Organization Study of Adishakthi Iron Castings PVT - LTD Inplant Training 2015

Adishakthi Iron Castings Pvt.
Ltd
CHAPTER - 1
INTRODUCTION
1.0 BACKGROUND OF THE STUDY
1.1 OBJECTIVES OF THE STUDY
1.2 SCOPE OF THE STUDY
1.3 SOURCES OF DATA
1.4 LIMITATIONS OF THE STUDY
1.5 CHAPTER SCHEME
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Adishakthi Iron Castings Pvt.Ltd
INTRODUCTION
1.0 BACKGROUND OF THE STUDY
This study is concerned to the Organization Study on Adhishakthi Iron
Castings. The foundry has full- fledged facility with Machine Moulding,
Material Handling and Pouring. The organization has more than 80 employees.
Oraganization is set up by Vision, Mission, Policies, Rules and Regulation.
Considering on human behavior plays important role in current organization
management process. Organization study focuses on behavior issues beyond
working environment in organization.
The internship study is helped for me to know about the all procedure of the
Organization. By doing this study, I learned easily about organization that may
be Human Resource, Production, Marketing and Finance department.
1.1 OBJECTIVES OF THE STUDY
The Project work is conducted and analyzed to fulfill the list of
objectives can be told as follows;
To study about vision, mission, goals and strategy of the organization.
To know the structure of the organization.
To get the practical experience of working in organization.
To examine the complete comprehensively evaluation through SWOT
analysis in the particular organization.
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1.2 SCOPE OF THE STUDY

The scope of the study is restricted to ADHISHAKTHI CASTINGS
PVT LTD, MACHENAHALLI for the period of 15days from Aug 28 th to Sep
13th 2013. The study focused on the HR department, Production department,
Purchase department, Marketing department, Development department,
Purchase department and Quality control of the organization.
1.3 SOURCES OF DATA
For the purpose of study data has been collected from the different
sources.
Primary Data
In this study the primary data is collected directly from the administrator of the
company and observation from the foundry.
Secondary Data
Secondary data is collected from Records, Annual Reports, and Information
sheet.
1.4 LIMITATIONS OF THE STUDY
The time provided for the study was only 15 days.
Company was not interested to give more information because company
not discloses any information due competition between other the
company.
1.5 CHAPTER SCHEME
Chapter 1: Introduction
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This chapter deals with objective, scope of the study, sources of data collection
and limitations of the study and chapter scheme.
Chapter 2: Industry Profile
This chapter deals with General Introduction, History of Castings, and Profile
of the Castings, Global Scenario of Castings, Indian Scenario of Castings,
Present Status of the Industry and Future outlook of the Company.
Chapter 3: Company Profile
This chapter deals with the General Introduction of the Company, Details of the
company, Nature of Business Carried, Vision, Mission and Quality Policy,
Ownership Pattern, Area of Operation, Product Profile, Competitors,
Infrastructure Facilities and Awards.
Chapter 4
Functional Departments
This chapter includes departmental structure, and departmental functions of the
company.
Chapter 5: McKinneys 7s Model
This chapter deals with the Introduction, Mckineys 7s frame work,
McKinneys 7s model of Organizational Study, Structure of the Functional
department, Skills, Style, Strategy, Systems, Staff and Shared values.
Chapter 6: SWOT analysis
This chapter deals with the General Introduction, Organization Strength,
Weakness, Opportunities and Threats.
Chapter 7: Findings, Suggestions and Conclusion
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CHAPTER - 2
INDUSTRY PROFILE
2.0 GENERAL INTRODUCTION
2.1 HISTORY OF CASTINGS
2.2 PROFILE OF THE CASTING
2.3 GLOBAL SCENARIO OF CASTINGS
2.4 INDIAN SCENARIO OF CASTINGS
2.5 PRESENT STATUS OF THE INDUSTRY
2.6 FUTURE OUTLOOK OF THE COMPANY
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INDUSTRY PROFILE
There are 6500 foundry units in India, out of which 350 units are in
Karnataka, which constitutes only 5 percent of total foundries in India, having
an installed capacity of approximately 3 million tons per annum. Karnatakas
production capacity of castings is 0.4 million tones.
The majority (Nearly 95 percent) of the foundry units in India falls under
the category of Small Scale Industry. The foundry industry is an important
employment provider and provides direct employment to about half a million
people.
A peculiarity of the foundry industry in India is its geographical clustering.
Some of the major foundry clusters in the country are shown in the map.
Among 6500 units out of which 80 percent can be classified as Small scale
units and 10 percent each as Medium and Large scale units.
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The various types of Castings which are produced are Ferrous, Nonferrous, Aluminum alloy, Graded cast iron, Ductile iron and Steel etc, for
application in Automobiles, Pumps compressors and Valves, and Diesel engines
for Special application. However, grey iron castings are the major share
approximately 70 percent of total castings produced.
2.1 HISTORY OF CASTINGS
Human being has first encountered with metals back in 5000-6000 B.C when
people were processing natural gold/silver/copper by hand beating. Thus, the
very first processing means of metals was forging. The prideful Japanese
Sword could be said as the most advanced forging technology in the world.
The start of casting technology which forms casting by pouring melted metal
into a mold solidifying it, origins back to around 3,600 B.C at Mesopotamia. It
is thought that peoples first encountering with iron was realized by meteorite.
Meteorite can be forged since it contains lots of nickel. A pattern called
Widmannstatten structure which was formed by solidifying at extra ordinarily
slow speed could be observed on meteorite. In Egypt, an iron necklace made
from meteorite of around 3000BC was found.
The casting technology, which produces product by pouring melted metal into a
mould, was first developed in China, approximately 7 th century B.C. It is
generally thought that the Chinese Bronze ware technology achieved an
extremely high temperature by utilizing bellows and from this line of
technology, it is assumed that pig iron was developed by melted iron with high
carbon content.
An iron with high carbon content has low melting temperature of about 1150
degree cc as well as good flow property and these have enable the casting of
iron. The components of cast iron of around 4 th century B.C in China were
about C2, 5-4.3 percent, Si0, 1-0.2 percent, Mno, 01-0.2 percent, Po 1-0.5
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percent, So, 01-0.1 percent. Due to the low Si, this sort of structure is called as
Chill which does not have graphite and has hard and brittle characteristics. This
brittle characteristic probably led to a factor for iron casting technology not
being introduced to Europe until 14th century. It was not until 1779, when the
Iron Bridge was constructed in England, that cast iron with non-chill structure
and high Si content was found.
From 7th century B.C to 18th century at the time of Industrial Revolution, cast
iron was made hard and brittle. Thus, no wonder iron with stickiness which
could be hardened by hardening used for forging products was more valued.
However, by increasing Si content, the property of cast iron has shifted largely.
This non-chill cast iron came to become an important material to support the
industry. All sorts of casting products as bridge and cannon begun to appear an
manufacturing line.
For modern cast iron, there are two significant developments. One of it is the
manufacturing method of Spheroidal graphite cast iron based on inoculation
technology which was developed by G.F Meehan and O. Smalley in 1940s. By
this technology, it became possible to produce high strength cast iron with
tensile strength more than 300N/mm2 stability. The second is Spheroidal
graphite cast iron which was discovered by Morrogh in England in 1947. By
this discovery, the manufacturing of cast iron with even higher strength of more
800N/mm2 realized.
By 1945 when Japan was about to experience the end of war, its cast iron
technology was already greatly advanced. Japan took in the technology of
postwar foreign countries, improved it and established the highest level of
casting technology in the world. Further from here on, the Japanese casting
technology grew in with the rapid progress in automobile industry
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2.2 PROFILE OF THE CASTING
Casting is the process of the melting metal and pouring it into a cavity that has
been molded on a pattern into a desired shape, then the metal is allowed to cool
and solidified. The solidified metal is called Casting. Usually casting is
manufactured in a commercial set up called Foundry.Founding, or metal
casting, involves the pouring of molten metal into the hollow inside of a heatresistant mould which is the outside or negative shape of the pattern of the
desired metal object. The mould may contain a core to determine the
dimensions of any internal cavity in the final casting. Foundry work comprises:
Making a pattern of the desired article
Making the mould and cores and assembling the mould
Melting and refining the metal
Pouring the metal into the mould
Cooling the metal casting
Removing the mould and core from the metal casting
Removing extra metal from the finished casting.
The basic principles of foundry technology have changed little in
thousands of years. However, processes have become more mechanized and
automatic. Wooden patterns have been replaced by metal and plastic, new
substances have been developed for producing cores and moulds, and a wide
range of alloys are used. The most prominent foundry process is sand moldings
of iron.
Iron, steel, brass and bronze are traditional cast metals. The largest sector of the
foundry industry produces grey and ductile iron castings. Gray iron foundries
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use iron or pig iron (new ingots) to make standard iron castings. Ductile iron
foundries add magnesium, cerium or other additives (often called ladle
additives) to the ladles of molten metal before pouring to make nodular or
malleable iron castings. The different additives have little impact on workplace
exposures. Steel and malleable iron make up the balance of the ferrous foundry
industrial sector. The major customers of the largest ferrous foundries are the
auto, construction and agricultural implement industries. Iron foundry
employment has decreased as engine blocks become smaller and can be poured
in a single mould, and as aluminium is substituted for cast iron. Non-ferrous
foundries, especially aluminium foundry and die-cast operations, have heavy
employment. Brass foundries, both free standing and those producing for the
plumbing equipment industry are a shrinking sector which, however, remains
important from an occupational health perspective. In recent years, titanium,
chromium, nickel and magnesium, and even more toxic metals such as
beryllium, cadmium and thorium, are used in foundry products.
Although the metal founding industry may be assumed to start by remelting
solid material in the form of metal ingots or pigs, the iron and steel industry in
the large units may be so integrated that the division is less obvious. For
instance, the merchant blast furnace may turn all its output into pig iron, but in
an integrated plant some iron may be used to produce castings, thus taking part
in the foundry process, and the blast furnace iron may be taken molten to be
turned into steel, where the same thing can occur. There is in fact a separate
section of the steel trade known for this reason as ingot moulding. In the
normal iron foundry, the remelting of pig iron is also a refining process. In the
non-ferrous foundries the process of melting may require the addition of metals
and other substances, and thus constitutes an alloying process.
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Moulds made from silica sand bound with clay predominate in the iron foundry
sector. Cores traditionally produced by baking silica sand bound with vegetable
oils or natural sugars have been substantially replaced. Modern founding
technology has developed new techniques to produce moulds and core.
2.3 GLOBAL SCENARIO OF CASTINGS
Competition has brought in many changes in the way of foundries used to
function earlier. These days the markets are demanding low cost, good quality
products with on time delivery with intense competition from other nations like
China, its more like the survival of the Fittest theory these days. Now,
foundries should start looking for export markets and explore the opportunities,
with Europe and US.
The Global production of ferrous and non-ferrous castings is estimated at 80
Million tons, value exceeding US dollar 100 Billion and is expected to multiply
in the coming years. Advanced countries are marked changes in the business
climate and rise in production costs. As a result they are opting for large scale
outsourcing to countries such as China, India, Brazil, Spain, Mexico and
countries of the erstwhile eastern block. The countries are now adopting latest
manufacturing techniques in order to meet the needs of the advanced countries.
Foundries have to update themselves in terms of technology, should become
more customers sensitive and oriented, cut down upon the shipping delays,
focuses on quality and still be low on cost. Accurate knowledge about the
sensitivity of customer needs is a main growth factor.
To sustain continuous growth in every aspects, the foundry industry has to
embrace change; Change to technological innovation, Change to improved
manufacturing practices to enhance cost effectiveness and Change to upgrade
human resource skill. All these are crucial in gaining a competitive edge.
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Worldwide Casting Shipments continued to increase from 2005, despite a slight
drop in the total number of metal casting facilities, according to the 36 nations
participating in MODERN CASTINGS 40th annual census of World Casting
Production.
Total global tonnage showed a 7.5 percent increase, based on the most
recent data available for all participants. Nine of the worlds top-ten casting
producers improved their totals for the year.
World Production Leaders
China
U.S
Russia
Japan
India
Germany
Brazil
Italy
France
Korea
2.4 INDIAN SCENARIO OF CASTINGS
India has 4,600 foundry units, 80 per cent of them in the SME sector. Annual
production is 7.4 million tons, approximately valued at $8 billion. The sector
employs 0.5 million people directly and an additional 1.5 million people
indirectly.
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The industry is making a contribution of Rs 7,000 per ton produced to the
national exchequer by way of excise and other levies. The sector exports
touched $215 million in 2011/12. The manufacturing units are located in 12
identified and recognised clusters and in 20 other clusters.
2.5 PRESENT STATUS OF THE INDUSTRY
The Casting production is considered of the main factors influencing the
development of world economy. Actual capacity of the worlds casting
production, which is higher than 91 million metric tons per year(2010), is
strongly diversified. The last decade brought significant changes in the world
map of the greatest casting producers. Globalization and transformation of
economic systems is reflected by variations of foundry production in different
countries.
A casting production in the last 3 years has had an increasing tendency. It is
shown by the fact, that the world casting production increased by 13.7 percent
from 2009 to 2012. However, the total casting production being 91.4 million
tons in 2012 .
The leader in the casting production from many years in China, which
produced 43 percent of castings in 2012. The second place, however with the
production 4 times smaller than China, belongs to India, which share is 10
percent due to 22 percent increase in relation to 2011. The highest fraction
constitute Gray iron castings, which tonnage in 2012 was 44.1 million tons, it
means above 48 percent. Castings of the Spheroial cast iron constituted nearly
25 percent and increased by 1 percent inrelation to 2011. Whereas the share of
steel casts equaled approximately 11 percent and was slowly decreasing during
the year 2012, in a similar fashion as the non-ferrous metals castings
(approximately 11 percent of the total world casting production). The share of
magnesium, zinc, copper and other non-ferrous metals was very small.
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The total number of foundry plants in the world amounts to more than
48000, out of which nearly 55 percent are located in China. The second place
in respect of the foundry plants number belongs to India, where there is more
than 9 percent foundry plants. The most of them are producing iron castings
(50percent). An average annual production of one foundry plant equals in 1,500
tons, in India approximately 2,000 tons, while in Japan nearly 3,000 tons, in the
USA 4,000 tons. This indicates that the foundry industry is highly fragmented
in the first two countries, which at the same time are the largest casting
producers.
The foundry industry is predominantly still an SME industry, with 80
percent of companies employing less than 250 people. The foundry production
which is now
2.6 FUTURE OUTLOOK OF THE COMPANY
Adhishakti Castings Foundry is very well developed and established foundry in
industry. They have created their good brand image in market. Now there is
scope for expanding their business. They can shift from their current manpower
of 80 to a higher level. Currently Adhishakthi Castings foundry is receiving big
orders from customers. The foundry has modern machines setup in factory. For
achieving improvement in the metal casting process they are focusing on
Adopting proper plan of actions on right time
Preventing the sand through recycling
Capabilities to meet future needs and expectations of customers.
Increase the revenue from overseas business segment sustainability
To satisfy employee needs
To improve infrastructural facilities.
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CHAPTER -3
COMPANY PROFILE
3.1 DETAILS OF THE COMPANY
3.2 NATURE OF BUSINESS CARRIED
3.3 VISION, MISSION AND QUALITY POLICY
3.4 OWNERSHIP PATTERN
3.5 AREA OF OPERATION
3.6 PRODUCT PROFILE
3.7 ESTEEMED CUSTOMERS
3.8 COMPETITORS
3.9 INFRASTRUCTURE FACILITIES
3.10 AWARDS
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COMPANY PROFILE
Adhishakthi Castings Private Ltd., is a mechanized modern foundry which is
installed keeping in mind of latest technology available to manufacture and
supply fully Mechanized SG Iron, Cast Iron and Weir Resistance Cast Iron. The
company is situated in Machenahalli.
The foundry started the production on 9-January-2012. The foundry is going to
cater to various manufacture sectors like Automobiles, Earth moving, Pumps
and Valves and Engineering Castings.
The Company is having a well experience development engineers along with
the versatile pattern shop with molding, inspection facilities.
Further the foundry has been very thoughfully established and committed to
have a high degree of self-sufficency in view to ensure highest level of highest
level of service is provided keeping in mind the requirements of the customers
by meeting both quality and delivery with best budgetary price.
3.1 DETAILS OF THE COMPANY
Name of the Company
Adhishakthi Castings Pvt.Ltd.,
Address
Plot No. 37-B,

Nidige Industrial Area,
KIADB Industrial Estate,
Machenahalli,
Shimoga-577222,
Karnataka, India
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Telephone No.
+91 8182 246031
Fax No.
+91 8182 246032
E-mail address
[email protected]
Nature of the Ownership
Private Limited Company
Year of Incorporation
2011
Contact Person Name
M. Veerashekar
Contact Person Mobile
+91 90082 61633
3.2 NATURE OF BUSINESS CARRIED

The Company is in the manufacturing of SG iron Casting, Iron Castings
and Weir Resistance Cast Iron Castings. Some of the castings go directly for
assembly but some Castings go for further finishing. Company caters to various
engineering industries that are in the manufacturer of air compressors, diesel
engines or generators earth moving, Equipments hydraulic cylinders, Actuators,
pumps values.
3.3 VISION, MISSION AND QUALITY POLICY
Vision
To be a Market Leader with a Supreme Standard of Quality and
Customer Satisfaction.
Mission
To Proudly Create Value
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Quality Policy
We at ADHISHAKTHI CASTINGS PVT. LTD are determines customer needs
and expectation and converts much committed ,
To strive continually to achieve highest customer satisfaction.
To deliver quality castings on-time.
To work on optimizing the process and system to reduce the cost of
manufacture.
To continual improvement in the working system and skills by
providing knowledge to all through employer training.
3.4 OWNERSHIP PATTERN
The foundry is managed by two business bar on Mr. S.S.Jyothi Prakash, Mr.
Manjunath.N.G. and promoted by highly qualified professionals with rich and
varied experience gained in reputed companies by Technical Director Mr.
Veerashekar who has more than 22 years of rich casting foundry experience.
3.5 AREA OF OPERATION
ADHISHAKTHI PVT LTD., exports their casting products to Punjab,
Mumbai, Hyderabad, Bangalore, Chennai, Koimbatthore, and Mysore.
3.6 PRODUCT PROFILE
Company have been catering to various engineering in to the manufacture of
compressors, diesel engines/generation, earth moving equipments, hydraulic
cylinders & pumps, fluid pumps, valves and automobile, and are one of the
leading suppliers of casting and components for hydraulic applications amongst
a host of other products. They produce a product such as.,
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Fly Wheel
Weight: 40 kgs to 360 kgs
Grade: FG300 with high
They are offering a wide range of Fly Wheel. Our

range of products are manufactured using Superior
Quality Steels. These wheel are of round shape with fine bearing rod in the
center which enables easy fixation. These fly wheel assemblies are applied in
varied industry verticals. These Fly Wheels are used in Diesel Cylinder Block.
Silicon Molly & Chromium
Main Bearing Manifold
Weight: 15.29 kgs
Grade: SG 400/12
To maintain over a good reputation and client fulfillment. They are
efficiently engrossed in offering a broad spectrum of
SG Iron Casting. Outstanding to its salient features such
as remarkable finish and corrosion resistance nature.
Main Bearing Manifold supports the bearing in cylinder
block.
Exhaust Manifold
Weight: min-5 to max-2
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Grade: SG40/12 & FG 260fluctuate energy.
It is used diesel engine to Hydraulic

Application. These Hydraulic Application are designed
for Superior Quality of raw material that provide them
Superior
flexibility,
Pressure
resistance,
Longer
performance life and durability.

Exhaust Manifold
Weight: min-5 kgs to max-20 kgs
Grade: SG 40/12 & FG260
They are the Supplier and Exporter of
Exhaust Manifold. These Exhaust Manifolds are
fabricates by using well-tested material and
thoroughly tested on several parameters to
ensure their high quality. These are efficient
equipment mainly used in Diesel Engine
Generator and Earth moving Equipments.
Earth Moving Equipments
F.D. Case, Grade: 500/7
Weight: 157 kgs Used as a final cover for earth moving equipments
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They offer quality Spheroidal Graphite Castings

that are manufactured as per drawings, specifications, measurement and
material details provided by the clients. They are widely used in various
industries like earth moving equipments, automobiles, engineering, electrical
equipments.
3.7 ESTEEMED CUSTOMERS
M/s, Bharat Fritz Werner Ltd.
M/s, Makino India Pvt Ltd.
M/s, GCI Exports Pvt Ltd.
M/s, Kennametal India Ltd.
M/s, Godrej & Boyce Mfg Ltd.
M/s, Tool Grinding Technologies Pvt Ltd.
M/s, SLN Industrial Solutions.
M/s, Titan Engineering.
M/s, High Vacuum Technologies Pvt Ltd.
M/s. BOSCH
3.8 COMPETITORS
Now a days as all Companies are facing cut throat competition. Obviously,
Adhishakthi Castings also faces competition from various companies. The
following are the major competitors for Adhishakthi Casting Private Ltd.,
Malnad Industry Pvt Ltd., Shimoga
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Shanthala Spherocast Pvt Ltd., Shimoga
Vijay Technnocrats Pvt Ltd., Shimoga
Menon and Menon, Pune
3.9 INFRASTRUCTURE FACILITIES
Building
Available Area = 8.50 acres and

Factor Working Area = 2500 square meters
Machineries
1. Induction Furnance
2. 5000kgs EOT Overhead Crane
3. 68 Double door shot blasting Machine
ARPA 300 Moulding Machine with Automatic
Sand Plant(DISA)
4. In
laboratory,
26
elements
Spectro
Machine
Man Power
80 employees working in the company
Power
KVA Diesel generation set is installed in the

company
Raw material
Raw
material
is
supported
by
Mangalore,
Bangalore, Mumbai, Hydrabad and Puna
3.10 AWARDS
Certified by ISO 9001-2008 QS Standards
The company meets the requirements of various International
Standards like ASTM, DIN.
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CHAPTER 4
FUNCTIONAL DEPARTMENT
4.1 PRODUCTION DEPARTMENT
4.2 FINANCE DEPARTMENT
4.3 HUMAN RESOURCE DEPARTMENT
4.4 MARKETING DEPARTMENT
4.6 QUALITY DEPARTMENT
4.6.0 QUALITY DEPARTMENT STRUCTURE
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FUNCTIONAL DEPARTMENT
4.1 PRODUCTION DEPARTMENT
Production department structure
Director Technical
Development
In-charge
Executive Foundry/MR
Quality
Assurance,
foundry
Maintenance In
charge
Production
Manager
Planning &
Purchase
In-charge
Dispatch
Inspector
Chemist
Supervisor
CChemiCh
emist
Draughts
Man
Pattern
Maker
Production
Supervisor
Molders
Melters
Core Makers
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As per the above structure of Production Department Managing Directors and
MR are the top level persons who control all the activities going on the
organization, he assigns to the Production Manager who have will plan for the
necessary requirements which are all needed for the production then it comes to
Production Supervision
who will make plan for preparing mouldings and
finally it comes to Moulding Operators and Melting Operator unit.

4.1.1 OBJECTIVES OF THE PRODUCTION DEPARTMENT
To produce castings by using minimum resources.
To produce quality castings.
To satisfy the customer by meeting their requirements.
4.1.2 FUNCTIONS OF THE PRODUCTION DEPARTMENT
Handling of customer complaints.
Verification of QA (quality assurance) activities.
Identifying opportunities for continual improvements and take
appropriate actions.
Identifying and implementing preventive actions as required.
Nominated as customer representative during regular production.
Defining and review of quality objectives and targets.
Ensuring appropriate training on the job for operatives.
Control of changes at production (foundry).
Validation of identified processes.
Monitoring and measurement of processes in the functional area.
Control of non- conforming products at identified stages.
Analysis of appropriate data.
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4.2 FINANCE DEPARTMENT
Finance is the lifeblood of any economic activity concerning the field of
manufacturing processed and distribution of any commodity and service.
Finance department is one of the important departments of Adhishakthi Iron
Castings Private Limited. Like every business house Adhishakthi Iron Castings
Private Limited also maintain a systematic record of day to day activities. So
that the desired information can be obtained at any time. The finance
department structure is as shown below.,
4.2.0 FINANCE DEPARTMENT STRUCTURE
Managing Director
Director Commercial
Finance Incharge
Chief accountant
Finance assistant
Accounts assistant
The above diagram clearly shows that how finance department is inter relate
from Managing director to staffs. Finance department is headed by finance
incharge, he assigns the task to assistance, and assistance assigns the work to
staffs.
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4.2.1 FUNCTIONS OF THE FINANCE DEPARTMENT

Working capital assignment
Customer receipts
All work under VAT Act
Planning of term loans
Bank payment and bank receipts
Maintenance of cash book.
Accounts reconciliation of customers and suppliers
Attending all the TDS matters
Bank reconciliation
Monthly expenses analysis
Preparation of Annual reports, Internal audit, Statutory audit, Credit
analysis
4.2.2 KINDS OF REGISTER
The various kinds of audit done in the company are:
Internal audit .
External audit.
Statutory audit (one year once).
Submission of budget for working capital and term loan.
4.3 HUMAN RESOURCE DEPARTMENT
Human resource management is the specialized branch of management
that deals with the most precious assets of an organization, namely its human
constituents; HRM refers to the planning, organizing, directing, and
coordinating the functions of procurement, development, maintenance and
integration with regard to a competent workforce.
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HRM department is divided in to 3 groups.

General administration.
Appointment and Labour loss.
Employee relation and training.
4.3.0 HR DEPARTMENT STRUCTURE
Board of Directors
Director Commercial
HR admin/Assistant
HR Officer
4.3.1 OBJECTIVES OF HRM

To maintain good relationship between employer and employee.
To recruit and select the prospective candidate for an interview and to
fill the vacancies in the concerned department.
Planning for training of employees and implementation of schemes for
the development and up gradation of the skills of employees
4.3.2 FUNCTIONS OF HRM
Attracting, screening, hiring and orienting new employees.
Explaining and enforcing management policies and procedures.
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Planning for accurate wage and salary packages.
Training and developing the employees towards attaining greater
efficiency.
4.3.3 PRACTICES OF HRM
Recruitment.
Selection.
Induction.
Training and development.
Performance appraisal.
Employee relation and training.
4.3.4 COMPANY HUMAN RESOURCE
Company has more than 80 members workers farming Adhishkthi team. Over
the year the company witnessed excellent employee and
employers
relationships, employee have been taught to appreciate team spirit and the use
safety equipment on the shop floor. Utmost importance has been placed
providing periodic training to upgrade their technical set. The management has
been providing support to employee determining their career paths. HRD has
infrastructure like training halls, computers for the training.
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4.4 MARKETING DEPARTMENT

Marketing Department receives the purchase order from customers. It has some
10 to 15 permanent customers who give regular orders. The marketing
department structure is as shown below:
4.4.0 MARKETING DEPARTMENT STRUCTURE
Technical Director
Marketing In-charge
Sales/Marketing assistant
Supervisor
4.4.1 OBJECTIVES OF THE MARKETING DEPARTMENT

To ensure 100% customer satisfaction.
On time delivery of the product.
To improve the business of the company.
4.4.2 FUNCTIONS OF THE MARKETING DEPARTMENT
To ensure strong customer base, develop new customer and to ensure customer
satisfaction.
To improve the business of the company.
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To attend quality related problems and pricing decision.
On time delivery of the product.
To prepare quotation, order follow up, scheduling, payments and
negotiation.
4.4.3 MARKETING AND TRAINING SKILLS
The marketing and training skills given to the employees are:
Technical skill.
Negotiation skill.
Pricing skill.
Communication skills.
Drawing
Marketing condition study
4.4.4 CUSTOMER SATISFACTION SURVEY
The survey done is three ways are as follows:
Internal competition for major customers, every month they give
schedule for purchase order.
Customer feedback rating.
Sending questionnaire to customer.
4.4.5 MARKET STRATEGY
The Adhishakthi Iron Castings Private Limited Companys marketing strategy
always considers the following to satisfy the customer requirement and
customer retention:
P a g e | 31

Technical competent
Quality
On time delivery
Dependability
4.4.6 MARKETING DEPARTMENT PROCESS
Customer Enquiry
Quotation
Purchase Order
Information to Development Dept.
Planning
Purchase
Production
Inspection
Dispatch
Market Department
P a g e | 32
The marketing department is handled by the two people. One is the Director of
Marketing, second is Marketing and Dispatch Head. Marketing Director took
all the authority and responsibility of production and he transfers it to
Marketing and Dispatch Head who handle the marketing department by
internet receiving mails of purchase order or by the letters from the customer.
Marketing function of the company mainly concerned with the responsibility to
identify business opportunities and generates business. The function includes
identification of new products, product promotion, contract processing and
monitory delivers to customer classification. The marketing department
enquires about purchase order and gives the quotation to customer. The
company approves the order after enquiry. After it will produce the product.
The dispatch department will send the products to the customer as per their
requirement.
4.6 QUALITY DEPARTMENT
Quality is a measure of excellence in manufacturing. Thinking of excellence in
the quality department will lead to define value proposition and facilitate
excellence in every department, which contributes to the profitable growth of
the organization. Adhishakthi Iron Castings Private Limited has adopted 6
sigma
techniques which is used for maintained and improving level of
Productivity and Quality.
P a g e | 33
4.6.0 QUALITY DEPARTMENT STRUCTURE
Technical Director
Executive Foundry/ MR
Quality Assurance Incharge
Inspection (Product
Lab/Chemist
HOD Quality Assurance,

Machine Shop
Inspection
inspection)
Incoming Material
Final Material Testing
From the above structure it is clear that Technical Director and Executive
Foundry/MR controls the quality department. They assign the work to the
Quality Assurance In-charge who is responsibility over the quality department
and he transfer the task to the Inspector will check the over all products once.
The management team of the company believes that, one of the key
factors for their success in business is total improvement of quality. It is equally
important that this is achieved at the minimum cost possible. It is the function
of quality control to ensure that these quality objectives are realized quality
control should be exercised at all key stages of processing so that variation in
the final product can be minimized, if necessary be traced back to the variation
in the raw material or from the process from which it originated. It is also
P a g e | 34

essential to keep the products under continuous observation to obtain
immediate warning of any new source of variation, such as defect in a machine.
Also for quality control to be effective it must have its own staff with clearly
defined duties and responsibilities. The emphasis should be to prevent defective
items before they occur by exercising appropriate technical controls at different
stages, good machinery maintenance. The standard should be subjected to
periodic review that depending on the technological progress quality of product
raw materials used and end use of the product.
4.6.1 OBJECTIVES OF THE QUALITY DEPARTMENT
The quality objectives are consisted with the quality policy including the
commitment to continual improvement. The objectives are
On time delivery
Cost effective quality casting
Customer satisfaction
Reduce Rejections
4.6.2 FUNCTIONS OF THE QUALITY DEPARTMENT
To define quality policy.
To provide adequate resources.
To ensure that production is carried out under controlled condition.
4.6.3 QUALITY TESTING TECHNIQUES
The company uses the following quality testing techniques are:
Rockwell hardness tester
Impact testing.
P a g e | 35

Universal testing machine
Ultrasonic testing
Radiography testing
Boro scope
Spectrometer
Wet analysis
4.6.4 QUALITY MANAGEMENT SYSTEM PLANNING
The Adhishakthi Castings Private Limited, will carry out Quality Planning
activities to achieve the defined Quality Objectives, while quality planning is
ensured that the integrity of the quality management system is maintained and
the output of the planning is documented as defined below,
INPUT
Enquiry
from
ACTIVITY
OUTPUT
the Review of the enquiry, Review output
customer for new product
while reviewing any

discrepancies
observed,
the
same
will be discussed with

the
customer
resolved
Review report
with
and
the
customer.
Based on the review Plan for Procurement
report, requirement of
new
machinery
devices, resources etc.,

are
decided
arranged
by
and
the
P a g e | 36

Plan for Procurement
directors
Procurement action as Action Plan
per plan and review of
existing documentation
by
MR
for
additional
any
documents
for new products.

Review
of
each New Product
Action Plan
activity to complete the

project.
In case, Customer asks Customer Approval.
New Products
for sample submission,

sample
will
be
submitted along with

the associated reports
Customer feedback
for approval.
Team reviews
the Regular
Production
feedback, if it is as per activity

requirement,
release
Regular
for
then
regular
production.
Production If Customer asks for Resubmission of sample
activity
any changes, the same to the Customers.

shall be reviewed and
implemented.
documents
amended
Customer approval
The
will
be
accordingly
by MR
Team will reviewed the Regular production.
situation and release
P a g e | 37

for regular production.
P a g e | 38
CHAPTER 5
MCKENSEYS 7S MODEL
5.0 INTRODUCTION
5.1 MCKINNEYS 7S MODEL OF
ORGANIZATIONAL STUDY
5.2 STRUCTURE
5.3 SKILLS
5.4 STYLE
5.5 STRATEGY
5.6 SYSTEMS
5.7 STAFF
5.8 SHARED VALUES
P a g e | 39
MCKENSEYS 7S MODEL
5.0 INTRODUCTION
The 7s framework for management analysis was developed by McKinsey and
company 7s model provides an effective way of analyzing an organization, in
terms of dynamic relationship among 7 key elements namely-Structure,
System, Strategy, Style, Staff, Shared values (subordinate goals) and Skills.
Richard Pascal identified these factors in his book the art of Japanese
Management. According to Pascal, it was because of these factors the
Japanese companies excelled over American firms. A very important future of
this model is that McKensey consultants in their studies of several firms have
extensively tested it.
7s model is a very good tool available to the managers to study the
organizations. This study is important from a strategic, marketing,
organizational behavior and competitive perspective. A major premise of the
model is that many performance related issue are rooted among the 7 factors
outlined. The 7s are interconnected, aligned and working together in high
performing organizations.
P a g e | 40
McKinneys 7S FRAMEWORK
5.1 MCKINNEYS 7S MODEL OF ORGANIZATIONAL STUDY

Some years later Waterman, Peters and Philips (1980), working for the
US management consultancy Machesney, developed a rather similar approach.
They suggested that there were seven aspects in an organization that needed to
harmonize with each other, to point in the same direction like the needless of
seven compasses. If each aspect supports the others then the organization can
be said Organized. As each of these aspects can be titled with a word
beginning with S this web has become known as 7s model.
5.1.0 THE SEVEN ELEMENTS
A simplified description for each of the elements can be given as:
P a g e | 41

Strategy: The company plan or route-map to maintain competitive
advantage
Structure: The company hierarchy
Systems: The day-to-day processes and procedures throughout the company
Shared Values: The core values of the company
Style: The company leadership style
Staff: The company's employees and their broad abilities
Skills: The skills and competencies of employees
The diagram illustrates the Multiplicity and Interconnectedness of
elements that influence an organization ability to change. The other notable
feature in this diagram is no starting point or implied hierarchy; in any one
organization different factors may drive the business. In an excellent
organization, each of the S complements the other and consistently advances
the companys goal.
This is not different from a marketing plan. Which should be internally
consistent and mutually supportive? The 7s models is helpful tool to organize
ones thoughts in order to define and effectively attack complicated problem.
P a g e | 42
5.2 STRUCTURE
5.2 Organization Structure of the Company
5.2.0 The Organizational Structure of the Company is as follows
Board of Directors
Director Technical
Director Commercial
HR/admin
assistant
Development
Incharge
Purchase Incharge
Executive Foundry/MR
Finance
accountant
Sales/
Production
Marketing asst.
Manager
asassist
Quality
Planning &
Assurance,
foundry
Maintenance
Incharge
Dispatch
Supervisor
Production
Inspector
Draughts
Pattern
Man
Maker
Supervisor
Chemist
Moulders
Melters
Core Makers
P a g e | 43
The Organizational Structure of the Company would depend upon Size,

Product manufactured and its Functional division. The Organizational Structure
may be flexible. The Company may change its Structure according to the needs
and Suitability.
In AICPL, the Board of Directors is having the major position in the Company.
Next position is to Technical Director, Commercial Director and Executive
Foundry/MR.
The Technical Director is responsible for formulating and implementing the
Policies and Procedures to the Purchase, Development, Quality and Marketing
with the assistance of Board of Directors.
The Commercial Directors is responsible for formulating and implementing the
Policies and Procedures to the Human Resource and Finance with the
assistance of Board of Directors.
And the Executive Foundry/MR is responsible for formulating and
implementing the Policies and Procedures to the Production, Planning and
Dispatch and Maintenance with the assistance of Board of Directors.
Each Functional department are responsible to follow the rules and regulations
set by the respective heads and act accordingly. The Functional departments
includes the work processes like Pattern Making, Inspecting, Moulding,
Melting etc.,
5.3 SKILLS
Skills are the abilities and competence of the employees of the organization. It
says about the knowledge, skills and creativity embedded among the people of
the company. A training action plan is prepared by HR department for teams in
all functions as well team members. The Management in Adhishakthi Iron
P a g e | 44

Castings Private Limited is composed of highly qualified and experienced
people with specialization in their areas. Incharges are highly experienced with
basic degree related to their area. They possess skills for communication,
administration, leadership, and motivation. They are also trained under various
other aspects like supervisory development programs, self development
programs, advanced technology, quality control, internal auditing and computer
knowledge. Most of the workers educational qualification is below SSLC, but
they have a very knowledge about their job which is a result of effective
training programs.
5.4 STYLE
Style refers to the leadership of the top management and the overall operation
style of the organization. Style imports the norms that people follow and how
they work and interact with each other and customers. The leadership style
depends upon the organization culture that is in practice. The Adhishakthi Iron
Castings Private Limited Company follows the Benevolent- Authoritative style
of management. The style of working followed in this organization is:
In case of the flow of information and orders it is top- down.
In case of decision making they follow a participative style decision
making.
5.5 STRATEGY
Strategy is the method of director and the action that company adopts to
achieve its objectives in competitive solution. A strategy explains what the
objectives of the organization are go about to achieve its objectives. Strategy
means planning for the allocation of firms scarce resources overtime to reach
identified goals.
P a g e | 45

The Adhishakthi Iron Castings Private Limited Company is aiming at
gaining a sustainable advantage over competition through quality products. It is
also trying to improve its position in the minds of the customers.
Ex: Marketing Strategy
The AICPL Companys marketing strategy always considers the following to
satisfy the customer requirement and customer retention:
Technical competent.
Quality.
On time delivery.
Dependability.
5.6 SYSTEMS
A system refers to the formal processes and procedures to manage the
organization including the Management Control System, Performance
Management System, Planning, Budgeting, Resource Allocation System,
Performance, Information Systems and Distribution Systems.
The AICPL Company has full- fledged ERP (Enterprise Resource
Planning) system in place, ERP is a software package developed for optimum
use of resources of an enterprise in planned manner. ERP integrates the entire
enterprise into a single unit, which has significantly added to efficiency in Job
Order Processing, Production Planning, Managing Incoming Materials and
Delivery Schedules.
The AICPL Company also has the Quality Assurance System which
facilities Quality in each and every step in the companys manufacturing
system and in the overall management. A quality assurance system includes
P a g e | 46

Quality control and also refers to emphasis on quality in the design of the
Products, Procedures, Jobs and in Personnel Selection and Training.
5.7 STAFF
Staff means that the company has hired able people, trained them well and
assigned them to the right jobs, employees are the functional unit of the
organization. Selection, training, reward, recognition, retention, motivation and
assignment to work are the key issues. The organization has 15 staff team. Over
the years, the company witnessed excellent employees in determined their
career paths. The office staff is selected based upon the qualification prescribed
by the board of directors or the managing director. HR department does the
selection process. Diploma, ITI or any technical degree holders are directly
interviewed and selected. Promotion of employees is done based on both merit
and seniority.
5.8 SHARED VALUES
A Shared value means the values shared by all the members of the
organization. Any organization has a certain set of values, all the employees
must respect these values and must constantly work in unison to maintain these
values. These values are designed to bring about sense of oneness among the
employees. Every employee has to abide the rules and regulation of the
company and uphold the company. Some of the shared values by Adhishakthi
Iron Castings Private Limited are:
To meet the needs and expectations of the customer.
To respect each individual.
Open communication, innovation and creativity, diversity, respect of
individual, 100% commitments are the basic values of the company.
P a g e | 47

Employees growth and development.
Therefore, Mckensys 7S framework highlights the important of some
interrelated and interconnected factor within the organization and there in
successful implementation of strategy.
P a g e | 48
CHAPTER - 6
SWOT ANALYSIS
6.1 STRENGTHS
6.2 WEAKNESS
6.3 OPPORTUNITIES
6.4 THREATS.
P a g e | 49
SWOT ANALYSIS
SWOT Analysis is a basic, straight forward model that provides direction and
serves as a basis for the development of marketing plans. It accomplishes this
by assessing Organizations Strength and Weakness in addition to Opportunities
and Treats. The role of SWOT analysis is to take the information from the
environment analysis and separate it into internal issues and external issues.
6.1 STRENGTHS
Technical and Experienced Manpower
Automated and Highly Sophisticated Machines
Certified by ISO 9001-2008 QS Standards
Well Placed Location Industry Facilitating Easy Transportation.

6.2 WEAKNESS
Facing problems with forecasting technique.
Lack of motivation.
Retention of best talent leading to turn over of employees.
Effective evaluation of training provided to various levels of employees.
P a g e | 50
6.3 OPPORTUNITIES
Huge demand for the production manufactured.
Availability of dedicated/skilled employees.
Well defined plant layout and availability of wide space for future
expansion,
Cordial relationship between union and management.
6.4 THREATS.
Increases in cost due to increase in overhead cost.
Competition from some other bigger foundries.
Lack of employees satisfaction level leading to employees turnover.
Price of goods is comparatively high.
P a g e | 51
CHAPTER 7
FINDINGS, SUGGESTION AND CONCLUSION
7.1 FINDINGS
7.2 SUGGESTION
7.3 CONCLUSION
P a g e | 52
FINDINGS, SUGGESTION AND CONCLUSION

After evaluating the whole in-plant training on Adhishakthi Iron Castings
Private Limited., Shimoga
The present study has certain Finding and
Suggestion that need to be taken into account, which are mentioned below.,
7.1 FINDINGS
The Companys vision, mission and policies are all towards enhancement of
customer satisfaction.
The Company is adopted Six sigma Concept.
The Company follows an active internal control system i.e., internal
audit and other measures.
The Company is giving much attention towards quality of the products.
In this Company there is no co-ordination between subordinates and
employees.
The Company is not providing proper training to their employees.
In this Company employees are not satisfied with their facility.
The Organization employees having the transportation problem.
The Organization is not fulfilling the customer order.
The Organization structure of AICPL presents a complex combination
of line and staff function which is relatively taller.
P a g e | 53

The Organization infrastructure is not proper to produce the product for
reach customer order.
P a g e | 54
7.2 SUGGESTION
Suggestions are accept like tips given to a particular Person or a
Company by studying its overall performance and the views towards those
company activities by which the Company is enabled to improve themselves to
complete with others and also work towards welfare of their employees and
customers.
There is always a threat from the domestic players for the AICPL
Company., so it is desirable to contract effective barriers to reduce
competition.
The management should try to fulfill customer order in time.
The management may be tried to open another branch to fulfill
customer order.
The management should maintain long term cordial relationship
between employees and workers.
The company can introduce new quality practices to cut costs in
various process of production and increase competitiveness in the
market.
Company may think of providing recreation facility to the employees.
P a g e | 55
7.3 CONCLUSION
From this inplant training, I came to know that the Operational Workout of a
Adhishakthi Iron Castings Private Limited. The Organizational study has
created a sense of practical exposure and enlightenment in my as to what
actually an Organization is and how theoretical concepts are practiced. And
also I have felt empowered with confidence to understand different
management concepts in an practical manner. I have come to know how
different works would
be done through others and with others in a
decentralized structure. After the Organization Study, I have come to know how
different employees/workers have different skills, talents, abilities, attitudes
and how workers are being co-ordinated and utilized in an optimum manner
and also in achieving Organizational goals.
From this study it is cleared that quality and delivery performance are the
major attributes, which the customers takes in to account while making the
purchase decision. Customers are highly satisfied with the product quality of
manufacturing as per quality system and standards but it has to improve more
on on-time delivery performance with its customers.
Adhishakthi Iron Castings Private Limited is operating with its existing
technology, which requires modernization. Developing and implementing an
appropriate strategy for leveraging such a huge potential is essential for AICPL
Company to grow and become the market leader. Keeping in mind, the
company should modernize its plant and adopt new technologies to produce
special type of products offered by customers to compete in the present
scenario.
P a g e | 56

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Adishakthi Iron Castings Pvt.

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

1.2 SCOPE OF THE STUDY

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

Adhishakthi Castings Pvt.Ltd.,

Plot No. 37-B,

Adishakthi Iron Castings Pvt.Ltd

+91 8182 246031

+91 8182 246032

Nature of the Ownership

Private Limited Company

Contact Person Name

Contact Person Mobile

+91 90082 61633

3.2 NATURE OF BUSINESS CARRIED

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

They are offering a wide range of Fly Wheel. Our

Adishakthi Iron Castings Pvt.Ltd

It is used diesel engine to Hydraulic

performance life and durability.

Adishakthi Iron Castings Pvt.Ltd

They offer quality Spheroidal Graphite Castings

Adishakthi Iron Castings Pvt.Ltd

Available Area = 8.50 acres and

80 employees working in the company

KVA Diesel generation set is installed in the

Bangalore, Mumbai, Hydrabad and Puna

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

who will make plan for preparing mouldings and

finally it comes to Moulding Operators and Melting Operator unit.

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

4.2.1 FUNCTIONS OF THE FINANCE DEPARTMENT

Adishakthi Iron Castings Pvt.Ltd

HRM department is divided in to 3 groups.

4.3.1 OBJECTIVES OF HRM

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd

4.4 MARKETING DEPARTMENT

4.4.1 OBJECTIVES OF THE MARKETING DEPARTMENT

Adishakthi Iron Castings Pvt.Ltd

Adishakthi Iron Castings Pvt.Ltd