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CHAPTER - 1

INTRODUCTION

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INTRODUCTION OF THE STUDY

In the modern world of tough competition and rivalry among the companies it has

become necessary that one should be able to understand each and every aspect of the

functioning of the organization than only concentrating on his work alone. So in order to

make students aware of the overall working of the organization the university as well as

the institution has made it mandatory to conduct a detailed study into the working of an

organization and also to submit a report at the end of the study.

Since the industrial revolution in the early 18th

century, the world has witnessed a

significant growth in the field of infrastructure, industry and allied activities. In India

after the globalization in 1993, the foreign counterparts started coming to India and the

need for doing project was realized and now it has become an important component of

economic development. Projects are defined as an economic activity with well defined

objectives and having a specific beginning and end. The engineering industry is one of

the second largest components of India‟s manufacturing sector over the year. This

particular sector has registered an average growth of 16% during the last two decades. It

includes production of the electronic gadgets and machines and drives to run those

machines.

Need for the study

To learn about the origin and development of the company.

The role of each department in an organization dealing in industrial products

To know the impact of each department of the organization in building up

framework on which company stands and face forthcoming challenges

To understand the structure and departmental functions of the organization

To study the work culture of the executives an d workers

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To study about the general aspects of organisation.

To study about the industry in which it operate.

To know about organization structure

To study various departments in the organization and its functioning

To analyze the strength, weakness, opportunity and threat of the company

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CHAPTER – 2

PROFILE OF INDUSTRY

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INDUSTRY PROFILE

Pumps are the vital elements in an enormous range of fluid handling applications

& range from small household pumps to immense units utilized in the water, chemical

and energy industries. Pump performance requirements and duties vary considerably in

terms of material of construction, wide range of temperature, pressure, viscosity, density

etc. Pumps are employed in almost all the industries.

The United States will remain the largest purchaser over the next 5 years but

China will experience the largest growth rate. Large investments will be made in a wide

range & applications from Semiconductor ultra pure water to boiler feed water. China

will build nearly half of the world‟s new coal-fired plants in the next five years.

Significant pump market exists in 80 countries and regions. In Chile the largest

pump purchasing segment is the copper industry whereas in Germany it is the chemical

industry. The Middle East is a big pump market due to oil & gas industries. The market

for pumps in buildings in Europe is much bigger than in the U.S. because Europe

depends on water rather than air for heat.

All major pump types will experience growth over next 5 years. Demand share for

different types of pump is given below:

Centrifugal Type 50% of total sales.

Submersible Effluent Pump 5% of total sales.

Submersible Domestic Pump 4 % of total sales.

Progressive Cavity Pump 1% of total sales.

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The Indian Pump industry has more than 500 manufacturers with worker strength

of over 30,000 producing about 1.2 million pumps. Indian market for pump is estimated

to be Rs.25000 million growing at an annual rate of 8%.

Irrespective of other industry pump industry will continue to grow as long as we

need water.

Growth of Pump Industry

Although some pumps were used in 19th century, the real growth of Pump Industry took

place in 20 century

1905: Multistage Centrifugal Pumps were developed.

1929: Considerable light was thrown on the vexing problem of pressure pulsations in

large hydraulic turbines & pumps.

1932: Proper understanding of the origin and nature of pressure pulsation & the

accompanying, vibratory, structural, mechanical response.

1955: Dependence of cavitation erosion on liquid was established. This led to an

understanding of why high-energy pumps are more likely to suffer from this damaging

phenomenon.

1956: How the thermodynamic vaporization properties of the pump liquid could lead to

reduction of cavitation activity at high temperatures at the same NPSH (Net Positive

Suction Head) (Liquid pressure head in excess of vapor pressure head).

1994: How cavitation can cause profound instabilities in pump & inducer operation.

1990-2000: It is found that sometimes obscure fluid phenomena can produce mechanical

instability in rotodynamic pumps.

2000-2010: With the effect of LPG (Liberalization, Privatization and Globalization) the

Indian pump manufacturers have started exporting to foreign countries, where pumps are

used for various purposes in different industrial sectors like, oil refineries, steel mills,

mines etc. This has led to the increasing trend in export of pumps.

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What are the drivers of pump development?

1. Industrial Revolution: Pump industry had been fueled by the massive

demands of the industrial revolution that built our modern society.

2. Post World War II Expansion: In order to satisfy the pent-up demand that

had gone unfulfilled in war years. Here the emphasis was on large, multistage

electric utility boiler feed water pumps & oil-field injection & pipeline pumps.

3. Energy Crisis: Energy crisis all over world led to lot of research &

development work for developing energy efficient pumps & systems.

4. Environmental Challenges: Curbing emissions was the paramount concern.

This influence has led to better sealing of pumps including sealless, magnetically

coupled chemical pumps. The ultimate product in this regard could be „integral

motor pump‟.

5. Globalization: The fluid engineering & other technical challenges are assumed

to be solvable by the MNC who emphasize quality, productivity & faster delivery

of the product in order to battle global market share. The apparently mature pump

product has a lot of room for improvement. The technical improvements will

continue to be necessary to maintain global competitiveness.

What were the applications of pumps?

Various applications of pumps are listed below:

Transportation: It is a prime function.

Circulation: For homogenizing the temperature and/or composition of fluid.

Mixing: Two or more streams can be connected at the suction of pump & mixing

can be achieved.

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Injecting: High pressure can be developed by using pump and fluid can be

injected in pipe or tank.

Metering: Pumps can be used as metering device.

Pressure Reducing Device: Rotary pumps can be used for reducing the pressure in

polymers.

Agitator Pump: Submersible pump keep the solids in suspension & prevent

setting.

Vacuum Generation: Liquid ring vacuum pumps are well known. Dry vacuum

pumps are also developed.

Reactor: When two liquids are to be reacted with very small residence time then

pump can be used.

Cavitation Reactor: When one liquid and another in vapor form are to be

reacted, the principle of cavitation can be used.

Indian pump industry at present met the pump requirements of 95% of

applications.

What is the role of Pump Manufacturers?

Manufacturers to ensure that maximum possible indigenous pumps are locally

available & thus avoid import of pumps. Thus save on foreign exchange. Depending on

feasibility study import substitute as well as export market can be explored. For example,

Ceramic pumps, High performance alloys, High precision gear pump for spinning m/c. in

manmade fiber industry, peristaltic pumps, magnetic drive pumps etc.

Pumps consume about 30% total power. Pump is an item which will consume more

energy throughout its life if it is not energy efficient. Hence, it is necessary to improve on

energy efficiency of the pump. Even for small Kw rating it is essential to have high

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Energy efficiency because in future, we will likely to use solar energy where pump

efficiency plays vital role.

In Germany, 20% increase in energy efficiency by 2005 is made mandatory. In

Netherlands, 33% improvement in energy efficiency compared to 1995 to be achieved by

2020.In European industry 15-20% of energy saving potential is widely accepted through

implementation of new technologies which are commonly available but not widely

applied at present.

In India, in 15% of the cases, motor selection is by consultant where as more than

45% of the cases motor selection is by manufacturers. Hence by selecting energy efficient

motors & variable speed drive, pump manufacturers can contribute to energy saving.

There is demand from user that manufacturer should take the responsibility for

optimization of material selection. Here manufacturers should focus on application of

new materials of construction. E.g. Ceramic coating.

Manufacturers should arrange training programs for user & consulting engineers.

Manufacturers to ensure “PASS”. (Prompt After Sales Service)

IPMA (Indian Pump Manufacturers Association) should

1. Arrange more national / international seminars / exhibitions for further

business developments.

2. Submit their recommendations about export / import policies, excise,

custom duties policies etc. to Govt. of India at least once in a year.

3. Take a lead role in setting up of laboratory facility required for pump

manufacturers.

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CHAPTER - 3

COMPANY PROFILE

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PROFILE OF THE COMPANY

GENERAL ENGINEERING COMPANY (GEECO) was established in the year

1945 in the pump city of India, Coimbatore. It is a private limited company. The man

behind GEECO PUMPS is Mr. Govardhan .The Company has more than six decades

experience in pump set manufacturing. Quality is tradition at GEECO

pumps. Standardization and easy availability of spares make our product user friendly

and reduces break down time. All our pumps are designed with utmost care considering

the prevailing field conditions and customers‟ needs. Careful selection of right material

for the application makes our pump a grand success.

Vision

To manufacture:

Cost effective value engineering pumps with great quality and provide best customer

service.

To make:

Energy efficient and cost effective pump sets.

Mission

• To display highest commitment to excellence in product quality, service and

enriching customers through added value.

• Build exceptional standards and systems for productivity, performance, safety,

environment and quality.

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QUALITY POLICY

According to our quality policy we are committed to:

Complying with the requirements of the quality management system

implemented.

Effectively utilizing the available resources;

Constant striving for improving the level of customer satisfaction; and

Continually improving the effectiveness of the quality management system

QUALITY OBJECTIVE

1. Reduction of customer‟s complaints related to safety.

2. Timely delivery.

3. Low downtime of equipments.

4. Safety in operation.

5. Pollution free environment.

6. Pride of quality through customer‟s feedback.

Goal

“Quality, Safety & Security”

To provide good quality products to the consumers

Give more importance to the safety of workers in the work place

To provide job security to the employees

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INFRASTRUCTURE

The company has a built up area of 4500sq.mts mostly roofed by concrete and

another 10,000 sqmts are used for stocking and parking. Apart from this a land measuring

about 2.5 hectares is available in the vicinity of the company for future expansion and

diversification. The company has the unique distinction of constructing a huge pump for

rain harvesting, the first of its kind in India before anybody could think of rain

harvesting. Assembling arena, conference hall, guest rooms, canteen, TV room and

dormitory are other facilities available in the premises. Trees are planted in the factory to

have an echo friendly atmosphere. A large testing bench to test pump sets up to 50HP has

been constructed. Modern methods are used for stocking and handling and even the raw

materials are stored in the stock yard through the palletts. This has helped the industry to

have an elegant look apart from making the handling easy. The present net worth of the

company will be around Rs. 600 millions.

PLANT AND MACHINERY

The company is installed with all modern and precise machineries required to

manufacture the pumps in high caliber. Most of the works are done in the factor itself by

using CNC machines. Special purpose machines are used to do jobs of intricate nature.

Utmost care is taken in the planning stage itself to keep the rejection at the lowest level

and also to get the job done in minimum time with less effort. Computers are installed at

every stage to monitor the processes. Generators of adequate capacity are installed for

uninterrupted power supply. Instruments of high accuracy are used along with standard

gauges for inspection. Efficient engineers are provided at each level to monitor and also

to contribute their knowledge for continuous improvement. Testing benches more than

the required are installed for taking care of each and every pump set for its performance

and longevity.

PRODUCT RANGE:

The company is engaged in manufacturing the following products:

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Submersible pumps for bore wells of different sizes ranging from 100mm to

250mm and above. The capacity range of these pumps falls between 0.5 and 2HP

for single phase operations and 3 to 120HP in the three-phase category.

Easily rewindable motor with low friction carbon bearings. Hydraulically

balanced design of impeller ensures long life. Motor designed to withstand wide

voltage fluctuations and operate with high efficiency to minimize the power

consumption, proper selection of advanced engineering materials ensures long life

and trouble free service. Multi stage pump directly mounted on the motor is

designed for maximum efficiency and low power consumption, Control Panel is

microprocessor based and has built in probe less dry run preventer, over load

protection, water level controller and status indicator.

Open well submersible pumps with capacity range from 3 to 120 HP In the three

phase category is a product with immense popularity for its ease of handling, high

discharge and trouble free operation especially in the agricultural sector.Ideal

features are No rigid base plate or bed required. No suction pipe & foot valve

required. No need of pump room. Winding cooled by water and designed to

withstand high. Voltage Fluctuation. Journal bearings lubricated and cooled by

water and needs. No external maintenance. Motor light in weight and can be

easily handled. Noiseless Operation

Amphibian monoblock pumps that can work inside and outside water and hence

can be applied for Critical applications like in well bores, filter point, bore wells,

dewatering pumps and as a flame proof pump sets.Ideal features are Pressurised

water from the pumping main in used as coolant for the windings. So power loss

due to external fan on the motor shaft is saved. No rigid base plate is required.

Can be used to pump water from inwell bores and filter point bores. No suction

pipe & foot valve required. No need of pump room. Journal bearings lubricated

and cooled by water and needs no external maintenance.

Centrifugal monoblock pumps For pumping water from wells, rivers & ect., huge

volumes (up to 3600 LPM) . For agricultural irrigation, industrial water supply &

ect.Ideal features are Totally Enclosed Fan cooled the motor with IP 55

protection. Monoblock construction eliminates misalignments & couplings.

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Ceramic & Carbon mechanical seal prevents. Maintenance of stuffing box.

Windings designed to withstand wide voltage fluctuations

Induction motor :Prime mover for pumps, compressors, machine tools & ect.

Ideal features are Designed for high over load carrying capacity and withstand

wide voltage fluctuations. Heavy size of bearings ensures long life. Ample size of

terminal boxes with provision for 90° rotation. Energy efficient with higher frame

sizes available request.

Domestic open well pumps For pumping out water from shallow wells, Sumps for

houses, factories, gardens and commercial buildings.Ideal features are No rigid

base plate or bed required. No suction pipe & foot valve required. No need of

pump room. Winding cooled by water and designed to withstand high Voltage

fluctuation. Journal bearings lubricated and cooled by water and needs no external

maintenance. Motor light in weight and can be easily handled. Noiseless

Operation.

Jet pumps For pumping water from 100mm & above bore wells, open wells.

Single phase control panel Suitable for operating submersible pumps with built in

running and starting capacitors for running the motor.Ideal features are Wide

voltage operating range 130 – 250 Volts. Built in electronic instant over load

protection for total safety. Probe less dry run protection. Built in water level

control. Status Indicators. Itching switch for staring capacitors.

D.O.L control panel Suitable for operating submersible pumps with built in

running and starting capacitors for running the motor.Ideal features are Total

Protection for submersible pumps. Suitable sized three phase contactors make

(BCH / L&T). Electronic over load protection and current sensing single phasing

preventor Ensures total protection for the pumpsets. Auto start facility when three

phase current not available. Phase Reversal Protection. Probe less dry run

preventor protects your pump from burn out due to dry running. Status indicators

indicates the availability of power, if pump is running or stopped due to overload,

single phasing, dry running or phase reversal. Auto start when three phase current

available and programmable time delay start and stop facility.

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Star delta panel Total operating and protection device for submersible

pumps.Ideal features are Total Protection for submersible pumps. Suitable sized

three phase contactors make (BCH / L&T). Electronic over load protection and

current sensing single phasing preventor Ensures total protection for the

pumpsets. Auto start facility when three phase current not available. Phase

Reversal Protection. Probe less dry run preventor protects your pump from burn

out due to dry running. Status indicators indicates the availability of power, if

pump is running or stopped due to overload, single phasing, dry running or phase

reversal. Auto start when three phase current available and programmable time

delay start and stop facility.

BRANCHES OF THE COMPANY ARE LOCATED AT

• Chennai

• Vellore

• Trichy

• Secundrabad

• Chittoor

COMPETITORS

Texmo Industries

Deccan pumps

C R I pumps

Suguna motors & pumps

Indus pumps

Mahendra pump

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CHAPTER - 4

DEPARTMENTAL STUDY

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ORGANIZATIONAL STRUCTURE

M.D

HR

manager

Marketing

manager Unit head

G.M

Finance

manager

Accountant Marketing

executive

Purchase

manager

Stores

manager

Production

engineer

Assembly

in charge

Winding in

charge

Packaging

in charge

Painting in

charge

MRS assistant

Store keeper

(process store)

Store keeper

(component

store)

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VARIOUS DEPARTMENTS

The various departments in this organization is as follows:

Purchase Department

Stores Department

Production Department

Finance Department

Marketing Department

Quality Control Department

Human Resource Department

PURCHASE DEPARTMENT

The purpose of purchase department is to streamline the system of purchase

components and raw materials. The process flow chart details the procurement process

and issue of material from the stores.

Stores in charge inform the requirements to the purchase manager. I shall generate

the requirements of the next month before 25th of the current month along with

the current stock available

Purchase manager maintains the pattern list for casting components.

Based on the requirement the functional head prepare Purchase Requisition Slip

and get the approval from the managing director. And based on the PRS raises the

puchase orders for all non-planned materials and purchases.

Based on the requisition from different, the stores in department issues the

materials and records the same.

Vendor Identification and Approval Process and Vendor Rating Process

Critical components are evaluated using ABC Analysis based on total value.

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Items are supplied and approved after vendor rating is done and recorded.

The Purchase manager does the Vendor rating

Parameters for evaluation shall be right quantity, right quality, correct delivery

schedule and price. For each parameter 10 points are allocated and rated for

individual vendor.

If the Total points exceed 28 – Very Good

Total points > 20 but < 28 – Good

Total points > 12 but < 20 – Fair

Total points < 12 - Poor

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THE ORGANIZATION CHART OF PURCHASE DEPARTMENT

Purchase Manager

Asst. Purchase Manager

Manager (Issue)

Foreman

Foreman

Manager (Receive)

Foreman

Foreman

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STORES DEPARTMENT

STORES INWARDS

The materials received are verified for quantity correctness, proper maintenance

at the godown (heat, pressure, rain etc), and defects due to transportation by the stores

personnel. Depending on the nature of the materials received, the material inward and

receiving inspection form is computer printed and issued to QC personnel for the

correctness of quality and dimensions.

The material inward and receiving inspection holds the name of the material

received, vendor details, the purchase order placed, purchase document details. The

Quality Inspection is carried out by the quality engineers and assures the quality of the

material received. The items found to be defective are sent back.

On the tested ok by the QC engineers, the materials are accepted into stores and

suitably stored for issue. The materials inward and receiving inspection report is duly

filed and retained by the stores personnel as a document for future reference.

If the materials are found to be defective, the received materials are sent back to

the vendor. Rejection goods report is generated by the stores in charge and the same is

forwarded to purchase department.

The operations are classified as:

Receipt Of Materials

Material Inward And Receiving Inspection

Inspection

Storing Of Materials/Purchase Return And Rejection Goods

Report

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STORES ISSUE

The production, service and machine shop makes a request entry in the system to

procure the materials required from stores. The physical stock available in the stores at

the time of requisition is made known to the requestor so as to decide the quantity

requested. On generation of the request a person physically moves to the stores to collects

the requests made.

MATERIAL BELOW ROL

The stores personnel view the request in his system and issue the material and

data punches the quantity issued as a mark issued. The stocks are immediately reduced

from the stores by the quantity issued. In the event of nonavailability or shortage of

materials, the stores personnel indicate the same to the purchase department for

procurement.

The stores personnel are aided with the above reports so as to verify himself the

correctness of the physical stock at his disposal. The purchase manager also views the

reports at any given time and plans for regular procurements of those materials which

have come down the re-order level.

The above said operations are classified as:

Stores Inwards

Stores Issue

Material Below Rol

Various files such as purchase requisition slip; approved vendors, vendor rating,

monthly indent, pattern list, new vendors, drawing files, vendors alphabetically arranged,

proforma details, and monthly requirements are maintained for reference.

The purpose of stores department is to store the raw materials which are needed

for the various departments in the organization. It is collected with the help of Purchase

Requisition Slip and the materials are given to the departments according to the necessity.

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The materials which are given to the department is lessened from the stores and it is

recorded. The raw materials are collected and stored in the store room. A minimum

quantity is kept in the stores.

Cast Iron : 1 tonne

Winding Wire : 5000 mtrs

Copper : 500 kg

Shaft : 2 tonnes

Pipe Rod : 500 kg

Pipe Sheet : 1000 kg

Stamping : 500 kg

Bolts and Nuts : 1000 kg

Sleeve : 500 nos

Bushes : 1000 nos

Impeller : 2000 nos

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THE ORGANIZATION CHART OF STORES DEPARTMENT

PRODUCTION DEPARTMENT

The production is the most important department in the organization and is paid

utmost attentation. The employees involves in the production adhere to the organization

on contract basis and are paid based on the number of pumpsets they manufacture.

The production of the components are carried out using both CNC and lathe

machines. The CNC machines are imported from Korea and are used in case of mass

production and Lathe machines are obtained from Kirloskar. Two CNC machines are

operating in the main unit, one with single spindle and the other double spindled. In case

of double spindled CNC machine, two separate processes are carried out and two separate

monitors are there to control them. Auto door function is also there in double spindled

CNC machine.

Stores Manager

Asst. store Manager

Store keeper (component

store)

Store keeper (process store)

MRS Assistant

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PRODUCTION IN-PROCESS

The production of in-house machined components are planned based on

forecasting taking into account the previous week productions pending orders and stocks.

Materials needed to produce as per production plan are acquired from the stores and

issued to the operator and the same is recorded in inprocess inspection note book.

Production Planning: This includes acquiring the raw materials from the stores

department according to the order received from the sales department.

Quality Control: The raw materials should be in good quality as per the

standards set by the company, otherwise the products turned to be poor quality.

Therefore the raw materials should be undergone the quality control process.

Acquisition And Issue Of Materials : The issue of materials after checking is

given to the department for the production process

Production: The production process is continued with various steps. They are as

follows:

Pressing

Welding

Winding

Fitting

Painting

Stocking of Finished Goods: The finished goods are stocked in order to meet the

orders from the customers and suppliers.

ASSEMBLY PROCESS

The schedule is prepared according to the order. The stocks of the finished

product, store stocks and machined components are taken into account. Based on the

schedule, production log book entry is done by the production engineer. Pump

assembly details work instructions are also included in the production log book entry.

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The pump and motor are assembled based on procedures. The fitter ensures the

perfect functioning of the product. Pump serial No. is generated by the welder at the

initial process. Then it goes for final inspection

The operations are classified as follows:

Production Schedule

Pump Assembly Details Work Instructions

Production Log Book Entry

Assembly Of Pump/Motor

Final Inspection

The purpose of production department is to convert the raw materials into finished

Pumps or Motors with high quality standards.

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PRODUCTION PROCESS

PRODUCTION

PLANNING

QUALITY

CONTROL

ACQUISITION AND

ISSUE OF RAW

MATERIALS

PRODUCTION

PROCESS

STOCK OF FINISHED

GOODS

PRESSING

WELDING

WINDING

FITTING

PAINTING

TESTING

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THE ORGANIZATION CHART OF PRODUCTION DEPARTMENT

FINANCE DEPARTMENT

Finance department is fully computerized and that enables fast recording

editing and alteration of records. They are responsible for arranging finance and monitor

the cash flow and allocation of fund to each department of the company, and they are

responsible the controlling over all finance.

The transactions are also accounted as per law in force Sales Tax, Income Tax,

Central Excise Duty, Tax Deducted at Source and service tax etc. Training will be

provided in computers and accounting packages for the new comers and existing

employees whenever required. Accounts department is also responsible for maintaining

good relationship with the dealers, customers, suppliers, Government bodies and public

etc.

Production engineer

Winding in charge

Machine shop in charge & assembly in

charge

Painting in charge

Packing in charge

Maintenance in charge

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During the mid‟s the company policies such as dealership policy and distribution

policy was very attractive, so the dealers were able to easily get done their needs from the

company so as to cater their customers. The company realized the competitive markets as

no submersible are in the field. Inorder to cater their dealers and customers the company

has amended its policy so as to strengthen their services such as timely delivery, zero

stock at dealer point, twelve hours clearance of serviced warranty and after warranty

pumpsets. This effectiveness they have achieved by adopting the modern administrative

tool ISO. Since accredited as an ISO company in the year 2000, the company‟s growth is

remarkable as the staff, worker and as the whole company itself is driven to the ISO

system

Functions of finance department

To raise necessary funds for company business operation

To arrange finance for each departments of the company

Prepare budget for every year

Take control measures in order to check the accounts

Maximize wealth of GEECO Pumps

Preparing the balance sheet of the company for every finance

Year

31

ORGANIZATIONAL CHART OF FINANCE DEPARTMENT

Joint Managing Director

Administrative Officer

Manager Accounts

Auditor

Data Entry Clerk

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MARKETING DEPARTMENT

The main feature of the marketing department of GEECO is that the publicity and

the advertisement they give for the product is very low. Their main strength is Reference

Marketing. At present, the organization is engaged in wall paper advertisements, paper

advertisements and radio advertisements.

GEECO have a wide dealer network spread all over the country. They are trained

to provide technical assistance to select suitable pumps to meet the requirements of

customers. Apart from the umpteen private customers all over the country, they have

regular patronage from various Governments. The main customer is Crompton greaves

Notable among them are

Tamilnadu Water Supply and Drainage Board

Kerala Water Authority

Andhra Pradesh State Irrigation Department

Public Health Engineering Department of Rajasthan

Southern Railways and various Collectorates all over Tamilnadu

The amount for the pumpsets ranges from Rs. 2500 to Rs. 1.5 lakhs. Their sales

for one month are more than 100 pumpsets. They give 1 year warranty period. Their main

attraction is the First ISI mark holder in India and First Launcher in Open Submersible

Pumps.

The companies have only 35 dealers all over India. There will be All India

Dealers Meet and State Dealers Meet for the dealers conducted in each year. The meet

includes taining, fixing targets, prizes for achieving the target and entertainment also.

Prizes will be Gold coins and Cash prizes.

Target for Sales Executives: Rs. 5 lakhs per month

Target for Dealers: Min – Rs.10 lakhs per annum

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Max – Rs.1 crore per annum

ORGANIZATIONAL STRUCTURE OF MARKETING

DEPARTMENT

The marketing department design suitable formats to procure feedback, suggestions and

complaints periodically based on the earlier analysis reports. Feedback of the reports is

collected through Market Survey, Questionnaires or Direct Meeting with the customers.

The operations are classified as :

Marketing Director

Marketing Manager

Business Development

ManagerSales Manager

Sales Executives

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Feedback Planning

Feedback

Analysis

Feedback Analysis Report

QUALITY CONTROL DEPARTMENT

The purpose of Quality Control department is to check whether the

Products are produced according to the right standard as specified by the ISO Standards.

The quality control takes place in a sequence which is as follows:

Process Sheet : In this before the processing a particular material is tested whether it has

good quality and what all process it should undertake i.e. how many cuttings are there,

tools used, speed needed, operations included in the process, jigs, fixtures used etc….

Inprocess Inspection: It is conducted during the process itself because this can lessen

the wastage of the products due to fault or damage. A record is maintained for this

inspection which includes description, operation, quality inspected, quality rejected

etc…. In every 10 piece the quality of 1 piece is checked.

Inspection approval Card: This is the inspection which is made for the materials which

have bought from outside like bolts, nuts, bushes, sleeves etc……..

Inprocess Material for Scrap: In this process the rejected materials which are off less

standard or quality are tested whether it can be reused after reprocessing. The record is

kept for this also which includes the reason for rejection, quantity rejected, whether it can

be reprocessed or not.

Quality Control Department also does the Machine Maintenance. The machine

maintenance is recorded on the following basis:

Daily Maintenance: Oiling the machine, pressure maintenance in the machine, air-

condition temperature, applying grease, lubrication of supply system etc…

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Fortnight Maintenance: Clean air conditioner filters, change coolant water, check belt

tension etc.

Six Months Once Maintenance: Check or Clean oil tanks

Yearly Maintenance : Replace all filters, Change CPU battery etc.

Two Years Once Maintenance: Overhaul the machine

Maintenance Record Details

Major faults, sudden accidents, break down which happens in the organization are

recorded with detail description, reasons, defaults and it is analysed in detail for further

avoidance of such happenings in the company.

In each stage of the process, quality is checked then it goes to the next stage so

that damages are much less.

THE ORGANIZATIONAL STRUCTURE OF QUALITY CONTROL

DEPARTMENT

Quality Manager

Quality Inspector

Foreman Foreman

36

HUMAN RESOURCE DEPARTMENT

The human resource department in the company can be divided into three:

Training

Recruitment

The GEECO pump on the whole consists of 240 workers, 42 staff and in the

managerial level there are 4 senior managers. The workers are both in the contract basis

and permanent workers. In 240 workers, 120 are contract basis and 120 are company

workers.

Again 240 workers can be classified into skilled, semi skilled, unskilled workers.

Skilled – 80

Semi skilled – 120

Unskilled – 40

The company workers get incentives for not being absent and overtime. The staff

apart from this gets festival bonus annually and 15 days paid up leave for 1 year and they

can encash the leave too. In workers there are 230 men and 10 women and in the case of

staff there are 31 men and 11 women.

Training

The training manager assesses the need for training with the help of documented

reports and if he finds necessary, arranges for the training with the confirmation of the

MD. The suitable faculty handles the class to impart the necessary training. External

training conducted by reputated institutions, is also attended by the staff on the approval

of the MD, recommended by manager

The feedback of the training is obtained from the trainee detailing the faculties

performance, arrangements and other information. This serves as a document of refernce

for the organization to improve the quality of training in future. The trained participants

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are evaluated on their performance by the end of training or after a particular period and a

report of the same is submitted to the MD.

The training operations are classified as:

Requirement Identification

Request Assessment & Approval

Training

Training Report

Training Appraisal

Trainee Report

Recruitment

The Manpower requirement is identified by the top management or department

heads with a view to ensure the activities are performed to the designed quality system is

forwarded as a requisition for manpower to the manager, training for further action.

The training manager assesses the need with assistance from concerned

department authorities and on conformance prepares a document detailing the required

skills, education, experience etc... And proposes the same for MD‟s approval.

The training manager identifies the suitable candidates and calls for a personal

interview, by a perusal of CV‟s. The CV‟s are gathered and interview panel is formed for

the suitable candidates to conduct a formal interview. Selected candidates are appointed

after the approval of the MD. Candidates, if necessary should undergo training for a

prescribed period of time.

The recruitment processes are classified as:

Manpower Recruitment Identification

Request Assessment & Approval

Interview Call

Recruitment

Requirement Report

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CHAPTER - 5

SWOT ANALYSIS

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SWOT Analysis

SWOT is an acronym for Strength, Weakness, Opportunities and Threats. It is a

part of strategic business process. SWOT analysis is broken into two parts because of the

different nature of information required each. These parts of environmental analysis for

identifying opportunities and strength and corporate appraisal for identifying strength and

weakness.

STRENGTH

Good Infrastructure:

The design department uses the most modern CAD solutions to design with

cutting edge technology. The unit is sufficiently support by high precision

engineering tools like CNC machines and special purpose machines. This enable

us to produce quality products Fully integrated computers that tracks and controls

the process within the organization helps in reducing the lead time, effective

utilization of available resources and better customer relations

management.Various functional departments of the firm are linked through

computer networks, which speedens up processes with accuracy and facilitate

immediate responses to satisfy customer's needs.

Location of the Plant:

The factory is situated on the highways at Kavundampalayam just 3 Kms

away from the main Bus Station and around 6 Kms from the Railway Station.

This makes an easy availability of raw materials from different areas and

customers can also reach the head office to make the orders.

Well equipped Quality Systems:

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The entire team at GEECO has been trained to focus on quality at every

stage. This has earned it numerous awards of excellence and recognition.

Intra & inter department communication are effective:

The communication procedures used in the company are very effective. They

convey all the informations using notices, memos, letters etc. They also conduct

monthly meetings to take decisions and to convey messages.

Expertised manpower:

Both the workers and managers are experts in their field with a long period of

experience. It improves efficiency and helps to increases the productivity

Wide range of products.

WEAKNESSES

Lack of availability of raw materials in the peak season.

During peak season (March, April & May) there will be a high demand for

their products. But they are unable to meet this demand because of the non

availability of large amount of raw materials.

Fails to meet competition in the market due to less number of dealers.

They have only 30 dealers allover India it reduces their competitive advantage.

But the competitors are having large number of dealers.

Promotional activities are less.

Their promotional activities like advertising and personal selling are limited to

the local area.

Rash usage of machinery by workers. Proper care is not employed

Less safety measures

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OPPORTUNITIES

The company can diversify into new product lines

Embracing the Latest Technology:

GEECO pump is adopting the latest technology in the machines which is used

to make the products and speedens the process with accuracy and facilitate

immediate responses to satisfy customer's needs.

THREATS

Tough competition

They face tough competition from Kirloskar Copeland, CRI Pumps, Sharp

Pumps, Aqua Sub Pumps, Suguna Motors & Pumps, Texmo Pumps and

Mahendra Pumps, who are the major players in the pump industry.

Importing of pump by china at low rate.

42

CHAPTER - 6

FINDINGS AND CONCLUSIONS

43

FINDINGS

The company started on 1954 by Mr. Govardhan

Its area of operations are Tamilnadu and Andhrapradesh

Flat organization structure

There are seven departments in the company

Flat structure.

Healthy intra & inter department communication

Promotional activities are less

The use of safety gadgets such face masks are not compulsory

Less Number of dealers

Less supervision is needed as the company is possessing expertise employees

The quality control department is having good quality control techniques and

standards.

Over time allowance is not only for the workers but also for the staff working

in the company.

SUGGESTIONS

The use of safety gadgets such a face mask should be made compulsory so as to

minimize respiratory problems or diseases.

Promotional activities should be increased so as to enhance better brand image.

Improve the number of dealers by providing incentives

Company should take initiatives for social activities.

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CONCLUSION

The study gave a wide exposure towards the practical aspects regarding the

functioning of a manufacturing organization. The training primarily focused on the

identification of various departments in the organization and their respective roles in the

functioning of the organization. Various information regarding Company Profile,

Products, Production Process, Quality Control, Stores Department, Organizational

Structure of each department were collected. Finally a SWOT analysis was also

performed to identify the Strength, Weakness, Opportunities and Threats of the company.

45

REFERENCES

I.M Pandey : “Financial Management”, Vikas Publications, 2006

K.Aswathappa, : “Human Resource Managent”, Tata Mcgraw-Hill Publishing

Company Ltd, 2006

Philip Kotler, Kevin Lane Keller, Abraham Koshy, Mithileshwar Jha, , New Delhi

:“Marketing Management”, Pearson Education, 2009

S.N Chary, “Production & Operations Management”, Tata Mcgraw-Hill Publishing

Company Ltd, New Delhi, 2008

http://www.geecopumps.com

http://www.wikipedia.com