspects of customers. This topic deals with the customer satisfaction towards forging components of KFL. This project report contains 5 different chapters. The report begins with the introduction of the industry, company information, and the functional area information. The second chapter is about the literature review which tells about the customer satisfaction. The third chapter is about the reseach methodology which was adopted by me in my topic. It contains research problem, objective, data collection, limitations about the topic. The fourth chapter is a comprehensive study of forecasting concepts and techniques which shows analysis and interpretation through graphical representation of the data collected in survey. The fifth chapter deals with the findings/conclusions/suggestion/future plans which is very much important after analysis is made. 6
  • 7.  TABLE OF CONTENT SR. NO TOPIC PG. NO 1 INDUSTRY OVERVIEW 1 2 ORGANIZATION OVERVIEW 9 Marketing department 10 Production department 12 Finance department 25 Human resources department 32 Future plan of KFL 37 S.W.O.T. analysis 37 3 MARKET METHODOLOGY 39 Introduction 40 Literature review 40 Objectives of study 41 Sample survey 42 Analysis and interpretation of data 47 4 SUGGESTIONS & CANCLUSION 57 5 LEARNING FROM SIP 59 6 BIBILOGRAPHY 60 7 ANNEXURE 61 7
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  • 9. Introduction:- Forging is the process by which metal is heated and is shaped by plastic deformation by suitably applying compressive force by using hammer or a press. Forging refines the grain structure and improves physical properties of the mental. Forging changes the size and shape, but not the volume, of a part. The change is made by force applied to the material so that it stretches beyond the yield point. The force must not be strong enough to make the material deform. It must not be so strong; however, that it destroys the material. The yield point is reached when the material will reform into a new shape. Normally this results in metallurgical soundness and improved mechanical properties. Strength, toughness and general durability depend upon the way the grain is placed. Forging are somewhat stronger and more elastic. The feature of greatest importance is that there is a greater ability to resist shock, wear and impact than across the grain material properties also depend on the heat treating process after forging. Good forging practice makes it possible to control the flow pattern resulting in maximum strength of the material and the least chances of fatigue failure. These characteristics of forging, as well as fewer flaws and hidden defects, make it more desirable than some other operations for products that will undergo high stresses. Physical properties such as strength, ductility and toughness are much better in a forging than in the base metal, which has, crystals randomly oriented. Forgings yield parts that have high strength to weight ratio thus are often used in the design of air-craft frame members.  Types of Forging:- Hammer Forging, Press Forging. What is forging? Forging is manufacturing process where metal is pressed, pounded or squeezed under great pressure into high strength parts known as forgings. The process is normally (but not always) performed hot by preheating the metal to a desired temperature before it is worked. It is important to note that the forging process is entirely different from the 9
  • 10. casting (or foundry) process, as metal used to make forged parts is never melted and poured (as in the casting process). Why use forgings and where are they used? The forging process can create parts that are stronger than those manufactured by any other metalworking process. This is why forgings are almost always used where reliability and human safety are critical. But you'll rarely see forgings, as they are normally component parts contained inside assembled items such a airplanes, automobiles, tractors, ships, oil drilling equipment, engines, missiles and all kinds of capital equipment - to name a few. Who buys forgings? Forged parts vary in size, shape and sophistication - from the hammer and wrench in your toolbox to close tolerance precision components in the Boeing 747 and NASA space shuttle. In fact, over 18,000 forgings are contained in a 747. Some of the largest customer markets include: aerospace, national defense, automotive, and agriculture, construction, mining, material handling, and general industrial equipment. Even the dies themselves that make forgings (and other metal and plastic parts) are forged. How big is the forging industry? The forging industry is composed of those plants that; a) make parts to order for customers (referred to as custom forgings); b) make parts for their own company's internal use (referred to as captive forgings); or c) make standard parts for resale (referred to as catalog forgings). The largest sector - custom forging - accounts for over $6 billion dollars in sales annually. These custom forgings are produced by about 250 forging companies in approximately 300 plants across the U.S., Canada and Mexico. How many people are employed by the forging industry? Approximately 45,000 people from coast to coast are employed by the forging industry in the United States and Canada. Because the modern forging process is capital intensive (requiring an abundance of heavy equipment for manufacture and the people to run and 10
  • 11. maintain it), most forging plants are small businesses which generally employ between 50 to 500 employees each, with a few larger facilities employing over 1000 people. What metals are forged? Just about any metal can be forged. However, some of the most common metals include: carbon, alloy and stainless steels; very hard tool steels; aluminum; titanium; brass and copper; and high-temperature alloys which contain cobalt, nickel or molybdenum. Each metal has distinct strength or weight characteristics that best apply to specific parts as determined by the customer. What kind of equipment is used to make forgings? Although the styles and drive systems vary widely, a forging can be produced on any of the following pieces of equipment. Hammers with a driving force of up to 50,000 pounds, pound the metal into shape with controlled high pressure impact blows. Presses with a driving force of up to 50,000 tons, squeeze the metal into shape vertically with controlled high pressure. Upsetters are basically forging presses used horizontally for a forging process known as "upsetting". Ring Rollers turn a hollow round piece of metal under extreme pressure against a rotating roll, thereby squeezing out a one-piece ring (with no welding required). History Of Kadvani Forge Ltd “Every one has a goal to win, but a very few have a strong will to prepare to win. ” I would like to brief a History of the company which is following the thought mention above. The company named “KADVANI FORGE LTD.” After seeing huge potential in the field of forging the company started its career in the forging with small scale industries. The Kadvani forge ltd. got the certificate of its 11
  • 12. incorporation on 1st August, 1995 and certificate of its commencement on 20th June, 1995. But it started its commercial production in 1997. It has established its forge-shop in the area of Gujarat Industrial Development Corporation (G.I.D.C.). And it becomes popular with the name of “KFL” i.e. Kadvani Forge Ltd. Its production capacity in the initial stage was 50 tons per month. In the 1 st year of operation the company faces losses but then after through its sincere efforts it covers all losses and making profit. “Success seems to be connected with action. Successful people keep moving. They make mistake, but they don’t quit.” The company proves its efficiency and move further without any fear of the failure and results into developing a new 400 components within 6 years. The company exported its industrial products in the international market in countries like U.S.A., Europe and Middle East. The company establishes its foot step in the international market by their hard work and sincerity. All the products are successfully accepted in the international market. Vision, Mission & Value VISION:- To prepare continuous value through innovation, expertise, excellence & attain highest level of customer satisfaction. MISSION:- To become a global leader by incorporating highest level of quality through a combination of technology, service, creative, marketing, prizing and cost efficiency. The vision and mission of KFL is supplied by integrated set of core values. VALUES:- integrity & ethics:- 12
  • 13. KFL is committed to conducting to themselves with non-compromising integrity & ethics whenever KFL operates. innovation:- KFL is committed to fostering innovation through an entrepreneurial spirit team work & creativity. costomer satisfaction:- Customer are at the heart of their strategy & KFL wants to maintained their relationship to maximize growth and profitability. Five “S” Systems KADVANI FORGE LTD. Is implemented 5s system production. This include:- 1) Self Discipline, 2) Systematic Arrangements, 3) Spic and Span, 4) Standardize, 5) Sorting, With the help of 5s System in production, the smooth accurate, speedy production is possible. 13
  • 15. COMPITITORS As the demand for Automobiles, Machines are increasing the need for forging components are also increasing so; this change has attracted many business houses to get entered into the forging industry. The KFL has many competitors at state level as well as national level. Some of them areas bellow: Bharat Forge Kalyani Forge Ajk Forge Pvt Ltd Silver Forge Pvt Ltd Super Forge Crystal Forge Forge & Forge Pvt Ltd Echjay Industries Pvt Ltd Jay Forge 15
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  • 17. MARKETING DEPARTMENT INTRODUCTION Financial success often depends on marketing ability. Finance operation, accounting and other business function will not really matter if there is not sufficient demand for products and services so, the company can make a profit. Marketing also deals with identifying and meeting human and social needs. One of the shortest definitions of marketing is “Meeting needs profitably” According to American Marketing Association: “Marketing is an organizational function and a set of process for creating communicating and delivering value to customer and for managing customer relationships in ways that benefit the organization and its stake holders.” Markrting Management At Kfl KFL is not in a need to practice marketing activities by putting great efforts. That because the company is not producing components by their own, but it manufactures components those are demanded by the customers. So, it is dealing with B to B market and need not do heavy advertisement and other marketing activities. The company‟s marketing department is working for getting the orders from the customers by giving them presentation if they are new to the company. The KFL is doing marketing in such a way that it is having a membership of many forging associations. As well as by participating in various events and fairs related to the industry at national and international levels. The starting point of each activity is the customer‟s inquiry. The marketing department in handles all the inquiries and check the feasibility of the orders and for that the department 17
  • 18. is preparing APQP and PPC. The prim Moto of the marketing department is „customer satisfaction‟. Market Traditionally, a „Market‟ was a physical place where buyers and sellers gathered to buy and sell the goods. But in today‟s modern world there is no as such necessity of physical place due to the highly technological development i.e. internet and all. Market can be product market, demographic market, geographic market, labour market, donor market etc. The key consumer markets are: 1. Consumer Market 2. Business Market 3. Global Market The KFL is having business market that the finished components are sold to the another business houses of automobile, defense, earth movers etc. So, to deal with B to B market will demand extra specifications of the quality, timely delivery, relation, price etc. aspects in that. Target Market The following are the target markets of KFL: Mahindra & Mahindra TATA Motors RSB John Dear tractor Eaton Truck 18
  • 19. PRODUCTION DEPARTMENT Product Offering “A product is a bundle of benefits which are been offered to the consumer” It is a complex of tangible attributes including material, packaging, colour, price, and manufacture‟s prestige, retailer‟s service which the buyer may accept as offering satisfaction of wants or needs. The products those are offered by KFL on the demand of the customers are: Automobile Petrochemical Earthmoving Electric Transmission Machine Tools The KFL only manufactures what customers have given in his drawing so, in this case the New Product Development activity does not take place. Distribution Chennel “Physical distribution comprises the task involved in planning and implementing the physical flows of material and final goods from the point of origin to points of consumption to meet the needs of consumers at a profit.” The distribution of component of KFL differs with the market: Domestic Market: The company uses the transportation facilities by roadways as per the demand of customers. Foreign Market: For export order the company‟s components are transported by shipment at seaway from nearer port. 19
  • 20. Product Gallery Kadvani Forge Ltd. Manufactures Closed Die Steel Forged products as per the customer specification in Carbon & Alloy Steel and supply them in as Forged, Heat Treated, Partially Machined Condition. They are producing forged components up to 80kg Weight. Kfl are Capable of Manufacturing Forging items for Diverse Industries Viz. Automobile Petrochemicals Earthmoving Electric Transmission Machine Tools All together 850 type of Components. Transmission Components. Transmission Shaft Pinion Crown Wheel Sliding Gear Differential Bevel Ring Gear Fixed Gear Internal Gear. Etc Engine Components. Crank Shaft Connecting Rods Connecting Rod Cap Cam Shaft Half Piston Rocker Arm. Etc 20
  • 21. Propeller Assembly Components. Flange Yoke Tube Yoke Long Fork UJ Cross Short fork, Etc Earth Moving Components. Track Links Track Roller Shafts Ring Bush Coupling Set Worm Gear Blanks Drill Bits Etc Machine Tools and Electrical Components. Shafts, Hubs Spindles, Etc Other Components. Bell Crank Lever Slack Adjuster Brackets Eye Arms Stub-Axels Wear Pad Drop Arms, Etc Machined TC Cover Nuts Plates. Etc 21
  • 22. Part Manufactured And Supplied For Tata Nano Car Gear Crank Shaft, Gear Balancer Shaft, 1st Gear Lay Shaft, 2nd Gear Lay Shaft, Reverse Gear and Shafter Sleeve 1st / 2nd, Lay Shaft 4th Speed, Input Shaft 4th Speed, Synchronic Ring (1 st / 2nd Speed Lay Shaft), 3rd Gear Input Shaft, 4th Gear Input Shaft, 3rd Gear Lay Shaft, 4th Gear Lay Shaft, Reverse Idle Gear, Shafter Sleeve 3rd / 4th Speed, Final Drive Gear, New Product Development New product means all below six categories of new product: A product which is new to the world. New product line. Addition to the existing product. Improvement and revisions of existing products. Re-positioning (launch for new target group). Cost reduction. To develop a new product or part directors of technical and marketing KADVANI FORGE LTD. Consider, Its final usage and the user of the parts, Its application, 22
  • 23. Quantity to be produced, Availability of raw-material, and Capability of the company to make the product or part. As the company is making the parts for automobile companies, it is responsible for the quality parts manufacturing. Machinaries Without adequate machineries production is not possible. Machineries can be parched from the country or out-side the country. KADVANI FORGE LTD. Is using different machineries like: Forge-Shop Equipment :- Pneumatic Hammers, Double Column Trimming Presses, Heating Furnaces, Reduce Roll, Heat Treatment Equipment : Semi Automatic Continuous Pusher, Brinell Hardness Testing Machine, Cutting Shop Equipment : Band Saw Machine, Shearing Machine, Hacksaw Machine, Portable Platform Scale, Die Shop Equipment : Copy milling machine single and double spindle, Vertical Machining Center (Linear), Electric Discharge Machine, Planning Machine, 23
  • 24. Shaping Machine, Tool and Cutter Grinder, Heavy Duty Lathe Machine, Die Grinder, Final Inspection Equipment : Magana Flax Crack Detector, Shot Blasting Machine, Double Column Coning Press, Flexible Grinder, Lathe Machine, Portable Platform Scale, Die And Material Handling Equipment : Forklift, Cranes, Design And Software : Auto CAD-2000, Unigraphics-Nx2, Laboratory Equipment : Poldi Hardness Tester, Metallurgical Microscope with Binocular Camera & Screen, Balance Digital, Balance Manual, Single Disc Polishing Machine, Water Still, Muffle Furnace, Spectrometer, 24
  • 25. Stand By Captive Power : Generator Set-1000 KVA, KADVANI FORGE LTD. Had started its production with only one hummer in 1996. Presently, it has 6 hummer and 8 press machine including 2 press machines which are imported from Australia and other equipment as started above to make the production quick, accurate and smooth. 25
  • 26. Process Lay Out Of The Company 26
  • 27. Manufacturing Process The main products of the company are forging components. The company is passed by the following procedures while manufacturing the forging components. First or all the company purchases the raw-material from the various companies in addition to procurement of raw-material the company also receives the respective data about the raw-material and it is checked in their own laboratory. Step:-1 Cutting Process Here the raw-material which is in billets form is cut into required length according to cutting slip for this the company is using manual and electrical equipment like band-saw, sharing machine, heck-saw, for cutting raw-material Smoothly. Step:-2 Forging Process In first of all cut metal piece is heated in oil fired furnace, than die forging is done. In forging first of all die is fixed in hummer with top half impacts in the metal thus the process of heating the cut metal and to give the shape of heated metal piece is called forging. In Forging there are three steps: Heating, Forging, Trimming. Step:-3 Heat Treatment After the forging process the components are subject to best treatment which remove the residual stresses that are formed during the forging process and this process is called heat treatment. The steps in heat treatment are:- Normalizing, Quenching, Trimming, ISO Thermal Hardening and Tempering, 27
  • 28. Step:-4 Shot Blasting For clearing of rods, bars, angles, girdle etc. and make them shining shot blasting machine are used. These shot blasting machine house powerful and strategically located blast wheels in up-ward and down-ward position. Blast wheels throw stream of shot on the job from all side. The job is cleaned perfectly inside work chamber. Number of blast wheels stations and basis of output requirement and configuration of job. Step:-5 Coining Sometime when long and thin component are forged it may possible that the shape goes somewhat bend. After measurements if the part is bend than it is kept in the coining machine to make it straight and perfect in shape. Step:-6 Packing And Dispatching After final inspection the finished product is packed in a wooden box and dispatched as per customer order when parts are exported mainly at that time the packing is necessary and then are sending to the customers. 28
  • 29. Quality Policy We shall be customer focused. We shall consistently satisfy customer by providing products conforming to customer requirements at competitive prices. 29
  • 30. Drawing & Designs Department Introduction Product design is concerned with how the product will be made. Designs that is poor- quality products. Engineers tend to over design products, with too many features, options and parts. When any new part is designed at that time feasibility study is under taken. In that prototype design is prepared this contains.  The design review,  Reliability and maintainability prediction,  Failure mode effect and critical analysis,  Safety Analysis,  Value Engineering, etc. are checked. Drawing department of Kadvani Forge Ltd. Prepare the sample drawing based on customer specifications, machine and forging drawing are also prepared by using the C.A.D. (Computer Aided Design) and this is the process by which a computer assists in the creation or modification of a design. Engineering Drawing Specifications:- Timely Review, Distribution and Implementation of customer engineering specification. Master List Cum Distribution Record (M.L.C.D.R.) is prepared. Process Of Drawing Forging Drawing:-  Customer Approve,  Drawing issue to the customer,  Data control. 30
  • 31. Die Designing:- Dies are prepared by draft man mechanic. Die is designed as per forging. First it is checked by die shop in charge. Approved by technical person and then issue is possible. Modification:- If there is any problem in design or implementation in the parts drawn from the customers and internal department. The technical director will approve the modification and that will be followed by the draft man and drawing in charge. And then correction steps are taken. Mission And Vision Vision :- “Where the vision is one year, cultivate flower. Where the vision is ten year, cultivate trees. Where the vision is eternity, cultivate people.” It is a universal saying. So, keep this I the mind the company wants to increase its manpower strength not only in quantity but also in the quality. And through that the company wants to become one of the company wants to become one of the best forgers in the world by providing quality forged components. Mission :- The tags line of the company itself shows mission of the company i.e. “Forging the Bright Future” and reach M to M i.e. Mahindra to Mercedes reach from national to international best customer with quality product. 31
  • 32. FINANCE DEPARTMENT Introduction Finance is an important function in any business as money is required to support its various activities. Finance is defined as the provision of money at the time it is needed. The term “Business Finance” is composed of two words :- Business, Finance, The word business literally means a state of being busy. All creative human activities relating to the production and distribution of goods and services for satisfying human wants are known as “Business”. Broadly, the term business includes industry, trade and commerce. The word Finance refers to the management of flows of money through an organization. It concerns with the application of skills in the Manipulation, use and control of money. Finance is considered as the life blood of any business. “Business Finance may be said to deal with acquisition of funds, use of funds, and distribution of profits by a business organization.” - Charles W. Gerstenberg 32
  • 33. Organisation Chart Of Finance Department C.E.O. & M.D. FINANCE IRECTOR CHARTED ACCOUNTANT ADMINISTRTION STAFF CLEARKS 33
  • 34. Capital Structure Capital Structure refers to the makeup of a firm is capitalization. In other words it represents the mix of different sources of long term funds such as equity share, preference share the long term loans and retained earning etc.  PATTERNS OF CAPITAL STRUCTURE :- There are four Patterns:-  Capital Structure with equity shares only,  Capital Structure with equity and preference share,  Capital Structure with equity share and Debentures,  Capital Structure with equity share and preference share and debenture. The choice of an appropriate capital structure depends on nature of business, earning, conditions of money market, attitude of investors‟ etc. Pattern of capital structure of KADVANI FORGE LTD. Consists of share holders fund and long term liabilities. In the Year 2009-„10 SHARE HOLDERS FUNDS Rs. Deferred Tax Liabilities 8,146,180 Equity Share 8,00,00,000 Reserves & Surplus 2,47,69,952 TOTAL:- 11,29,16,132 LONG TERM LIABILITIES Rs. Bank C.C. A/c 16,00,00,000 Secured Loans 28,48,60,918 Unsecured Loans 4,99,14,467 TOTAL:- 49,47,75,385 34
  • 35. Working Capital There are two concept of working Capital.  Gross Working Capital:- It refers to the firm is investment in total current or circulating assets.  Net Working Capital:- It is the excess of current assets over current liabilities. It also defined as the different between current assets and current liabilities. Working Capital In the Year 2008-„09 Current Assets 35,78,10,926 Less:- Current liabilities 9,98,36,001 Net working Capital 25,79,74,925 In the Year 2009-„10 Current Assets 297,788,187 Less:- Current liabilities 66,923,855 Net working Capital 230,864,332 Cash Management Cash Management includes:  Controlling level of cash,  Controlling inflows of cash,  Controlling outflows of cash,  Optimum investment of surplus cash, 35
  • 36. One of the basic objectives of cash management is to minimize the levels of cash balance with firm. From controlling the cash inflows Of KADVANI FORGE LTD. Is having a system of decentralization collection of account receivable. It also makes sure that all the receipts come on time as decided. bank and cash a/c.:- In the Year 2007-„08 Cash on Hand 3,95,314 Add:- Bank a/c 86,83,821 TOTAL:- 90,79,135 In the Year 2008-„09 Cash on Hand 6,92,603 Add:- Bank a/c 14,77,800 TOTAL:- 21,70,403 In the Year 2009-„10 Cash & Bank a/c 25,80,893 TOTAL:- 25,80,893 Sources Of Finance The business cannot run efficiently if it does not have adequate finance to meet its requirements of business can be classified into two categories:-  Short Term Finance Requirement:- This required meeting working capital needs. They are usually for a period up to one year. 36
  • 37.  Long Term Finance Requirement :- These funds are usually for meeting the fixed capital requirements of the business. They are required for a period exceeding one year. In KADVANI FORGE LTD. The finance is usually generated form:-  Bank Loans,  Term loans or long term Loans,  Cash Credit,  Retained Earnings. Generally, company is generating finance from the internal sources,  Using depreciation as a source of finance.  Plugging back of profits.  From commercial banks etc. Company cannot generate the finance by external sources like issue of debentures or preference shares because it has not yet taken the initial public offering. Inventory Management Inventories are goods held for eventual sales by a firm. Generally, there are three kinds of inventories:- 1) Raw-material:- These are the goods which have not yet been committed to production in manufacturing firm. It consists of basic raw-material and it is in KADVANI FORGE LTD. Is steel billets. 37
  • 38. For the year 2007-„08 = 3.46 For the year 2008-„09 = 3.31 Credit Policy The term credit policy refers to those decision variables that influence the amount of trade credit means the investment in receivables, the length of credit period to be extended, the cash discount to be offered depending upon particular circumstances of the company and the customer. Credit policy of any company determines the amount of risk the company is willing to undertake in its sales activities. Terms of Credit :- The two important components of the credit terms are:- i. Credit Period, ii. Cash Discount. Credit Policy :- It refers to the time duration for which credit is extended to the customers. It is generally expressed in terms of net Days. [In KADVANI FORGE LTD. The credit of 60 days to the regular customers and 45 days for the other customers is given. When the due date comes at that time through mail and agent, reminders are given to the customers for the payment.] Cash Discount :- Many companies offer cash discount to their customers for encouraging them to pay their dues before the expiry of the credit period. 38
  • 39. HUMAN RESOURCES DEPARTMENT Introduction The management of man is a very important and challenging job; important because it is job not of managing „men‟, but of administering a social system. No two persons are similar in mental abilities, tradition, sentiments and behavior. They differ widely also as group and are subject to many and varied influences. According to Edward Flippo: “Human resource Management is the planning, organizing, directing and controlling of procurement, development, compensation, integration, maintenance and separation of human resources to the end that individual, organization and societal objectives are accomplished.” Recruitment It is the generation of applications for the specific positions through any source. It makes possible to acquire the number of people necessary to ensure the continued operation of the organization. It has been regarded as the most important function of personnel administration because if the right type of people is not appointed even the best policies, organization charts and control system would not do much good. In KFL the recruitment is done by using the following three sources: 1. Advertisement: The company gives advertisement in the news paper about the vacancy with the specification required. 2. Known Source: In that the company uses the source which is known by the company‟s employees that may be friend, relative, or from any other reference group. Mainly this source is used for lower level workers. 39
  • 40. 3. Placement: In this type of source the company visits various colleges and takes the interview and invites application from them. Selection Selection is the second step after recruitment in the process of procurement of people. It is the process of choosing the individuals who possess the necessary skills, ability and personality to successfully fill specific job in the organization. The selection process is a number of specific steps taken to decide which recruits should be hired. The process involves grouping the applications into unsuitable and appearing to be suitable candidates, conducting tests on suitable candidates, if needed interviewing them, contacting for references and eliciting their opinion, getting them medically examined and making final hiring decision. The selection process begins with screening of applications and ends with hiring decision and placement. The selection process of KFL for employees and workers are as bellow: For employee selection all of first the inquiry or information has been gathered whether he or she as per the job specification eligible or not then after the candidates are being interviewed and finally out of all, the best one is gone select for the particular job. For worker‟s selection criteria are as bellow: Basic knowledge of language ( i.e. read or write) either Hindi or English. He must be having Knowledge and ability to do the work in the production department. He must be obedient to follow the orders from supervisor or in charge. Training & Development Training is the important subsystem of human resource development. Training is a specialized function and is one of the fundamental operative functions for known resource management. It is designed primarily for nonmanagers, it is for a short duration and it is for a specific job related purpose. 40
  • 41. According to Dale S Beach: “Training is the organized procedure by which people learn knowledge and for skill for a definite purpose.” The KFL gives training when the employee is selected about the procedures, how to fill the various forms and all. Apart from that the company is providing regular training programmes like: Operation management Attitude development First aid Production planning and controlling Advance process quality plan ISO:TS:16949 Statistical process control Six sigma Time management Document, data and control Leadership Motivation etc. So, by all such training programmes are provided for updating and improvement of the knowledge of the employees and workers to gate the desired level of output. Salary & Wage Management Wage and salary administration is the process by which wage and salary levels and structures are determined in organizational settings. Wages are payments for labor services rendered frequently, expressed in hourly rates, while a salary in a similar payment, expressed in weekly, monthly or annual rates. 41
  • 42. Wage and salary administration is one of the vital areas of HRM, for sound wage and salary policies and programmes are essential to procure, maintain, develop, promote and transfer employees and to get effective results from them. In KFL the wage and salary administration is done very effectively. The wages are paid on time based as per the government rules and Act. Salary paid monthly basis as per the rules and regulation of lows. Welfare Activities The KFL provides the following welfare facilities to the workers and employees, the basic purpose of employee welfare is to improve the lot of working class and thereby make worker the good worker and happy citizen. Provident fund to experienced workers Insurance Policies Bonus Transportation facilities Housing facilities Interest free loans to the employees Regular medical checkup camps Human Resource Audit In KFL the Human Resource Audit is not done separately but it is included in the overall internal audit that is been done every four month. Workers & Time Schedule  workers :- In KADVANI FORGE LTD. There are 300 workers and employees (including non- technical staff). 42
  • 43.  Time schedule :- In KADVANI FORGE LTD. There are three shifts per day for the workers and eight Hours per shift. SHIFT TIME Shift-1 8 a.m. To 8 p.m. Shift-2 8 p.m. To 8 a.m. Weekly off Day Wednesday During each shift there is break for half an hour. Working hour for the Non-technical and Administration Staff employees is:- 9 a.m. To 6 p.m. (With munch and tea break) In KADVANI FORGE LTD. Time wage system is used for the payment of wages and salaries. 43
  • 44. FUTURE PLAN OF K.F.L.  To increase the production.  Implementation of performance appraisal system.  Implement corporate and professional attitude.  Enhancing technology and scientific technical in all the departments.  Increase export in more countries.  To develop each area of quality. S.W.O.T. ANALYSIS The overall evaluation of a company is Strength, Weakness, Opportunities and Threat is called S.W.O.T. Analysis. It involving monitoring the external and internal environment of the organization. Each business needs to evaluate its internal strengths and weakness.  strengths:-  Prestige and goodwill that company has created in the market in the span of more than 11 years.  Strongest production department.  Skilled and experienced workers and employees of production and drawing department.  Timely delivery of goods.  ISO/TS-16949 : 2002 certificate for technical specifications and use of 5‟ “S”  Employment generation.  Customized products.  Lesser in house rejection.  Weakness:- Every business whether big or small can have the weakness. Here I am pointing out some weaknesses because “we can get the success if we can change the weaknesses into our strength.” 44
  • 45.  Human Resources department of the company is lagging behind.  Lack of marketing strategic.  Business is run in a traditional way to fight with the national and international competitors it has to become more professional and should have clear corporate strategies.  Flexibility.  Poor adaptability of changes.  Opportunities:- Opportunities can take many forms and company has to be a good at spotting them some opportunities that I have observed are as given below.  Company has still its I.P.O. (Initial Public Offering) as reserve. It has not yet issued its share to the public.  Company can get more growth by increasing the exports to reach its goal.  Capacity can be increased for mass production.  If company emphasis on marketing than it can grow more.  More export promotion activates can get a better future.  Threats:- Threat is a challenge posed by an unfavorable trend or development that would lead in the absence of action to lower sales or profit. Threats should be classified according to its seriousness and probability of occurrence. To deal with threats the company needs plans that spell out changers it can make before or during the threats.  Shortage of workers who can work in the forge shop and other process department of production.  Communication Gap.  High Turnover of Workers.  Economics conditions like value of rupees price rise in steel which is used as a raw-material. 45
  • 47. INTRODUCTION According to American Marketing Association “Marketing research is the systematic gathering, recording and analyzing of data about problems relating to the marketing of goods and services.” Management in any organization needs information and in large quantities about potential markets and environmental forces in order to develop successful strategic marketing plans and to respond to changes in the market place. A mass of data is available both from external sources and within the firm. This forms a solid platform for a research to take place. Marketing Research includes all the activities that enable an organization, to obtain the information it needs to make decisions about its environment, its marketing mix and its present or potential customers and consumers. More specifically, Market Research is the development, interpretation and communication of decision oriented information to be used in the strategic marketing process. LITERATURE REVIEW This research study seeks to come up with a conceptual framework that investigates the different dimensions of total quality management (TQM) and its effects on knowledge management (KM). This is to help build a theoretical framework of TQM and its dimensions, which mainly consists of leadership, strategic planning, information and analysis, process management, human resource focus and customer focus. These constructs are rooted in the work of Malcolm Baldrige National Quality Award (MBNQA). To build the conceptual framework, the background of TQM and Knowledge Management theory served as a good starting point. The current research study is based on the complete assessment of present literatures, the six constructs of TQM and the three elements of knowledge acquisition, knowledge application and knowledge dissemination. This paper serves as a guide to senior management, who seeks to improve their company‟s organizational knowledge management activities through the execution of TQM practices, in which the TQM practices support their company‟s knowledge management efforts. Furthermore, the conceptual model serves as a benchmark for practitioners to execute their TQM programmes more effectively and efficiently in their own respective firms. This paper seeks to close the gap on the existing literature, by giving guidance to the senior management of TQM companies that aspires to discover the competency of knowledge management. By developing a deeper understanding of the relationship between TQM practices and knowledge management, senior management can thus focus their efforts on the practices that ensure the firms‟ ability to establish a competitive knowledge management capability. 47
  • 48. Undeniably, TQM and KM contribute significantly to the improvisation of performance for any organization. The proposed model in this study seeks to close the gap in the literature for the assessment of the multidimensionality of TQM and its association with organizational KM. Furthermore, this model seeks to advance the literature regarding the relationship between TQM and KM research and at the same time, to provide a means for both the practitioners and the academicians to better comprehend the link between TQM practices and KM behaviours. Apart from that, this paper propose this model to be used for the implementation of TQM practices and also to measure the organizational processes such as the effectiveness of strategic planning, leadership,process management, customer service, human resource management and the employment of information analysis. The initial study on the model, which is to examine the link between TQM practices and the KM, has led to further studies on the six dimensions of TQM, which are known to be important attributes to the KM management. As for improvements, further surveys and research should be done using the multivariate analysis to test, validate and enhance the model. The results obtained will be reported in afuture article. Nature Of Research The Marketing Research is carried out on forging company in rajkoj of appled total quality managamant. The research where the application of all Marketing Concept and Strategies have been put into practice. The nature of research is also Syndicate Research, which can be carried out by anyone, a part from Research Organization. The Research has been carried out through the universally favoured approach of a personal interview survey. OBJECTIVES OF STUDY The Marketing Research is carried out on the following subject:- The main objectives kept in mind while selecting the subject and conducting the survey were as listed below: 48
  • 49. 1. Customer focus The first and overriding feature of TQM is the company‟s focus on its customers. Quality is defined as meeting or exceeding customer expectations. The goal is to first identify and then meet customer needs. TQM recognizes that a perfectly produced product has little value if it is not what the customer wants. 2. Continuous improvement Another concept of the TQM philosophy in the focus on continuous improvement. Traditional systems operated on the assumption that once a company achieved a certain level of quality, it was successful and needed no further improvements. Traditionally, change for American managers involves large magnitudes, such as major organizational restructuring. The Japanese, on the other hand, believe that the best and most lasting changes come from gradual improvements. Continuous improvement, called kaizen by the Japanese, requires that the company continually strive to be better through learning and problem solving. 3. Employee Empowerment Part of the TQM philosophy is to empower all employees to seek out quality problems and correct them. With the old concept of quality, employees were afraid to identify problems for fear that they would be reprimanded. Often poor quality was passed on to someone else, in order to make it “someone else‟s problem”. The new concept of quality, TQM, provides incentives for employees to identify quality problems. Employees are rewarded for uncovering quality problems. In TQM, the role of employees is very different from what is in traditional systems. Workers are empowered to make decisions relative to quality in the production process. SAMPLE SURVEY The gathering of primary data through experimentation involves use of sampling, survey method and observations. The survey conducted on kadvani forge ltd. involved a survey based on personal interview. 49
  • 50. The details of the selected samples for the survey is as under:  City chosen for Sample Survey:- Rajkot  Sample size:- 20 Samples Market Research Methodology Formulation of Research Problem Research Design Determination of Sources of Data Collection of Information Processing and Analysis Present the finding Formulation Of Research Problem First step of the marketing research process is the formulation of research problem. Marketing management must be carefully note to define the problem too broadly or too narrowly for the marketing researcher. The marketing manager and the researcher must work closely together to define carefully and agree on the research objectives. The managers best understand marketing research and how to obtain the information. In order to avoid waste of time and money it is necessary to define the problem in specific terms. 50
  • 51. Research Design The second step of the marketing research process calls for determining the information needed and developing a plan for gathering it efficiently. A research design can be defined as “The plan, structure and strategy of investigation conceived so as to obtain answers to research questions and to control variance.” The marketing manager needs to know the cost of the research plan before approving it. Designing a research plan calls for decisions on the data sources, research approaches, research instrument, sampling plan and contact methods. The researcher can gather secondary data, Primary data or both. Secondary data were collected for another purpose and already exists some where. Primary data are freshly collected for specific purpose for a specific research project. The Survey Method: - Surveys are best suited for descriptive research. This method involves learning about people‟s knowledge, beliefs, preferences and satisfaction and to measure these magnitudes in the general population. As in observation, survey research can be structured or unstructured. Structured survey use formal lists of question asked of all respondent the same way where as in unstructured researcher use an open format that lets the interviewer probe respondents and guide the interview, depending on their answers. There are three types of surveys namely: Determination Of Sources Of Data In marketing research literature, there are two types of data: primary data and secondary data. The researcher can gather primary data or secondary or both. 1. Primary Data: The first hand data collected for a specific purpose or for a specific research project constitutes primary data. When the needed data do not exist or are inaccurate, incomplete or unreliable the researcher collects primary data. Most marketing research projects thus involve some primary data collection. The main primary data sources consist of consumers, dealers, buyers, etc. Consumers and buyers constitute the main source of information in most researches. A buyer may not be the user of the product, although in some cases the consumer and the buyer may be the same person. 51
  • 52. 2. Secondary Data: Information collected by other organization or individuals which might be relevant to the study constitutes secondary data. Researchers usually start their investigation by examining secondary data to see whether their problem can be partly or wholly solved without collecting costly primary data. Secondary data provides a starting point for research and offer the advantages of low cost and ready availability. In my study, I have primarily used “Primary Data” obtained through retailer survey with the help of questionnaire. Collection Of Information Marketing researchers have a choice of two main research instruments in collecting primary data: Questionnaire and mechanical devices. Questionnaire: A questionnaire consists of questions presented to the respondents for their answers. Because of its flexibility, the questionnaire is by for the most common instrument used to collect primary data. In preparing a questionnaire, care should be taken in choosing the questions and their form, wording and sequence. The questions included in the questionnaire can be closed end questions prosperity all the possible answers and are easier to tabulate and interpret. Open end questions allow respondents to answer in their own words and they often reveal more as they give an insight into how people think. Sampling plan: After deciding research approach and instruments the marketing researchers must design a sample plan. This calls for three decisions. Sampling Unit: The marketing researcher must define the target population that will be sampled. Sample Size: Large samples give more reliable results than small samples. However, it is not necessary to sample the entire target population or even a substantial portion to achieve reliable results. In my survey the sample size was 20. 52
  • 53. Sampling Procedure: To obtain a representative sample a probability sample of the population should be drawn. Probability sampling allows the calculation of confidence limits for sampling errors. When the time and cost are involved the in probability sampling is excessive, marketing researcher will take non-probability samples. Simple random sample My survey falls under the category of the convenient sample under Non-probability sampling. In this method the researcher is free to select. The respondents are selected on the basis of the being available at the time of survey. 53
  • 54. ANALYSIS AND INTERPRETATION OF DATA Q.3:- What is your position? Top management 3 15% Manager 5 25% Officer 2 10% Supervisor 4 20% General staff 6 30% TOTAL 20 100% position 15% Top management 30% Manager Officer 25% Supervisor 20% General staff 10% From the above analysis and conclusion, we can say that 15% of organization employees is come forom top mamagament. From the above analysis and conclusion, we can say that 25% of organization employees is come forom manager. From the above analysis and conclusion, we can say that 10% of organization employees is come forom officer. From the above analysis and conclusion, we can say that 20% of organization employees is come forom supervisor From the above analysis and conclusion, we can say that 30% of organization employees is come forom general staff. 54
  • 55. Q.4:- Is your organization ISO 9000 certified? NO 0 0% ISO 9001 Certified 4 20% ISO 9002 Certified 3 15% ISO 9003 Certified 5 25% ISO 9000 Certified 8 40% TOTAL 20 100% certified? 0% 20% NO 40% ISO 9001 Certified ISO 9002 Certified 15% ISO 9003 Certified ISO 9000 Certified 25% From the above analysis and conclusion, we can say that 0% of organization is related with ISO NO CERTIFIED. From the above analysis and conclusion, we can say that 20% of organization is related with ISO 9001 CERTIFIED. From the above analysis and conclusion, we can say that 15% of organization is related with ISO 9002 CERTIFIED. From the above analysis and conclusion, we can say that 25% of organization is related with ISO 9003 CERTIFIED. From the above analysis and conclusion, we can say that 40% of organization is related with ISO 9000 CERTIFIED. 55
  • 56. Q.5:- Does your organization apply total quality management? YES 14 70% NO 6 30% TOTAL 20 100% Sales 30% NO YES 70% From the above analysis and conclusion, we can say that 70% of organization apply total quality management From the above analysis and conclusion, we can say that 30% of organization not apply total quality management 56
  • 57. Q.6:- Does your organization apply statistical process control? YES 12 60% NO 8 40% TOTAL 20 100% statistical process 40% NO YES 60% From the above analysis and conclusion, we can say that 60% of organization apply statistical process control. From the above analysis and conclusion, we can say that 40% of organization apply statistical process control. 57
  • 58. Q.7:- What other benefit(s) does your organization gain with ISO/TQM? Improve Productivity 3 15% Less Waste 1 5% Less Rework 4 20% Improve Image 4 20% Increase Market Share 1 5% Better Teamwork 3 15% Lower Staff Turnover 2 10% Lower Stock Level 2 10% TOTAL 20 100% Improve Productivity 10% 15% Less Waste 10% 5% Less Rework Improve Image 15% Increase Market Share 20% Better Teamwork 5% Lower Staff Turnover 20% Lower Stock Level From the above analysis and conclusion, we can say that 15% of organization gain with Improve Productivity. From the above analysis and conclusion, we can say that 5% of organization gain with Less Waste. From the above analysis and conclusion, we can say that 20% of organization gain with Less Rework. From the above analysis and conclusion, we can say that 20% of organization gain with Improve Image. From the above analysis and conclusion, we can say that 20% of organization gain with Improve Image. From the above analysis and conclusion, we can say that 5% of organization gain with Increase Market Share. From the above analysis and conclusion, we can say that 10% of organization gain with Better Teamwork. From the above analysis and conclusion, we can say that 10% of organization gain with Lower Stock Level. 58
  • 59. Q.8:- What side effect(s) does your organization suffer with ISO/TQM? Decrease Productivity 2 10% Weaken Morale 1 5% Higher Costs 8 40% Higher Stock Level 6 30% Higher Staff Turnover 3 15% TOTAL 20 100% suffer with ISO/TQM 10% 15% 5% Decrease Productivity Weaken Morale Higher Costs 30% Higher Stock Level Higher Staff Turnover 40% From the above analysis and conclusion, we can say that 10% of organization suffer with Decrease Productivity. From the above analysis and conclusion, we can say that 5% of organization suffer with Weaken Morale. From the above analysis and conclusion, we can say that 40% of organization suffer with Higher Costs. From the above analysis and conclusion, we can say that 30% of organization suffer with Higher Stock Level. From the above analysis and conclusion, we can say that 15% of organization suffer with Higher Staff Turnover. 59
  • 60. Q.9:- Did your organization use consultant(s) during ISO/TQM? YES 14 70% NO 6 30% TOTAL 20 100% consultant 30% NO YES 70% From the above analysis and conclusion, we can say that 70% of organization use consultant(s) during ISO/TQM. From the above analysis and conclusion, we can say that 30% of organization not use consultant(s) during ISO/TQM. 60
  • 61. Q.10:- Did your organization employ additional staff since ISO/TQM? YES 16 80% NO 4 20% TOTAL 20 100% additional staff 20% NO YES 80% From the above analysis and conclusion, we can say that 80% of organization employ additional staff since ISO/TQM . From the above analysis and conclusion, we can say that 20% of organization employ not additional staff since ISO/TQM . 61
  • 62. Q.11:- Has your organization structure change since ISO/TQM? YES 8 40% NO 12 60% TOTAL 20 100 structure change 40% NO YES 60% From the above analysis and conclusion, we can say that 40% of organization structure change since ISO/TQM. From the above analysis and conclusion, we can say that 60% of organization structure not change since ISO/TQM. 62
  • 63. Q.12 Overall, Do you think that ISO/TQM brings positive effect to your organization? YES 18 90% NO 2 10% TOTAL 20 100% positive effect 10% NO YES 90% From the above analysis and conclusion, we can say that 90% of organization is ISO/TQM brings positive effect to your organization. From the above analysis and conclusion, we can say that 10% of organization is ISO/TQM brings not positive effect to your organization. 63
  • 64. 64
  • 65. No company is perfect in all ways, so as KADVANI FORGE LTD. During my training and experience in the company, I have observed some points which I want to mention. Professional attitude or professionalism is needed. Suggestion Boxes for the staff employees and for workers in plant should be kept to know the view of the employees as well as the workers. Rest room or canteen facilities, if not for food than for tea and snacks is needed. Management should find out different way to motivate employee. They should make advertising through television, newspaper and holding etc. for increasing their sales and profit. Give more information in the web-site therefore person who is interested to know about the company. CONCLUSION India is a key part of most of the global companies‟ overall growth strategy in auto components. To utilize the resources provided by the education system and the resources which are within the company 100% is the success mantra. These industries are also depending on the growth of OEMs. (Original Equipment Manufacturing) and there is a bright future of them. 65
  • 66. Learning From Sip I have prepared project report on ”total quality management practies in forging company of rajkot city with reference to kadvani forge ldt”. I learnt so many things like . . . I came to know that how company sustain its position during the recession period. If sale are increase, it does not means that profit will be increased because of operating expenses also increase. If you have no proper planning for investing the investment, then you cannot earn more return on the investment. There is difference between bookish knowledge and real work at company. Company‟s planning is not easier at real situation in comparison to the paper work. If you want to get better work from the company‟s employees and workers then company requires proper co-ordination. Customers‟ satisfaction is important for any organization. If customers are not satisfied then company cannot survive in the market. 66
  • 67. BIBILIOGRAPHY BOOKS  M.Y.KHAN, “INDIAN FINANCIAL SYSYEM”, 3rd edition Publication by TATA McGraw hill.  Ashwathappa, “Personnel Management”, 3rd edition.  Philip Kotler, “Marketing Management”, 11th edition, Pearson education Asia Publication.  Walker, Boyed, Mullins, Larrenche, “Marketing Strategy”, 4 th edition, Tata McGraw hill publications.  Thompson and Stickland, “Strategic Management” 13 th edition, Tata McGraw-Hill publications. NEWSPAPERS  Business standard  Economics times DOCUMENTS, RECORDS & STATEMENT OF KADVANI FORGE LTD.  Www.kadvanigroup.com  www.forgingmagazine.com  www.forging.org  Www.indianforging.org 67
  • 68. CUSTOMERS Domestic Customers:- NAME Component Supplied Fairfield Atlas Ltd. Transmission, Differential and Engine Gear, (TS-16949) Transmission and Bull shaft. Snderam Fasteners Gears Mahindra Sar Transmission Pvt. Ltd. Engine Gear, Helical Gear, Straight Bevel Gear, (TS-16949) Spleen Shafts, Synchronizers (Gear) R.B.S. Transmission Ltd. Flange Yoke, Cross, Forks, Slack, Adjuster, Brackets, Stub-Axeis etc. B.E.M.L. Flanges and Covers. V.S.T. Multi Throw Crank Shafts. Fortuna, Garima, Amul. Connecting Rods, Piston, Rocker Aam. Overseas Customers (Exports):- NAME Component Supplied G.Elbe and Sohn Gmb, Fork Flange, Welding Pin, Fork shaft. Germany Kampwerk Vieregge, Germany Balancer Shaft, Eccentric Shaft. Keystone Bahntechnike, Druckplatte, Zugmutter, Kronenmutter. Germany Defontaine, France Fly Wheels, Unique Industrial Company, Torque Converter Cover, Front Race Cover, U.S.A. Threaded Flange. 68
  • 69. NAME OF COMPANY SURVEY IS BEING TAKING 1, Patel Steel Forgings 2, Ajk Forge Pvt Ltd 3, Arora Refractories & Forgings 4, Ability Auto Pvt Ltd 5, Advik Hi-Tech Industries 6, Kadvani Forge Ltd ( Registered Office) 7, Kishan Autoparts Ltd 8, Silver Forge Pvt Ltd 9, Super Forge 10, Forge & Forge Pvt Ltd 11, Advik Hitech Industries 12,Crystal Forge 13, Echjay Industries Pvt Ltd 14, Mehta Forgings 15, Sakhiya Industries 16, A K International 17, Jay Forge 18,Ability Auto Pvt Ltd 19. Leo Tech Pvt Ltd 20. Akshar Industries 69
  • 70. “TOTAL QUALITY MANAGEMENT PRACTIES IN FORGING COMPANY OF RAJKOT CITY WITH REFERENCE TO KADVANI FORGE LDT” Q1: Name of the company? ________________________________________________________________________ Q2. Name of employee? ________________________________________________________________________ Q3:What is your position? Top management Manager Officer Supervisor General staff Q4: Is your organization ISO 9000 certified? NO ISO 9001 Certified ISO 9002 Certified ISO 9003 Certified ISO 9000 Certified Q5: Does your organization apply total quality management? NO YES Q6: Does your organization apply statistical process control? NO YES 70
  • 71. Q7:What other benefit(s) does your organization gain with ISO/TQM? Improve Productivity Less Waste Less Rework Improve Image Increase Market Share Better Teamwork Lower Staff Turnover Lower Stock Level Q8:What side effect(s) does your organization suffer with ISO/TQM? Decrease Productivity Weaken Morale Higher Costs Higher Stock Level Higher Staff Turnover Q9: Did your organization use consultant(s) during ISO/TQM? YES NO Q10: Did your organization employ additional staff since ISO/TQM? YES NO Q11: Has your organization structure change since ISO/TQM? YES NO Q12: Overall, Do you think that ISO/TQM brings positive effect to your organization? YES NO 71