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summer training report on godreg industries,valia

summer training report on godreg industries,valia

Discuss summer training report on godreg industries,valia within the PUBLISH / UPLOAD PROJECT OR DOWNLOAD REFERENCE PROJECT forums, part of the Projects HUB for Management Students ( MBA Projects and dissertations / BMS Projects / BBA Projects category; CHAPTER 1: GENERAL INFORMATION BACKGROUND OF THE COMPANY Godrej Industries Limited is India's leading manufacturer of oleochemicals and makes more ...

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summer training report on godreg industries,valia - January 3rd, 2010

CHAPTER 1: GENERAL INFORMATION



BACKGROUND OF THE COMPANY


Godrej Industries Limited is India's leading manufacturer of oleochemicals and makes more than a hundred chemicals for use in over two dozen industries. It also manufactures edible oils, vanaspati and bakery fats. Besides, it operates real estate. GIL is a member of the Godrej Group, which was established in 1897 and has since grown into a US$1.875 billion conglomerate. The company was called Godrej Soaps Limited until March 31, 2001. Thereafter, the consumer products division got de-merged into Godrej Consumer Products Limited, and the residual Godrej Soaps became Godrej Industries Limited. This led to the formation of two separate corporate entities:Godrej consumer products and Godrej Industries.Besides its three businesses, Godrej Industries also runs four divisions — Corporate Finance, Corporate HR, Corporate Audit and Asurance and Research and Development — which operate on behalf of the entire Godrej Group. GIL has built a strong manufacturing base capable of delivering international quality products at competitive prices. It operates two plants, one at Valia in the Indian state of Gujarat and a second at Vikhroli in suburban Mumbai. The company's products are exported to 40 countries in North and South America, Asia, Europe, Australia and Africa, and it leads the Indian market in the production of fatty acids, fatty alcohols and AOS.The chemical division of Godrej Industries Ltd. is a leading manufacturer of oleo chemicals like fatty acids, glycerine and fatty alcohols, and surfactants like alpha olefin sulphonate. The division has a strong base capable of delivering international quality products, and two factories — one at Valia (in Gujarat state) and the other at Mumbai (in Maharashtra state). Besides being the leader in the Indian market, the division's products are exported to most of the developed and developing countries in the world. The chemicals division has a strong distribution network in India and abroad and it caters to a wide range of industries, among them detergents, cosmetics, pharmaceuticals and plastics. The division has a strong and committed management, and its continuous effort to enhance customer satisfaction levels has resulted in it undertaking a comprehensive. The vigoils division of Godrej Industries manufactures a wide range of edible oils, vanaspati, bakery fats and margarine. It has a state-of-the-art manufacturing facility at Wadala in Mumbai.This plant uses latest technology and adheres to the highest levels of hygiene.The division has comprehensive quality assurance system which ensures that products are backed by the best of quality processes and ingredients, and measure up to world - class hygiene standards.
VISION AND MISSION STATEMENT
• VISION
To become a global force in field of oleo-chemicals and surfactants, growing profitability through customize solution and innovation value chain.






• MISSION
Godrej industry is in the business of the oleo-chemicals and
Surfactant
Our objectives are:
1. To maintain our leadership in our business in India
2. To constantly improve our economic value addition.
3. To keep increase our export.
The company will achieve this by:
1. Consumer satisfaction
2. Quality
3. Cost reduction
MILESTONES
Godrej group has won many awards:
1. WWF awards for more then three times.
2. Indira Gandhi paryavaran puraskar from government of India.
3. Man of the tree award.

INVESTMENT IN PLANT AND MACHINERY
Investment in plant & machinery : Rs. 182, 28, 76, 715
Written down value : Rs. 93, 41, 05, 667
Investment in setting up new EOU plant : Gross amount=Rs. 55, 34, 31, 834
PERFORMANCE GRAPH OVER LAST THREE YEAR
Profit



Sales







FUTURE EXPANSION PLAN
• The company has planed to expand their international market inspite of having tightness of the supply of some raw material.
• Company has another challenges like to retain the competitiveness in the sourcing.
• Another major target is to increase production capacity and improvement in the supply chain management.
• To get a good position in market now GIL is trying to adding some value in the product.
• Company is researching for consumer value addition and developing a new chemical for paper industries.












Present profile

Board of directors :

Mr.A.B Godrej Chairman
Mr.J.N Godrej Chairman
Mr.N.B Godrej Managing Director
Mr.S.A Ahemrdulle MD
Mr.V.M chrishan MD
Mr.K.K Dastur MD
Mr.V.N Gogate MD
Mr.K.N Petigara MD
Mr.F.P sarkari MD
Mr.V.I Benaji Executive Director
Mr. Dub hash Director marketing
Mr. Eire ED & President of chemical
Mr. MR. Bushwalker ED & President of Food

Company secretary: mar. O.k. Bhatt

Auditors : mar. kalyaniwala & mistry

Registered office : Pirojshanagar,
Eastern express highway,
Vikharoli(east). Mumbai-400079.




Manpower status as on June 1, 2009
Category Number of employees
Management staff 106
Non management staff 321
Total 427


















ORGANISATIONAL STRUCTURE:







Types of communication channel
As any big industries use communication as the main source of information GIL Valia is using following channel for their exchange of information
• Vertical channel
• Horizontal channel
• The vertical one is use for pass the instruction, orders and messages. Horizontal channel is use for pass the information at the same level.

Competitive scenario
To point out as the regional competitor there is no one to compete. While at the national level AGLES is the only one competitor. At the international level HEKAL,PROCTOR & GSMBLE are the competitor










CHAPTER 2: PRODUCTION

DEPARTMENTAL STRUCTUE:




ACTIVITIES OF THE DRPARTMANT:
1. Production department collects the raw material from the stores department.
2. If stores department is enable to deliver the raw material in the time due to unavailability a purchase requisition is send to the department of the purchase for the purchase of the required material.
3. Production department maintain a record of the raw material consumed and of finished product.
4. it is the responsibility of the production dep to regularly check the efficiency of the plant operation.
5. For smooth production activity the department interacts with dispatch, maintenance department continuously.
RAW METERIAL USED
The basic raw materials for preparing the finished product are:
• Palm kernel Fatty acid oil.
• Solvent Extraction coconut oil.
• Catalyst:Nikel,Copper chromate
• Crude glycerin.
• Alpha olefin.
• Activated carbon.
• Bleaching earth.
• Palm tic acid oil.
• Mixed Fatty acid.



PRODUCTION PROCESS FLOW CHART:





TYES OF METERIAL HANDELING EQUIPMENT:
• Fork lift truck
• Pipe lines
• Various conveyers
INVENTORY MANEGEMENT FOR RAW MATERIAL AND FINISHED GOODS:
Following is the inventory management process for raw material and finished products:
Stores department assures that the minimum stock remain with them as to start the production quickly.GIL valia is using the ABC analysis for the inventory management
COORDINATION BETWEEN
A. stores and production
B.purchase and production
C.production and dispatch
D.production and engineering

STORES AND PROCUCTION:
A computer system coordinates both departments. Production functions as per the availability of raw material in the stores department. PURCHASE AND PRODUCTION:
As per the purchase requisition approved by the production department purchase department prepares the orders. As to decrees the idle time timely requisition should be kept by production department and according to that purchase department has to ensure that material is available with them on time.
PRODUCTION AND DISPATCH:
Production department ensures that the produce the product on time and the goods according to that specification and meet the demand of the dispatch department. It is very important to fulfill their demand on time as they are the link between consumer and the production unit. On the other hand dispatch department gives information regarding orders to the production department
PRODUCTION AND ENGINEERING:
The main function of engineering is to see that the production takes place without any fault timely maintenance is other main function
MICRO MOTION STUDY:
At present no need for doing micro motion study as all the equipments are fully automatic.
CHARECTERISTICS OF THE FINISHED GOODS: Gil valia produces the raw material for the various industries like soaps and beauty creams, QUALITY ASSURENCE MEASURE: Quality control department has established measures for the acceptance of the raw material so material meeting that specification are accepted for production.





CHAPTER 3: H R

DEPATMENTAL STRUCTURE:


V .P VALIA FECTORY


EXECUTIVR- P&A


JUNIOR OFFICER-2

ASST. - 2








ACTIVITES OF HR DEPARTMENT
The department has maintains balance between management and non management staff it concentrates on the legal aspect i.e Employees should be benefited.
• Recruitment and selection
• Induction
• Training and development
• Promotion and transfer
• Performance appraisal
• Grievance handling
• Welfare activities
FUNCTION OF TIME OFFICE

The main function of the time office is to see that the employees are coming on time and pay according to their time of work.In godrej time keeping is done with the swipe card system for the management staff members the identity card is used for punching. for non management staff attendance register is used.

OTHER FUNCTION OF THE TIMEOFFICE

• Issuing punch card
• Issue get pass
• Maintain record of over time
• Record of absence
• Recode of shift change

LEAVES GIVEN TO THE EMPLOYEE
Privilege leaves 30 days Casual leaves 10days
Sock leaves 15 days Maternity leaves 90 days per delivery


HUMAN RESOURCE PLANNING
The human resource planning is done only for management staff by preparing proper job description and maintaining them in the responsibility and authority manual. to reduce the labor turnover and absenteeism improves productivity and achieve the goal of the organization.
RECRUEITMENT
Recruitment Sources are :
1. internal sources
2. external sources
INTRNAL SOURCES:

These sources are mainly used for filling the management position in the company. It includes its present work force who is already on payroll/ whenever any vacancy arises for management cadre some body from the within the organization is promoted and transferred. This source also includes those persons who were in the organization.
EXTERNAL SOURCES:
These sources are mostly used for filling the non management positions. These sources contain advertisement in news paper, consulting management and other agencies that supply good personnel. They are recruited by personal interview.
PROCESS:
Based on the company identified future of personnel in the organization. The procedure for recruiting the personnel differs from the organization to organization. Every organization has its own procedure, which brings its desired quality of personnel at the minimum possible time and cost.
SELECTION

Selection procedure is carried out by recruiting committee which consist of HOD
and P&A manager.

The selection procedure in GIL is as follows :

• manpower requisition by HOD
• this requisition may be for replacement
• application are invited
• application short listed
• calling for interview
• physical test
• placement and induction of the candidate





PERFORMANCE APPRAISAL SYSTEM

GIL has developed package called B2e portal for performance appraisal system.
It is a computer system in which employee has to fill up information. This information goes to corporate office for assessing the performance.
For non management employees performance appraisal form is developed by company. In which all information is to be filed manually. There are seven factors to judge the performance of the employees:


• suppliers orientation
• commitment to quality
• team work and leadership ability
• knowledge and skills
• job performance and discipline
• personal attribute
• improvement over past performance
Methodology of performance review:
All seven factors are being judge through statement each statement has to be rated on a five point scale which is given below:

VERY HIGH HIGH AVERAGE LOW VERY LOW
5 4 3 2 1

The ratings given to the each of the statements are to be added to give the total score on the each factor. The results are to be multiplied by the weight assigned to that particular category of appraisal.




coordination for the external training. the identification of training is done by the HOD and internal training is also organized by them. The training cards for all the employees are maintained by the personnel department

PROCEDURE OF TRINNING AND DEVELOPMENT:
The HOD sectional heads decides on the training that is to be imported in the current year for the non management category based on the training carried out in previous years as well as current trends sends fills up training need form.
On the basis of the performance review discussion between employee and HOD ,the desire of the company is judge by the senior and need for the training is decided.
Employees in the W1 and W2 categories will be given general training by all HODS to develop skills in the day to day function.
A training plan is prepaid by each HOD based on the identification that is spared over the financial year.
A copy the training need of the non management category and training plan is sent to the personnel department for their information. Training is responsibility entrusted by HOD sectional heads to the person having sound knowledge of the particular subject. Training is out the person has been a trusted with the job doing so.
Photo copies of the training card, is given to the HOD for identification of the future needs.









TYPE OF TRAINING PROGRAMMES
1. behavioral
2. cross function
3. internal
4. external


PROMOTION AND TRANSFER POLICY
The promotion of an employee of godrej is subject to availability of vacancy in the next higher grad suitability and organization. At godrej promotion decision is taken carefully after keeping in mind his career development on the basis of foolowing:

• performance review
• merit and seniority
















WELFARE ACTIVITIES

Welfare activities are the facilities given to the employees which give benefit. These are as follows:


• canteen facilities
• insurance facility
• library facility
• transport facility
• health and safety
• education allowance


WAGE AND SALARY STRUCTURE


Wage and salary are the compensation given to the workers and employees as a reward for the contribution made by them


The criteria of deciding wages are as follows:

1. Arrangement between candidates and head office
2. According to the rates bearing in the market
3. temporary workers are paid on daily basis
4. The salaries are paid monthly before 1st




The components of salary are :
1. basic salary
2. dearness allowance
3. house allowance
4. utility allowance
5. educational allowance
6. L.T.C


INDUSTRIAL RELATION ENVIRONMENT



An industry operates only if personnel are introducing in it are capable. Hence for effective functioning of an organization it is very important to manage the man power effectively. only the work force satisfied the organization .so it is the duty of the hr department to maintain the industrial relationship.

ACTIVITIES CARRIED OUT TOWARDS ORGANISATION DEVELOPMENT

ACTIVITIES RELATED:

• Time office
• Function of recruitment
• Training and development
• Performance appraisal
• Union negotiation




ACTIVITIES RELATED TO INDUSTRIAL RELATION

• Employee welfare
• statutory compliance
• permit from the government

ADMINISTRATIVE ACTIVITIES
• Medical allowance
• Transportation
• Leave facility

SOFTWARE USED IN HR
Computer application is used to assist HR in time office management & for salary purpose. the department has “people soft” software to assist HR function.


























BUDGETARY CONTROL SYSTEM
The budget is prepared for the year. Budget is prepared based on sales and marketing plan. Based on this plan, production plant is prepared with respect to capacity in quantity mutually by the marketing (HO) & Production (Valia). The budged prepared is volume based budged.
Taking into account these plans, budget expense are estimated which includes following items.
• Administration expenses
• Salary
• Repair & Maintenance etc.
This budget then estimated the cost of production.
BUDGET MANUAL
The capital budget id prepared here at GIL, Valia. It deals with the proposed expenses, Which will be incurred during the year.
BUDGET PERIOD
Budget period is the period for which budget is prepared. Here at Godrej Industries Ltd. budget are prepared for finical year I. e. 1st April to 31st March.
BUDGET CENTERS
Budget centers are either department wise here, in GIL is taken as department-wise. The company considers each department as its cost center and accordingly prepares the final budget. Here the finance department has separated the budget centers in to production and services centers.


ACCOUNTING METHOD / SYSTEM

The financial statement are prepared ones the historical cost convection, on the accrual basis of accounting principles (GAAP) in India and the accounting standards issued by the institute of chartered accounts of India.

RATIOS


RATIO OF LAST 2 FINANCIAL YEARS

Liquidity Ratio

• Current ratio = Current Assets
Current Liabilities
2006-2007=36694.74
23757.27
=1.54:1
2007-2008=78779.16
31509.60
=2.50:1
• Liquid Ratio = Liquid Assets
Current Liabilities

Liquid Assets = Current Assets - stock
= 36694.74 – 15515.17 = 21179.57

2006-2007= 21179.57
23757.27
Liquid Assets = Current Assets - stock
= 78779.16 – 19771.19 = 59007.97

2007-2008=59007.97
31509.60
=1.87:1
• Acid Test Ratio = Quick Assets
Liquid liabilities

Quick Assets = CA – Stock – Debtors
=36694.74 - 15515.17=9253.24

2006-2007=11926.32
23757.27
=0.50:1

Quick Assets = 78779.16 - 19771.19 – 16640.35
= 43367.62

2007-2008= 43367.62
315098.60
=1.38:1









Profitability Ratio

• Gross Profit Ratio = Gross Profit X 100
Net Sales
2006-2007 =25009.16 X 100
65477
=38.20
Gross Profit = Net Sales – Cost of goods sold
=65477 – 40467.84 = 25009.16
2007-2008=55822.44
73530.54
=75.92 %

• Net Profit Ratio = NPAT X 100
Net Sales
2006-2007=7806.08 X 100
65477.60
=11.92 %

2007-2008=10888.97
73530.54
=14.81 %









• Return On Shareholders’ Fund
= NPAT X 100
Shareholders’ Funds


2006-2007= 7956.10 X 100
64818.35
=12.28 %


2007-2008=10771.56 x 100
137351.66
=7.84 %


• Return On Equity Shareholders’ Fund
= NPAT – Preference dividend X 100
Equity Shareholders’ Fund
2006-2007= 7806.08 X 100
41061.08
=19.01 %


2007-2008=10888.97 X 100
105842.06
=10.29 %








• Return On Equity Capital
= NPAT – Preference divided X 100
Equity Share Capital

2006-2007=7806.08 -Nil X 100
2918.52
=267.46 %

2007-2008=10588.97 X 100
3197.59
=331.15 %




COSTING OF THE PRODUCT
The particular product passes through many sections for getting the final product. The cost of each section-fixed cost and variable cost is calculated and added. The total cost of all section is added then to the cost of raw materials. Cost is valued as under.
• Finished product : At lower cost or Market Value
• Work in process : At cost.





RESPONSIBILITY ACCOUNTING AND RESPONSIBILITY CENTERS
The company has considered responsibility center to the cozen to the plant as a profit center.
In GIL the output of the raw material are transferred to one section to another so this is the process industry and the profit are taking in to the market price, such transfer will gave some profit to the responsibility centers.

LONG TERM FINANCE:
Sources :
GIL, Valia uses the long term finance sources like.
A) Share capital as the sources of 6, 17, 10,218 equity shares of Rs. 6 each fully paid.
B) Reserves and surplus funds securities account, capital investment, subsidy reserve, general reserves.
C) Secured loans as the term loans from financial institute’s term loans from banks, overdraft, sales tax department loan from MPSIDC.


• SHORT TERM FINANCE :
Sources :
GIL, Valia uses the short term finance like,
A) Safe deposits account for taking amount more than the deposited.
B) Unsecured loans as fixed deposits, inner corporate deposits, short term loans from banks.



• Other information about the sources of finance.
1) Choosing the proper types of finance.
2) Adjustment of quantum of funds raised.
3) Procedure for the raising finance.
• All are managed by the H. O. Mumbai branch of GIL
WORKING CAPITAL MANAGEMENT
Working capital management refers to the management of current asset such that the firm has a greater degree of flexibility in managing current assets. Working capital has two main concept that is gross working capital and net working capital the earlier refers to the total investment in current assets and later is the difference current asset and current liabilities.
To manage current assets means to have current assets in such a proportion that is lead profitable to the firm.
The main objective of working capital is to manage the current assets of the firm for smooth running of firm that is managing day to day requirements.
OPERATING CYCLE
The GIL operating cycle fluctuate into the duration of 45 to 55 days.
ESTIMATION OF WORKING CAPITAL REQUIREMENT*
The estimation of working capital is not done in same systematic procedure. As and when the requirement arises it is conveyed to the head office at Mumbai.



WORKING CAPITAL INCLUDES THREE MAJOR ASPECTS
• Cash management
• Receiver management
• Inventory management
here a deep study of working capital management done by the GIL which has been leading to smooth running and increasing profit of the company.
CASH MANAGEMENT
Cash is important current asset for the operation of the business. Cash is basic input needed to keep the business running on the continuous basis. it is the ultimate output expected to be release by selling the service or product manufacture by firm. The firm should keep sufficient cash neither more nor less. Cash shortage will disrupt the firms manufacturing operation why excessive cash will simple remains idle, without contributing anything towards the firm profitability.
• Cash Planning
• Optimum Cash Level
• Managing the Cash
• Investing Surplus Cash
Cash Planning :
A firm needs cash to invest in inventories receivable and fixed assets and to make payment for operating expenses in order to maintain growth and earnings.
Cash planning at GIL is required to cash planning as they have enough cash as and when required. They have their slaves on cash term as well as credit terms and no problems of cash shortage.

Cash Budget :
GIL to individual prepare cash budget Cash management is done by finance and accounts department and excess is keep with bank.
Budget includes :
• Receipts
• Payments
• Control issues
• Advance payment
• Salary advance
• Tour advance
• Salary disbursement
• Purchase bill passing
• Branch transfer from vikhroli
• Brokerage payment
• Capital goods payment
• Service / job work / related payments

This budget is sent to the head office Mumbai and then the head office approve for the fund to the Valia company.
the Valia GIL is also having the safe account which allows them to take the any kind of required amount which let company and check does not bounds inspect of the company have less balance at HDFC.
CASH INFLOW AND CASH OUTFLOW
The cash inflow are mostly meet by the Mumbai branch providing the fund for meeting all expenses so almost there is no need to manage case inflow.
Cash outflow are given as per the requirement occurs.
REMAINING CASH INVESTMENT
Remaining Cash investment is no need to control because company does not invest surplus money. They just deposit their money with HDFC Bank.

TAXES
TYPE OF TAXES
The company has to pay following types of taxes :
• Tax on salary of employees
• Tax on payment made by GIL
• Tax in received by GIL
• Sales Tax
• Income Tax

RATE OF TAXES
TDS on salary is deducted at 2% surcharge and the common charges is 2%
TDS income received by GIL is deduced at 2% other compliances are done by finance department at Mumabi.
INCOME TAX
Income Rate
1 to 150000 10 %
150001 to 250000 20 %
250001 to 1000000 30 %
TIME OF PAYMENT
The payment of the salary is paid before 7th of next month.

FINANCIAL INCENTIVE GIVEN BY THE GOVERNMENT
The company has got tax exemption of rupees 88 core or till the year 2005.

FINANCIAL MIS
Basically the MIS is prepared for the findings of the difference between monthly budget and actual budget which is generated by the vouchers, purchase order bills, case register prepared on system and it is thus reported to the HOD though computer system.

COMPUTER SOFTWARE USED TO ASSIST
IN FINANCIAL MANAGEMENT
The software used for assisting financial management in GIL in manufacturing is developed by QAD Inc. of USA, Basically the MGF_PRO is used as computer software.

ACTIVIES OF PURCHASE

• Procurement of raw material other than oil & chemical.
• Procurement of engineering spares and laboratory chemicals.
• Procurement of packaging materials.
• Vendor’s selection for purchase of materials.
• To check specification before placing order
• Vendor’s relation is the core function.
• To find out alternatives for procuring raw materials.
• To resolve between user department.

Purchase department is responsible for timely and cost effective supplies to meet requirement of its entire internal customer at the same time ensuring desired quality. Purchase department mainly function as a link between customer and the sub-contractor.








PURCHASE PROCEDURE
1. The purchase requisition has to be authorized by the department head.
2. The requisition is to be serially numbered with a prefix code allocated to that department.
3. Then the requisition is sent to the purchase department.
4. The purchase requisition is then carefully studied at the purchase department. Following action takes place depending up on the case if the item is consider to be important; quotation are invited by sending enquiry on fax and rates are obtain on fax from their Indian distributors.
5. If the order is a blanket order item, every time the order is released from the blanket order is released from the purchase requisition for the respective quality in the mfg/pro system.
6. For rate contact items, normally 2/3 sub contractors are maintained and orders are placed looking into availability material with approved the sub contractors only. The order is placed at the beginning of every year.
7. For other items. enquiries are sent by fax /phone to concerned approved sub contractor, upon receipt of quotation, comparative statement the approved sub contractor, in purchase order, Orders before placing are received by heard purchase and approved by authorized signatories.
8. The order is placed on the approved sub-contractor only. However for small purchase up to Rs. 5000 and under extreme emergency condition material can be procured on notes/phones etc.
9. For materials which are to be purchased, a purchase order is raised on the party. The other tax details, specification of material, purchase order serial no. with date, delivery time inspection details etc. Bearing authorized signature.
10. Two copes of purchase order are printed and distributed as following
• Supplier copy
• Record Copy
Once the purchaser material in dispatched. It is received at engineering /commodity stores and by means of goods receipt report and receiver the purchase department is informed. The chalan is either signed by the user department is either signed by the user department or the stores in charge. If the material is not as per the norms of purchase other relevant remarks are put on chalan and the matter is referred to the sub contractor by means of rejection memo/phone/fax as the case may be.

PROCUREMENT OF RAW MATERIALS
Procurement of raw materials is done normally on following grounds :
Packing Materials
Packing materials are procured based on purchase requisition received from logistic / production department through manufacture /production system. Based on the requirement the approved sub-contractor is given the order for the materials to arrive before the closing date. For various shipping marks on packing, the requisitions for stickers are given by production department.
Raw Materials
Raw Materials like oils and imported chemicals are handled by centralized purchase and import department and Mumbai combine with our production department.
Other Raw Materials
For the raw materials Viz. caustic soda lye, filter acid etc. The procurement is done by the department based on the purchase requisitions, given by the user/customers, department through manufacture / production system.
Engineering Equipment and Spares
Here the requirement is given by the user department only by means of purchase requisition. Incase of sundry items, non repetitive items and job workers, A manual purchase requisition is accepted. All other purchase requisition is raised through manufacture / production system only.
Fuel Oils
Fuel oil is procured according to the requirement intimated by user verbally in writing.

INVENTORY MANAGEMENT SYSTEMS
The most important part of producing a product is inventory. Here at GIL, Valia the use the method called ABC analysis and FIFO method for managing inventory. Now they has developed new concept called TOC i.e. theory of constrain. This method is computerized system where three colors are displayed-red, yellow and green. If the stock of particular product is “between” 0% to 33% then it comes in red light, which indicates a danger signal and also indicates the requirement of immediate production of that particular product. It the inventory is between 33 % to 66 % it shows yellow color and if it is “between” 66 % to 99 % then it shows green color and indicates that the stock in enough with the company for particular product.

STORES PROCEDURE AND MATERIAL CODING SYSTEM
The production department intimates the requirement to store if materials are available then it is dispatched to plant site. But if materials are not available then purchase requisition is submitted purchase department. The materials are received by the store manager and then the new stock quantity is feed into the computer, the materials then sent to the production department.





STORES PROCEDURE
1. Receipt system : The production department intimates the requirement, if materials is not available then purchase requisition is submitted to purchase department the material is received by the store manager and then the new stock quantity is feed into the computer system.
2. Storage System : According to materials coding system various materials and finished goods are stored in the stores department. For management of inventories they are applying a method called ABC analysis and FIFO method.
3. Issue system : the production department sends their requirement of raw materials and other tools to store department. If materials are available then it is dispatched to plat site to production department. If materials is not available then order is placed. The store department also issue finished product according to intimation (P.O.) and loading in the truck / container for dispatching to the party.








MATERIALS CONDING SYSTEM
The prefix code is allocated to all concerned department i. e.
Department Code
Instrumentation Department Che-20
Mechanical Department Che-21
Electrical Department Che-25
Logistic Department Che-26
Civil Department Che-27/28
Safety Department Che-29
Security Department Che-30
Production Department Che-35
QC Department Che-36
ISD Department Che-40
Account Department 01
Administration 02
P & A Department 10
Purchase Department 12
The codes are 8 digitize the 1st no. indicates the stores symbol the next two digits indicates the year then next two digit indicates department code and last three digits for serial number or requisition number.


For example : E0612001
E is stores symbol, 06 indicates year, 12 Indicates Purchased departments and 001 is serial number.





ACTIVITIES OF DEPARTMENT
The Quality Control department operates a central link between the customers and various department of the organization.
The various carried operations under this department are :
1. Quality Assurance of the raw materials which are imported while unloading them at the part.
2. Quality Assurance of the raw materials, which enters the unit for processing. This activity is done through sample testing. It is the Quality Control Department, Which sets specification for taking samples.
3. Also, it monitors the fractionation process.
4. Quality Assurance of work in process.
5. Monitoring the quality feed water is a boiler
6. Monitoring quality of nitrogen used for surfacing stearic alcohol.
7. Monitoring the quality of hydrogen used for hydrogenation process. The hydrogen used is 9.99 % pure.
8. Monitoring the safety measures of hydrogenation process which takes place at 300 bars pressure.
9. Inspection of the process of conversion, by ISO auditor.
10. Co-ordination which control rooms of DCS.
11. Recommendation for improving the process of manufacturing.
12. Even, customer complains handling is done by department

Software use to Q. C. function : Bliss SQ of Chennai.

TYPES OF INSTRUMENT USED
There are many instruments used in the laboratory, which are highly sophisticated. They are as follows :
1. Lovindbond Tintomitter: In ti colour is measured by comparison with standard colours. It is used or colour determination of oil and fatty acid having higher colour value.
2. PH Meter : PH meter is sued for determining PH value of given value.
3. UV Visible spectrophotometer : UV absorbed by the material will depend upon the concentration that means to find the concentration of the given solution.
4. GLC : these instruments are used for gas analysis and determination of composition of fatty alcohol and fatty acid. Here there are seven GLC. Nitrogen gas is used as a carrier gas.
5. Halogen moisture analyzer : these operate on the principal of thermo gravimetric content of sample e. g. AOS noodle.
6. Alpha meter : This is used for measuring the color of chemical and compare it with standard colour.
7. Karl fisher titrate : It is used for measuring the moisture content of given sample in liquid form in which titration is carried out with Karl Fisher reagent depending on moisture content instrument is calibrated with distilled water.



METHOD OF CALBIRATION
C16 & C18 is tested they are weighted and based on required weight they are injected in gas chromatographer. The instrument after the process is over displacing the constituents of percentage of C16 and C18 in weighted this process is carried out once in three months.
For titration Karl – fisher titration machine is used. It detects the moisture content. After weighting the sample it is past through the balance automatically for titration. The instruments shows the percentage of sample titrated after 100% titration the results are displayed. The instrument can display the result in three units mg. percentage.
Silica and Phosphorus present in water are detected through spectrophotometer and solution is put in the instrument for separating silica and phosphorus from water. Ph4 and Ph3 buffer tablets are used to judge Ph.

PARAMETER TESTED IN LABORATORY
For fatty acid and fatty alcohol
1. Percentage moisture content : The percentage of moisture present in the sample.
2. Acid Value : The number of mgm. of KOH required to neutralized free fatty acid present in 1 gm. of sample.
3. Specification value : Number of mgm. of KOH required to specify 1 gm. of sample.
4. Peroxide Value : Mille equivalent of peroxide content in 100 gm. of sample.
5. FOR AOS
1. Percentage moisture content.
2. Percentage active matter
3. percentage alkalinity
4. percentage sulphate
5. percentage chloride
6. Free oil Content
7. Sultone content
FOR GLYCERIN
1. Percentage moisture content
2. Percentage of glycerol
3. Colour
4. Chloride
5. Percentage of fatty acid and ester










ACTIVITIES OF THE DEPARTMENT
• Receiving of war materials.
• Dispatching of finished products in both global and domestic market
• Regulating activities of export and import.
• Excise duty regulation.
MODE OF DISPATCH AND LOGISTIC
The company has 30 dedicated tankers, trucks and containers. All the materials, which is to be dispatched, is transported in any of the above modes.
SOURCE OF MODE OF DISPATCHE
Except the 30 dedicated tankers, all modes are handled and owned by the contractors.
DISPATCH PROCESS
The marketing department sends order of goods to be dispatched this includes specification regarding order size, quality and quantity. Mode of dispatch time limit etc.
Based on this specification the logistic department, since the specification to production and quality control department.
It becomes the sole responsibility of the logistic department to see that goods and dispatch as per the specification of the customers and there are minimum complaints regarding the dispatched goods.



FOR EXPORT OF GOODS
Invoice given by the marketing department. Based on its specification given to the quality control department and production department and then checklist is prepared. Containers are sending from Mumbai as soon as they arrive, they are loaded and dispatched.



PERMANENT SECURITY STAFF

Executive Security Officer 1
Sr. Executive Security Officer 1
Gunmen 5
Security Guard 6






ACTIVITIES OF SECURITY DEPARTMENT
The security department plays an important roll. The major activities are given as follows :
• Watch and word of all over company.
• Tackle out theft cases
• Handling the producer of gate entry.
• Tanker and truck checking
• Comparing the material received with schedule.
• Record keeping of gate entry
• Maintaining the contract labour entry report
• Write down the name of contract labors and give them tokens.
• To check the driving precaution and if it is wrong, then penalty is done.
• Seal of tankers those arrive in the company with liquid material are checked.


WORKING HOURS
Security department is working for 24 Hours in to 2 shift each of 12 hours.




MAINTENANCE OF DATA RECORDS
• Security department prepares one book, which is known as entry register. It is the main book of record. All entries are also fed in computer.
• Particular format is maintained for vehicle’s entry, which is known as vehicle checklist, which includes vehicle no, driver and cleaner name, rules they have to follow in the area of company premises.
• They also keep the record of maintenance of loaded truck, unloaded truck, waiting trucks.
• The sap programmed is used to maintain information.

SECURITY EQUIPMENT
The equipments like mettle detector, guns are used besides general checking equipments.

PLACEMENT OF SECURITY GUARDS
1. Weight Bridge 1 person
2. Valia Housing 1 person
3. 66 KV south gate 1 person
4. E.T.P. 1 person
5. main gate 2 person



HOUSE KEEPING AREA
1. Main gate surrounding area
2. Tanker parking area
3. 24 section surrounding area
4. Boiler filling area
5. Dump housing area
6. Pump housing surrounding area Senior Officer and Junior Officer



CHAPTER 9: ENGINEERING DEPARTMENT

DEPARTMEWNTAL STRUCTURE:









ACTIVITIES OF THE DEPARTMENT


• To support the production department for smooth production activities
• Timely maintenance of all plants and equipments.
• Checking availability of spares.
• Determining requirement of new machinery.
• Sending the machinery for repair work if required.
• Coordinating with all sub department i.e with instrument , electrical

SIGNIFICANCE

This department has much important as major employees works under this department and valia is a manufacturing unit.

Lot of money has been invested in the plant like they have their own generator of 3 mega watt and engineering department plays significant role in maintaining and running the machinery.

Engineering department has to work for the standard quality of the product.









MINI PROJECT
ON
EMPLOYEE
WELFARE








INTRODUCTION:
Employee welfare or labour welfare is an important face of industrial relation the extra dimension, even a good wage can not. With the growth of industrialization and mechanization it has acquired importance. The worker both in industry and agriculture can not cope with the pace of modern life with minimum sustenance amenities. He needs an added stimulus to keep body and soul together. Employers have also realized the importance of their role in providing these extra amenities and yet they are not always able to fulfill workers demand however reasonable they might be.
They are primarily concerned with the viability of enterprise, labour welfare though it has been prove to contribute to efficiency in production. Each employers depending upon his priorities gives varying degree of importance t5o labour welfare it is because the government is not sure that all employees are progressive minded and will provide basic welfare measures that it introduce statutory legislation from time to time to bring about some measures of informality in the basic amenities available to industrial worker.



IMPORTANCE OF EMPLOYEE WELFARE
The importance for labour welfare arises from the very nature of the industrial system which is characterized by two basic factor –
The condition under which work is carried on are not congenial for health and secondly when a labour join industry. He has to work entirely strange atmosphere which creates problems of adjustments. These two factors are like “the long arm of jobs”. And “the social invasion of the factory”.
OBJECTIVE OF THE STUDY
• To know the standards of the employee welfare at GIL valia according to the knowledge level of the employees towards the employee welfare facilities
•
RESEARCH METHODOLOGY
The research was conducted through the questionnaire to get response from the employees.

RESEARCH PLAN
I have chosen descriptive type of study.

SORCE OF DATA
Source if data is primary as the data are collected first hand from the employees

DATA COLLECTION METHID
I have used structured questionnaire as a method of data collection.(face to face)
SAMPLE SIZE

Sample of 20 employees










DATA ANALYSIS & INTERPRETATION

Question 1: Are you aware about the welfare policy of the company?

























Question 2: Are you aware about the welfare facilities provided by the company?





Question 3: Are you aware of the statutory labour welfare benefits provided by the law?











Question 4: Tick mark the welfare facilities provided by the company.

ANS-All employees well aware of the various facilities available for them as everybody has answered most of the facilities they are getting










Question 5: Are you satisfied with welfare facility provided to you?











Question 6: How do you rate the welfare facilities being provided to you?














Question 7: Are you satisfied with canteen facility?













Question 8: Are you satisfied with transport facility?







Question 9: Is any amusement or sports activities are conducted for employees?






Question 10: According to you which other welfare facilities should be provided?


ANS-Employees have recommended following:

• loan facilities
• amusement facilities
• medical facilities to the family also
• improvement the canteen facility
• sports activity











RESULT AND FINDINGS


• GIL VALIA is providing better facilities to their employees
• Employees are highly satisfied with welfare facilities
• Satisfaction is giving high moral for work
• Statutory welfare facilities are provided
• It makes a friendly working environment at the factory




CONCLUSION
Labour welfare has two sides, negative and positive. on the one hand it is associated with the counteracting of the harmful effects of large-scale industrialization on the personal family and social life of the worker , while on the other, the positive side, it deals with the provision of opportunities for the worker and his family for a socially and personally good life. In other words, “ Labour welfare services” counteract the handicaps to which the workers are exposed both in their work-life and provide opportunities and facilities for a harmonious development of all-round personalities.
















Annexure:



QUESTIONNAIRE
DATE:


Respected sir,

I Mr. Surendra s Gamit student of narmada college of science and commerce zadeshwar (S.Y BBA SEM-4) currently doing vocational training in your company here by request you to kindly fill up the following questionare and provide me your opinion on “employee welfare” for the mini project on said topic.

Surendra s gamit

NAME OF THE EMPLOYEE: DESIGNATION :

DEPARTMENT :


QUESTIONS:

1.Are you aware about the welfare policy of the company?

yes no

2.Are you aware about the welfare facilities provided by the company?

yes no

3.Are you aware of the statutory labour welfare benefits provided by the law?

yes no

4.Tick mark the welfare facilities provided by the company.

i. Medical facility iii. Provision of safety


ii. compensation for accident iv.Transport facility


v. Provision of canteen vi. Housing accommodation

vii.Indoor and out-door recreation facilities


viii.Amusement and sports


ix.Others in your information :



5.Are you satisfied with welfare facility provided to you?

yes no


6.How do you rate the welfare facilities being provided to you?

• Very good

• Average

• Below average



7.Are you satisfied with canteen facility?

yes no


8.Are you satisfied with transport facility?

yes no

9.Is any amusement or sports activities are conducted for employees?

yes no


10.According to you which other welfare facilities should be provided?
i.
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Re: summer training report on godreg industries,valia
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Sudhakar Jadhav
sudhya is an unknown quantity at this point
 
sudhya
Student of B.Sc at adarsh college omrga
Aurangabad, Maharashtra
 
Status: Offline
Posts: 6
Join Date: Aug 2010
Location: Aurangabad, Maharashtra
Re: summer training report on godreg industries,valia - September 14th, 2010

i want inplatn training report any one help me pls
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