A STUDY ON THE INTERNSHIP TRAINING UNDERGONE AT UNICAST ALLOYS PRIVATE

LIMITED POLLACHI
Submitted By
S.SELVAKUMAR
[Reg.No:13B150]
Of
KARPAGAM COLLEGE OF ENGINEERING
(AUTONOMOUS)
Under the guidance of
Ms.A.ABIRAMI,MBA.,(Ph.D).,
INDUSTRIAL TRAINING REPORT
Submitted to the
FACULITY OF MANAGEMENT STUDIES
In partial fulfillment of the Requirements
For the Award of the Degree
Of
MASTER OF BUSINESS ADMINISTRATION
NOVEMBER - 2014

BONAFIDE CERTIFICATE

(Autonomous)
COIMBATORE 32

DEPARTMENT OF MANAGEMENT STUDIES

BONAFIDE CERTIFICATE
Certified that this Industrial training report title UNICAS ALLOYS PRIVATE
LIMITED is a bonafide work of S.SELVAKUMAR, Reg. No 13B150, who carried out the
project under my supervision. Certified further, that to best of my knowledge, the work reported
here does not form part of any other project report or dissertation on the basis of which a degree
or award was conferred on an earlier occasion on her or any other candidate.

Ms.A.ABIRAMI
FACULTY GUIDE

Dr.R.CHANDRASEKARAN
DIRECTOR

VIVA-VOCE EXAMINATION HELD ON

INTERNAL EXAMINER

EXTERNAL EXAMINER

COMPANY CERTIFICATE

DECLARATION

(Autonomous)
COIMBATORE 32

DEPARTMENT OF MANAGEMENT STUDIES

(Approved By AICTE/ NBA Accredited/ Affiliated To Anna University)

DECLARATION

I, S.SELVAKUMAR hereby declare that the report on UNICAST ALLOYS PRIVAE

LIMITED, submitted to Anna University, Chennai in partial fulfillment of the MASTER
DEGREE IN BUSINESS ADMINISTRATION is a record of original work done by me,
during the period of study 2013-2015 under the guidance of Ms.A.ABIRAMI

SIGNATURE

S.SELVAKUMAR
[Reg.No.13B150]

ACKNOWLEDGEMENT
ACKNOWLEDGEMENT
I record my sincere thanks and gratitude to god almighty who bestowed me his grace and
strength to complete this project
I would like to whole hearty thank and express my sincere gratitude to the Chairman
Dr. Vasanthakumar, Karpagam Educational Institutions, Coimbatore and our CEO

Shri.

K. Murugaiah, for thir encouragement in the development of this project.

I express my special privilege and heartfelt thanks to Dr. Nirmalkumar, Principal and
Prof. M. Gowrishankar, Vice principal, Karpagam College of Engineering, Coimbatore for
thir guidance and encouragement.
I would like to express my sincere gratitude to Dr. R. Chandrasekaran, Director of
Management Studies, Karpagam College of Engineering, Coimbatore for the constant
encouragement and stimulating atmosphere provided to me.
I extend my sincere thanks to my guide Ms. A. Abirami, Assistant Professor,
Department of Management Studies, Karpagam College Of Engineering, Coimbatore for
continuous support throughout the develop of this project.
I also extend my sincere thanks to my family and friend for their encouragement and
support.
I would like to extend my thanks to all faculty members of my department who have
helped me a lot to complete his project successfully.

ABSTRACT
ABSTRACT

This research is mainly conducted to study about the industrial training in spinning mills
among the employees Unicast alloys private limited.
The primary objective of the study is to benefit the employees and the organization by
identifying the level of training they are facing during the work and to identify the factors which
cause the mill among the employees of the organization.
This study considers the area of workload, feelings at work, interpersonal relationship, working
conditions, monetary policies and welfare facilities.
Major recommendation is that the employees would be more satisfied if they increase the salary
and compensation benefits.
The following article aims to show the benefit of textile design research to the textile designer.
alloys design is increasingly complex, and influenced by a number of factors such as ethical
alloys, sustainability, fast versus slow fashion, new digital technology and science. It is therefore
necessary for increased research by the alloys designer into these areas in order to understand
and gain knowledge that can be incorporated into the vast alloys industry so what we produce the
most relevant cloth and fabrics that satisfies both consumer and ethical requirements.

TABLE OF CONTENTS
LIST OF CONTENTS

S.NO
I

II

CONTENTS

Page no

CHAPTER I
Introduction

Organizational chart

CHAPTER II
Organizational profile
2.1 Industrial profile

2.2 Company profile

2.3 product profile

III

CHAPTER III
3.1 Purchase Department

11

3.2 Production Department

13

3.3 Quality Department

18

3.4 Finance Department

21

3.5 Marketing Department

24

3.6 Human Resource Department

26

Conclusion

32

Bibliography

33

CHAPTER 1
INTRODUCTION
The super alloy was used to produce the single crystal turbine blades, because it is first
generation super alloy that has good properties of molten metals. First generation Ni-based single
cry stall super alloys are mainly and sometimes Co and Mo partition preferentially to the
austenitic face-centered cubic nickel-based matrix where they act mainly as solution
strengthening elements. Cr also plays an essential role in the hot corrosion resistance since it
promotes the formation of a protective oxide scale. These alloys contain a high volume fraction
of strengthening ordered based phase particles homogeneously distributed in the matrix as nearcubical
More recently, alloy designers tried to improve again the high temperature capability of
the SC blade alloys by increasing the content of rhenium up to about. The challenge was to
achieve improved creep strength, without increasing the density and by keeping the alloy not too

much prone to the precipitation phases. Two typical third generation alloys are developed by
Cannon-Muskegon and Rene developed by General Electric. More recent development work
conducted by GE was devoted to third generation alloys containing also some additions of
ruthenium. A new generation of alloys, a typical example of which is the alloy, is developed in
France by onera and the alloys were developed in Japan.
The major phases present in most nickel super alloys are as follows gamma and gamma
prime. The continuous matrix (called gamma) is a face-centered-cubic (FCC) nickel-based
austenitic phase that usually contains a high percentage of solid-solution elements such as Co.
The primary strengthening phase in nickel-based super alloys is Ni3, and is called gamma prime.
It is a coherently precipitating phase with an ordered crystal structure.
The close match in matrix lattice parameter combined with the chemical compatibility
allows them to precipitate homogeneously throughout the matrix and have long-time stability.
Interestingly, the flow stress of the increases with increasing temperature up to about. In
addition, is quite ductile and thus imparts strength to the matrix without lowering the fracture
toughness of the alloy. Aluminum and titanium are the major constituents and are added in
amounts and mutual proportions to precipitate a high volume fraction in the matrix.
a) Elimination of grain boundaries made strengthening elements, such as carbon and
hafnium redundant. This has facilitated heat treatment and allowed for the further optimization of
the alloy chemistry to increase of the high temperature capability,
b) Elimination of grain boundaries transverse to the principal tensile stress axis has
reduced grain boundary cavitations and cracking, resulting in greatly enhanced creep ductility,
c) The preferred crystallographic solidification direction, which coincides with the
minimum in Youngs modulus and is oriented parallel to the component axis minimizes the
thermal stresses developed on engine start-up and shut-down, this has dramatically improved the
thermal fatigue resistance of the turbine hot gas path components.
In Research and Development Laboratory for Aerospace Materials is used Vacuum
Induction Melting furnace for investment casting of equated super alloy materials, directionally
solidified and single crystal materials for making aircraft engine turbine blades. This furnace has
a conventional Bridgman crystal-growing method. A speed of a few inches per hour is typical so that the solid/liquid interface progresses gradually along the casting, beginning at its base.
This has the effect of producing large, columnar grains which are elongated in the direction of

withdrawal, so that transverse grain boundaries are absent. Prior to casting, the chamber is
evacuated to a partial pressure of approximately 103 bar and the molds raised into the furnace
chamber, which is pre-heated to above the melting point of the charge using graphite resistance
elements. The whole assembly is then allowed to equilibrate for a number of hours prior to
casting. Vacuum Induction Melting furnace for investment casting of single crystal materials
Alloy castings an industry with tremendous growth and development is a vital part of
todays world. The reason why an alloy was taken for my study.
A reputed organization Ultimate alloys private ltd companies is being taken for this
purpose. It includes various manufacturing and trading practices of Ultimate Alloys private
limited like: carbon steel castings, aluminum steel castings etc. These aluminum steel castings
consists of various salient features like Pouring, Molding, Melting, and Felting. It also involves
in the process of importing those alloys to different countries in the world.

ORGANISATION CHART
MANAGING DIRECTOR

CHAPTER 2.1
INDUSTRY PROFILE
Alloying elements are added to achieve certain properties in the material. As a guideline,
alloying elements are added in lower percentages to increase strength or hardenability, or in
larger percentage to achieve special properties, such as corrosion resistance or extreme
temperature stability. Manganese, silicon, or aluminum are added during the steelmaking process
to remove dissolved oxygen, sulfur and phosphorus from the melt. Manganese, silicon, nickel,
and copper are added to increase strength by forming solid solutions in ferrite. Chromium,
vanadium, molybdenum, and tungsten increase strength by forming second-phase carbides.
Nickel and copper improve corrosion resistance in small quantities.
Molybdenum helps to resist embrittlement. Zirconium, cerium, and calcium increase
toughness by controlling the shape of inclusions. Manganese sulfide, lead, bismuth, selenium,
and tellurium increase machinability. The alloying elements tend to form either compounds or
carbides. Nickel is very soluble in ferrite; therefore, it forms compounds, usually Ni 3Al.
Aluminum dissolves in the ferrite and forms the compounds Al 2O3 and AlN. Silicon is also very
soluble and usually forms the compound SiO2MxOy. Manganese mostly dissolves in ferrite
forming the compounds MnS, MnOSiO2, but will also form carbides in the form of C.
Chromium forms partitions between the ferrite and carbide phases in steel, forming .
The type of carbide that chromium forms depends on the amount of carbon and other
types of alloying elements present. Tungsten and molybdenum form carbides if there is enough
carbon and an absence of stronger carbide forming elements (i.e., titanium & niobium), they
form the carbides W2C and Mo2C, respectively. Vanadium, titanium, and niobium are strong

carbide forming elements, forming vanadium carbide, titanium carbide, and niobium carbide,
respectively. Alloying elements also have an effect on the eutectoid temperature of the steel.
Manganese and nickel lower the eutectoid temperature and are known as austenite stabilizing
elements. With enough of these elements the austenitic structure may be obtained at room
temperature. Carbide-forming elements raise the eutectoid temperature; these elements are
known as ferrite stabilizing elements.

Alloy steel is steel that is alloyed with a variety of elements in total amounts between
1.0% and 50% by weight to improve its mechanical properties. Alloy steels are broken down into
two groups: low-alloy steels and high-alloy steels. The difference between the two is somewhat
arbitrary: Smith and Hashmi define the difference at 4.0%, most commonly; the phrase "alloy
steel" refers to low-alloy steels.
Every steel is truly an alloy, but not all steels are called "alloy steels". Even the simplest
steels are iron

alloyed with carbon . However, the term "alloy steel" is the standard term

referring to steels with other alloying elements in addition to the carbon. Common alloyants
include manganese, nickel, chromium, molybdenum, vanadium, silicon, and boron. Less
common alloy ants include aluminum, cobalt, copper, cerium, niobium, titanium, tungsten, tin,
zinc, lead, and zirconium.
The following is a range of improved properties in alloy steels (as compared to carbon
steels): strength, hardness, toughness, wear resistance, corrosion resistance, hardenability, and
hot hardness. To achieve some of these improved properties the metal may require heat treating.
Some of these find uses in exotic and highly-demanding applications, such as in the
turbine blades of jet engines, in spacecraft, and in nuclear reactors. Because of the ferromagnetic
properties of iron, some steel alloys find important applications where their responses to
magnetism are very important, including in electric motors and in transformers.
The first step in the production of single crystal turbine blade is to make its wax model. A
wax model of the casting is prepared by injecting molten wax into a metallic mould if
necessary by allowing wax to set around a ceramic core, which is a replica of the cooling
passages required. These are arranged in clusters connected by wax replicas of runners and

risers; this enables several blades to be produced in a single casting. Wax replicas consisting of a
feed arrangement, platen, starter, selector, and test bar sections were assembled.

CHAPTER 2.2
COMPANY PROFILE
UNICAST ALLOYS PRIVATE LIMITED was established in the year 1990 by B.
Govindarajan it is one of the leading firms for the manufacturing and supply of alloys and
casting services. Proficient team of professionals mange the firms by implementing the suitable
management policies. This allows in to stream lies unicast alloys private limited business
execution and makes it hassle free
Unicast alloys private limited range of products as well as services is known to be
premium quality. They are appreciated for their higher durability and precision engineering.
These products abide by all the industry guidelines and parameter. We are able to provide two
varieties of product range standardized and customized varieties. This allows their customer to
choose products that meet th41e industrial requirement exactly. Furthermore, we store all unicast
alloys private limited specious warehouses, before transit to see all to it that they come past no
harm and are delivered to their client in sound state.
Their range of easting services are known to be highly reliable and we execute these
services in a prompt and deft manner. Perfection is given to deliver the service as per the exact
specification of the client. It is high customization of their service range that has gathered a great
demand for in the domestic market
Unicast alloys private limited as esteemed managing director Mr. B .Govinfrajajan has
also been unicast alloys private limited mentor. It is under his guidance that we have been able to
fetch reputed name for the company young company in competitive market. His kind words of
wisdom and motivation has been driving force for unicast alloys private limited
Unicast group of companies is promoted by shiri B. Govindarajan, a well know
technocrat having more than 3 decades of experience in the foundry industry, now is a renowned
establishment is south India that produces SG iron, grey iron &steel castings with help of highly
dedicated work force &cutting edge technology.
Unicast alloys private limited establishment in 1990 a unit of united group of company is
professionally managed company engaged in mana factoring and supplying grey &SG iron
casting in rough and sully machined condition which are strictly in compliance in its own
premises, it has a molding capacity of 12000 mt per annum.

Their skilled work force with years of experience is the valuable asset they acclaim. Regarding,
their quality accreditation they are an ISO 16949:2002 certified company. Member of
engineering export promotion council combustors district small industries association and the
institute of Indian foundry men

NAME OF THE DIRECTOR

1
2
3

Year of establishment
Name of the managing director
Address

1990
Mr. B .Govindarajan
Achipatti9post0, pollachi-642002
Coimbatore(dist) tn. India

4
5
6
7

Phone Number
Fax Number
E-Mil
Scope of supply

04259-259306
04259-259746
[email protected]
Manufactured of rough and machined grey iron.
SG iron castings for chassis and engine
components for automotive applications

Maximum production capacity

500 tons/ month weighing 0.300kg

To 35kgs per piece to national and international
specification

9
10

Number of employees
Product/components

11

Group of companies

100
Auto motive, tractor, valve, hydraulic, and
general engineering industries
United foundries-rumpet unicust
alloys(Machining division) cbe.

VISION AND MISSION STATEMENT

1) Customer is their prime focus
2) They are encourage active participation of employee at all level for continues

improvement
3) Their aim at creating long term relationship with customer and vendor
4) They will strive for continuous improvement in product quality productivity and effective
utilization of resource
OBJECTIVES:

To maintain uninterrupted flow of materials to support the development schedules.

To procure materials economically at a cost consistent with the quality and service
required. However, generally all purchases may be attempted at the lowest cost.

To provide the necessary expertise, advice, information to the Curators and Education
Officers with regard to the best quality of material available in the market, suppliers
capability and performance etc.

To develop and maintain good buyer-seller relationship.

To promote source development

To maintain Organization reputation and credibility in the market by fair dealings and
prompt payments.

CHAPTER 2.3
PRODUCT PROFILE
PRODUCTS AND SERVICES

Auto motive sector

Hydraulic sector

Valve sector

Power sector

Pump sector

General sector
LIST OF PRODUCTS:
1) AUTO MOTIVE INDUSTRIES

Power cylinder and pressure plates, for auto mobile engines

Cam shaft crank shaft and fly wheels for portable petrol engines
Engine brake casting for exports
Brakes cylinder and master cylinder brake shoe and housings discs for brakes
Exhause manifolds, companion flanges clutch with draw plates for heavy tracks rotary
supporting arms crunts cases and connecting cases for tillers

2) VALVE INDUSTRY

Valve boclies, bonnets, hand whets for diaphragm valves.

Valve bodies, discs, glands and hand wheels for butterfly valves.
Bodies and allied components for beet globe, swing check knif and wafer bodies

3)

CHEMICAL AND HYDRULIC APPLICATION

Volute casting, stuffing boxes, bearing lanterns, glands for heat trans fer, refinery process,
non dog slurry , process, ask handling applications
Impeller, diffuser and vanned wheels
Wear plates, pressure rings and thruseplates
Reciprocating pumps and closing systems
Gear pumps and hydraelic application

4) EARTH MOVINGEQUIPMETS INDUSTRY

Sprockets idler wheels carriers end brushes and end collars.

5) POWER TRANSMISSION
Caps and flanges for insulators

6) TRANSMISSION PRODUCTS

Gear box housing

Gear blanks
Worm wheels

7) GENERAL ENGINESSRING

Mould rigs for poly propylene equipment

Power driven pumps
Ayitator spares
Terminal spares

CHAPTER 3.1
PURCHASE DEPARTMENT
Purchase Orders/RFQ
Purchase Orders / Request for Quote/Emergency Ordering/Supply Agreement. As a
component of continual improvement, the RFQ process is intended to establish specific costs for
supplied materials. Therefore, it is extremely important that Suppliers provide costs for material,
labor, burden and margin, so that through early Supplier involvement and value engineering, we
can identify and implement cost reduction opportunities. The purchase orders are done through
the some of the countries like Switzerland, china ,Sweden etc. At a time of purchasing of order
there will be the payment will be made only after the delivery or receivable of goods. The
payment transactions will be made through the bank transactions. The invoice will be issued to
the buyers at the time of payment transactions.
A purchase department is the division of a business that is responsible for purchasing or
procuring goods and services for a company. The purchasing department usually interacts with
other departments in order to determine the needs of the organization.
FUNCTIONS:The main functions of the Purchase Department are defined as follows:
Procurement of stores through indigenous and foreign sources as required in accordance

with the rules in force.

Checking of requisitions/purchase indents.
Selection of suppliers for issue of enquiries.

.Analyzing quotations and bids etc., and preparation of comparative statement (quotation
charts).
Consultation with the Indenter for selection and approval of quotations and with

Accounts Officer for pre-audit.

Negotiating contracts.
Checking legal conditions of contracts. Consulting Administrative Officer or Secretary, of

the organization where necessary.

Issue of Purchase Orders.
Follow-up of purchase orders for delivery in due time

 Verification and passing of suppliers bills to see that payments are made promptly.
Correspondence and dealing with suppliers, carriers etc., regarding shortages, rejections

etc., reported by the Stores Department.

Maintenance of purchase records.
Maintenance of progressive expenditure statement, sub-head wise.
Maintenance of vendor performance records/data.
Arrangement for Insurance Surveys, as and when necessary.
Clearance of foreign consignments.

CHAPTER 3.2
PRODUCTION DEPARTMENT
Production management means planning, organizing, directing and controlling of
production activities. Production management deals with converting raw materials into finished
goods or products. It brings together the 6M's i.e. men, money, machines, materials, methods and
markets to satisfy the wants of the people.
Production management also deals with decision-making regarding the quality, quantity
cost, etc., of production. It applies management principles to production. Production
management is a part of business management. It is also called "Production Function.
Production management is slowly being replaced by operations management.
The main objective of production management is to produce goods and services of the
right quality, right quantity, at the right time and at minimum cost. It also tries to improve the
efficiency. An efficient organization can face competition effectively. Production management
ensures full or optimum utilization of available production capacity.
"Production management deals with decision-making related to production processes so
that the resulting goods or service is produced according to specification, in the amount and by
the schedule demanded and at minimum cost."
Importance of Production Management
o

Accomplishment of firm's objectives

Reputation, Goodwill and Image

Helps to introduce new products

Supports other functional areas

Helps to face competition

Optimum utilization of resources

Minimizes cost of production

Expansion of the firm

The importance of production management to customers and society:

o

Higher standard of living

Generates employment

Improves quality and reduces cost Spread effect

DESIGN AND DEVELOPMENT OF PATTERNSHIP

Once the enquiry is received the following are to be verified/checked before informing to
marketing to entertain the order Overall size of the component to fit into in our mould size
Tolerances are achievable or not check entire dimensions are clear and nothing is missing. Box
weight should be minimum 10kys and yield should be minimum 55%in case of sg and 60% in
case of grey to decide material of the pattern to decide number of patterns Material specifications
like chemistry, micro-structure, Hardness, Tensile strength, elongation etc, in consultation with
quality laboratory should be verified monthly requirements
While designing the pattern, ensure to facilitate better productivity in the molding to
decide to have less/nil core work and the process of the core marking to have a less felting
/machining work to have an easy feeding system of metal. To decide manufacturing process of
the patter to decide the layout of the pattern to inform the purchase department suitably to order
for the patterns giving 100% details like manufacturing process and the material, etc. along with
the approximate time for the delivery and cost estimation on receipt of the pattern, countercheck
the dimensional report sent by the pattern supplier
Depending on the reliability of the pattern supplier, the pattern should be taken up for
mounting Immediately on receipt of the pattern, there should be a target data be given to the
management and marketing for sample submission. Pilot batch submission and regular
production. After mounting of the patterns there should be a check list for various parameters
before it is given for trials after trials the dimensions should be recorded at our end in addition to
the verifying correctness of the mothering
The sample should be sent to the customer without any deviations on the specification and
the first sample should be approved at customer end The pilot batch (quantum to be decided
based on the weight of the castings0 should be given and get the approval from the customer for
the specifications i.e., It is our responsibility to ensure that the casting once approved by the
customer, should not any problem at bulk production stage.
When we give pilot, we should take care of the total specifications. After approval of the pilot
batch the bulk supplies to be decided at least 3 to 4 batches to ensure that the process in set at our
end After satisfactory reports of bulk supplies of 3 to 4 batches It is handed over to production

The pattern layout drawing should be recorded offer establishing the bulk production The datas
like box weight, casting weight, number of putters piece weight, gross yield etc. Should be
recorded. The identification of the match plate codes should be clearly painted in the match plate.
After the tooling/ pattern is done properly with a right mothering taking care of the above
parameters, it solver lot of recurring defects/ rejections. There should not be any patching of the
patterns/running system by m. seal frequently as being done now. There should be 100% clarity
on all the above points mentioned the basic process and to deviate the established systems All the
people of all levels working in the department should be thoroughly educated to adopt the above
mentioned procedures/ systems There should be serious focus on the 3-d modeling. There should
be adequate load to everyone working in the respective section attached to the pattern shop there
should be a clear log on all the work done by each and every section of pattern shop giving clear
details of the work done by ever one to the management. A separate attachment is given
describing various defects that can occur due to improper pattern practice and its causes and
remedies. WE SHOULD WORK WITH O DEFECTCONCEPT

MELTING
To learn design and construction of the furnaces to learn principles of the operations of the
furnace to learn-what is the metal SG and GREY to learn the properties of the metal like
chemistry microstructure, Hardness, Tensile strength etc.

To learn how to prepare the metal for a required properties to learn what are the charges of
materials and alloys added in the furnace the achieve the required specifications of the metal To
know and check temperature of liquid metal tapping and pouring to learn what is the treatment of
SG and how the treatment is carried out under what conditions and procedures to learn the
inoculation procedure to learn the pouring practice and duration of the pouring to learn the
preparation of ladles and under what conditions, the ladles are to be used to learn the remedial
actions/solutions for the identified defects to learn the remedial actions/solution for the identified
defects. To learn how to improve the entire activities of the department keeping in mind the
improvement in productivity reduction in cost and improving the quality a separate attachment is
given describing various defects that can occur due to improper melting and pouring practice and
its causes and remedies

MOULDING

To learn the construction of molding machines and principles of working of the machines
to learn construction of the boxes and the tooling like pins, bushes clamps etc. anditsfunctional
importance and operation. To learn jolting and squeezing timing and its impact on quality of the
castings. To look for the pattern and gating system conditions before taking up for production
/core stock Check before for items taken up for production for whether chill or frame required
To verify and item taken up for production is an established item and see the past history of the

jobs in respect of rejection To learn and identify the defects due to the molding process To take
corrective actions and permanent solutions to avoid recurring defects related to molding separate
attachment is given describing various defects that can occur due to improper molding practice
and its causes and remedies

SANDPLANT
To learn the design and construction of sand mixers and the allied equipments To learn
the condition of the mixers and whether the scrapers are in good condition and there is no
deposits of sand in the side of the wall and bottom of the mixers to maintain the mixers always
in good condition by proper cleaning and maintenance To learn about the additives and its
properties and the purpose for which the additives and added to the sand To learn the procedures
and process of mixing (sand preparation)
To learn the necessary preparation of sand and the sand properties to be maintained while
preparing To learn and ensure all the tests required in clone on line while preparation of the sand
There should be continuous thinking and improving on quality of the sand keeping in mind the
defects/rejections are n/l due to sand properties. A separate attachment is given describing
various defects that can occur due to improper sand mixing practice and its causes and remedies
CORESHOP
To learn the working of the core sand mixers to learn the various process like, co2, no
bake, oil sand, shall cores, etc., To learn what is the purpose of using a particular process for a
particular type of casting based on the size of the core and strength of the core configuration of
the core and finish of the core surface in the castings. To learn the condition of the core boxes
and to have continuous monitoring of the core boxes to avoid dimensional defects on the cores.
To learn about the additives in the core sand and the purpose of the same to suggest on the
improvement of core making process, quality of the cores to have a nil rejections on account of

cores to use effectively the imported core shooter to have cost reduction and productivity
improvement separate attachment is given describing various defects that can occus due to
improper core practice and its causes and remedies
CHAPTER 3.3
QUALITY DEPARTMENT
The company includes Quality control departments, laboratories; quality assurance
intends to continuously improve quality in the framework of quality policies of the company
aiming to bring about customer satisfaction Taking advantage of educated and experienced
people, this department investigates all the inputs and outputs of the factory including raw
materials, components and products.
Subordinate departments of quality control in aluminum alloys Steel Industrial Complex
are as follows:
Steel production quality control:
In this department, quality control technicians control the arrived scrap iron and
cooperate with the production department in steel production during the steel production process
by sampling and analyzing molten steel with the desired rate and ultimately issue the casting
license after approval of the final product. At the next stage, the produced ingot will be
controlled in terms of dimensional parameters as well as metallurgical defects (crack, mac, offal,
etc.) to be receipted and delivered to the storage after the approval.
Any product that does not conform to the type of the desired steel, will be classified into
other steel categories if it could fall into them, otherwise, it will be delivered to the scrap
warehouse as the waste ingot.
Quality control of the arrived parts:
All parts produced or repaired outside the factory, will be inspected by the quality control
department after arriving at the factory and before getting receipted in terms of compliance with
the desired demands which have been informed by the applicant department in writing to be
delivered to the applicant department after confirmation. In case of any non-compliance, the part
shall be returned to the manufacturer to remove the non-compliance.

QUALITY POLICY

Maximum overall plant effectiveness by aiming at;

Zero break down, zero defects ad zero accident

Continuously improving machines and methods to maximize overall efficiency and

quality

Customer satisfaction by timely providing product of desired quality.

Total employees participation and team work

Environment policy

The sufficient lighting system is arranged with out any shadow to enable the workers to
work efficient during night shifts

The specter meter is housed in an air conditioned humidity controlled room to meet its
hot working condition

Fire exiting wishers and fire buckets filled with sand are placed in areas of work where
vulnerable for fire to meet any fire accident

LABORATORY AND QUALITY CONTROL:To understand dearly the specifications in respect of the chemistry. Physical properties,
metallurgical properties and Dimensional aspects and the materials used for testing to learn the
method and process adopted in the laboratory for testing chemistry wet analysis and Spector .To
learn the testing procedures adopted for metallurgical properties and physical properties.
To learn the operations of the equipment and the instruments used for testing the above
properties to learn the reading of drawing in respect of dimensions. To learn what is a sand, its
properties, its influence on the casting defects and finish to learn the equipments used for sand
testing To earn the procedures of testing of sand for various properties to suggest remedial
measures to cure the defects on permanent basis to ensure the calibration of the instruments/
equipment for its rightness to over check and counter-check the consistency of the individuals
capabilities of various parameters said above this should be recorded on regular basis for
traceability purposes to learn and understand the process capabilities for its consistencies and
adopt accordingly
To ensure an in built quality in the various manufacturing activities to work towards o
defect targets both in house and customer end, to have a correct and immediate feedback to the
customer complaints to create 100% customer confidence and satisfaction by introducing the
various checks particularly related to our type of products on case to case basis To introduce the
best and full proof process check right from the in-coming material stage to out-going product
stage to ensure for a product as per the customer specifications No deviations is entertained
without the customer acceptance To have a thorough recording system for a better feedback to
achieve continuous improvement on the product To maintain the systems as required for Iso and
other approval

CHAPTER 3.4
FINANCE DEPARTMENT
The Finance Department work closely with the management act as professional advice
and control service for the financial activities of the Company, Departmental Meetings are held
regularly, in which work related matters are discussed. Additionally the detail work in progress
of each section in monitored through meetings between the Senior Staff and the juniors for which
they are responsible.
The Finance Department helps the other departments to meet their service objectives by
acquiring services and goods, allocating the companys financial resources, processing financial
transactions, and providing information and analysis as a basis for decision making.
The Mission of the department is

The Finance Department is committed to providing the highest levels of financial

services to the Company.

This includes insuring that proper controls and procedures are in place to manage
properly.

We constantly evaluate and balance the types and levels of services provided

Efficiencies are developed through staff training opportunities, teamwork and by

providing employees with a challenging and fulfilling work environment

Objectives:-The broad objectives of the Finance Department are to provide a timely, efficient
and cost effective service:

Continuing to improve the level of operational efficiency of the Finance Department.

Maintaining effective working relationships with the rest of the Company.

Continuing to improve the quality of financial information supplied to departments.

Meeting the Reporting deadlines set by GAC

Ensuring wide compliance with the Financial Regulations.

FINANCIAL POSITION OF THE COMPANY

Audited

(Rs in lakhs)
Audited

Audited

31.03.11

31.03.11

31.03.11

1.

Working capital

641.00

741.00

941.00

Tangible networth

689.00

875.00

1080.00

Term loan

74.86

58.50

35.02

Current assets

1232.33

2212.42

1918.48

Current liabilities

1142.49

1931.42

1582.22

WORKING RESULTS
Particulars

Audited

Audited

Audited

31.03.11

31.03.12

31.03.13

Sales

2249.27

4003.65

4218.38

Gross profit

516.85

165.70

216.64

Depreciation

124.02

124.78

150.27

Interest

66.59

118.55

108.22

Operating profit

198.27

290.48

366.91

5
6

Taxes

9.72

41.54

50.98

Net Profit

84.19

135.87

174.32

STRUCTURE OF FINANCIAL DEPARTMENT

CHAPTER 3.5
MARKETING DEPARTMENT
Marketing is the management of process involved in identifying, anticipating and
satisfying consumer requirements profitably.
Marketing is the process by which companies create customer interest in products or
services. It generates the strategy that underlies sales techniques, business communication, and

business development. It is an integrated process through which companies build strong

customer relationships and create value for their customers and for themselves.
FEATURES OF MARKETING:

Marketing is aimed at finding out consumer needs and meeting these needs.

Marketing must consider profit as its main objective.

Marketing is ongoing all the time. The marketing process has no start or end

Businesses must be prepared to respond to the consumer reactions and changes all the
time

STRUCTURE OF MARKETING DEPARTMENT

IMPORTANCE OF MARKETING:

Marketing is playing a more and more important role in the success of a business. It can
be said that no marketing means any business.

There are generally some key factors which have made marketing so important for
businesses today.

THE FACTORS CAN BE SEEN AS IN THE FOLLOWING TABLE:

Factors
1. Economic

growth

2.

Fashion

Explain How
Economic growth leads to an increase of consumers incomes. So demand
for products and services will be increased. Through marketing, businesses
can promote their new products and services
Considerable changes in fashion and consumer taste force businesses to
produce more new products and services. Marketing makes it possible for
businesses to reach these changing customers

3. Technology

New technology has helped the business to create new or high quality
products. It is marketing that can make customers be aware of these new
products.

4. Competition

Facing more and fiercer competition, businesses must rely on marketing

strategy to win in the marketplace.

CHAPTER 3.6
HUMAN RESOURCE DEPARTMENT
A typical Human Resource Department is carries out the following functions:
MANPOWER PLANNING
It involves the planning for the future and finding out how many employees will be
needed in the future by the business and what types of skills should they possess.
It depends on the following factors

The number of people leaving the job

The projected growth in sales of the business

Technological changes

Productivity level of the workers

JOB ANALYSIS AND JOB DESCRIPTION

HR Department is also involved in designing the Job analysis and Job description for the
prospective vacancies. A job analysis is the process used to collect information about the duties,
responsibilities, necessary skills, outcomes, and work environment of a particular job.
Job descriptions are written statements that describe the:

duties,

responsibilities,

most important contributions and outcomes needed from a position,

required qualifications of candidates, and

reporting relationship and co-workers of a particular job.

DETERMINING WAGES AND SALARIES

HR Department is also involved in conducting market surveys and determining the wages
and salaries for different position in an organization. These decision may be taken in consultation
with top management and the Finance department.
RECRUITMENT AND SELECTION
One of the most important jobs HR department is to recruit the best people for the
organization. This is of crucial importance as the success of any organization depend on the
quality of its workforce.
PERFORMANCE APPRASIAL
Once the employees are recruited , the HR Department has to review their performance
on a regular basis through proper performance appraisals.
Performance appraisal is the process of obtaining, analyzing and recording information
about the relative worth of an employee. The focus of the performance appraisal is measuring
and improving the actual performance of the employee and also the future potential of the
employee. Its aim is to measure what an employee does. On the basis of performance appraisal
the HR Department will set up an action plan for each employee. If the employees needs any
training then he provided that.
TRAINING AND DEVELOPMENT

HR department is constantly keeping a watch over the employees of the organisation. In

order to improve the efficiency level of the employees they have go undergo regular trainings
and development programmes. All trainings and development needs are carried out by this
department. Training might include on the job or off the job training.
EMPLOYEE WELFARE AND MOTIVATION
Happy employees mean a healthy organization. HR Department conducts various
employee welfare activities which might include employees get together, annual staff parties etc.
HR department also reviews organizational policies and its impact on the motivation of the
employees.
ADDRESSING EMPLOYEES GRIEVANCES
HR department is the link between the workers and the management. Employees
grievances related work environment are usually entertained and resolved by the HR
Department.
LABOUR MANAGEMENT RELATIONS
For the smooth operation of any organization, it is crucial to have good labour
management relations. HR department has to ensure that these relations are cordial. In case of
any labour-management conflict the HR Department will play a vital role in bringing both
management parties to the negotiation table and resolving the issue.
IMPLEMENTING ORGANIZATIONAL POLICIES
HR Department has to coordinate with line manager and see that the organizational
policies are being implemented in a proper manner. Disciplinary action can be initiated against
employees who are not following organizational rules and regulations. All these actions are
conceived and implemented by the HR department.
DISMISSAL AND REDUNDANCY
HR Department has to take firm actions against employees who are not following the
organizational code of conduct, rules and regulations. This can result in the dismissal of the
employee.

Sometimes, an organization may no more require the services of an employee. The

employee may be made redundant. HR Department has to see that organizational and
government regulations are being followed in this process
THE ROLE OF HRM
Keep in mind that many functions of HRM are also tasks other department managers
perform, which is what makes this information important, despite the career path taken. Most
experts agree on seven main roles that HRM plays in organizations. These are described in the
following sections.
DEVELOPMENT OF WORKPLACE POLICIES
Every organization has policies to ensure fairness and continuity within the organization.
One of the jobs of HRM is to develop the verbiage surrounding these policies. In the
development of policies, HRM, management, and executives are involved in the process. For
example, the HRM professional will likely recognize the need for a policy or a change of policy,
seek opinions on the policy, write the policy, and then communicate that policy to employees. It
is the key to note here that HR departments do not and cannot work alone. Everything they do
needs to involve all other departments in the organization. Some examples of workplace policies
might be the following:

Discipline process policy

Vacation time policy

Dress code

Ethics policy

Internet usage policy

COMPENSATION AND BENEFITS ADMINISTRATION

HRM professionals need to determine that compensation is fair, meets industry standards,
and is high enough to entice people to work for the organization. Compensation includes
anything the employee receives for his or her work. In addition, HRM professionals need to

make sure the pay is comparable to what other people performing similar jobs are being paid.
This involves setting up pay systems that take into consideration the number of years with the
organization, years of experience, education, and similar aspects. Examples of employee
compensation include the following:

Pay

Health benefits

401(k) (retirement plans)

Stock purchase plans

Vacation time

Sick leave

Bonuses

Tuition reimbursement

RETENTION
Retention involves keeping and motivating employees to stay with the organization.
Compensation is a major factor in employee retention, but there are other factors as well. Ninety
percent of employees leave a company for the following reasons:

Issues around the job they are performing

Challenges with their manager

Poor fit with organizational culture

Poor workplace environment

Despite this, 90 percent of managers think employees leave as a result of pay. [2] As a result,
managers often try to change their compensation packages to keep people from leaving, when
compensation isnt the reason they are leaving at all. Strategies to retain the best employees
based on these four factors.

TRAINING AND DEVELOPMENT

Once we have spent the time to hire new employees, we want to make sure they not only
are trained to do the job but also continue to grow and develop new skills in their job. This
results in higher productivity for the organization. Training is also a key component in employee
motivation. Employees who feel they are developing their skills tend to be happier in their jobs,
which results in increased employee retention. Examples of training programs might include the
following:

Job skills training, such as how to run a particular computer program

Training on communication

Team-building activities

Policy and legal training, such as sexual harassment training and ethics training

TRAINING EFFECTIVENESS EVALUATION

The HOD personnel evaluate the effectiveness of the training through the performance
monitoring of the employees concerned. This is recorded in the training evaluation report.On the
job training skill imparting training
The concerned HODs evaluate there training programs after at least two months of the
completion of the training. This is recorded in training evaluation report
Through awareness training programs it is ensured that all the employees are aware of the
relevance and importance of their activities and how they contribute the achievement of the
quality objective of the organization

EMPLOYEES MOTIVATION AN EMPOWERMENT.

Suggestions review committee is set up under the leadership of director, comprising all
HODs and the operators from each and every department suggestions adjudges as the best are
rewarded to motivate the employee to achieve quality objective in periodical review of
suggestions and to create on environment to promote innovation

CONCLUSION:
The training programs under gone in the company UNICAST ALLOYS PRIVATE
LIMITED helps to know about the organizational structure and how it works. It was a good
experience to me and I gained a lot of knowledge and exposure about the industrial activities and
administrations performed in the company. Through this study it was found that the UNICAST
ALLOYS PRIVATE LIMITED has a predominant role in India. Yet, if the company adopts some
more different strategies to satisfy and motivate their employees accordingly to the current
trends, then this will pave the ways for a greater proportion of growth and development of the
organization in future period.

I learnt about Factories Act, The Maternity Benefit Act, The Payment of Wages Act and
few other acts. And also the concepts of selection and recruitment process, Training methods,
Labour welfare in HR department. I could understand the concepts of Bill of Materials,
Inventory, Stores management and Quality circles in Production department. The concepts of
market segmentation, sales promotion activities and Information system concepts in an industry
were understood practically.

BIBLIOGRAPHY
1) N.P Agarwal & S.K. Mangal (1998) reading in finanace management Print well

publishers,vol.1,P.No:140-176
2) Wayne F Cascio, (2011) managing human resources MC Graw Hill

publishers,P.No:58-93
3) Beckhard, Richard (1969) organisation development strategies and models MC Graw

Hill Publishers,P.No:135-152

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