project new
TRANSCRIPT
CHAPTER 1
INTRODUCTION
a) Introduction about the study:
Organizational study is the art of getting a practical knowledge of the practices done
in an organization. Nowadays practical studies are given more importance than theoretical
study. Organizational study helps a student to know how things are handled in an
organization. This will help a person to gather more practical knowledge in the field of
business. This covers almost whole of the organization’s departments. Each and every section
of the organization is covered collecting the maximum information that can be collected. This
study was for a period about 45 days.
Organization study is an exercise for the students who are undergoing M.B.A
program. It provides the student with the first hand idea on the practical working of the
organization. The students get an environment where he/she can actualize the knowledge he
has acquired in his curriculum. The exercise is an opportunity for the student to understand
the organizational structure, the major departments, flow of information and various other
functions in an organization.
An organization study is an excellent way to determine if the industry and the
profession is the best career option to pursue. Interns not only gain practical work experience
in a field that they intend to pursue but also build experience in international platforms. It
helps individual to combine theory with practical work experience.
Organizational study helps develop professional work habits; provides an
understanding of corporate cultures, gives an opportunity to analyze international business
settings, offers Platforms to compare differences in work styles.
It is on agreement between us and a company or organization for a fixed period of
time such as a semester or quarter .Agree to work for them and they agree to mentor and
teach us internships can offer valuable insight into practical field or career.
1
The institutional training programs is to gain knowledge of various management
activities and strategies involved in the day-to-day activities and strategies involved in the
organization. It is the bridge between campuses to corporate is the need these days. It enables
us to be future corporate is the journey from being a person to professional.
We get corporate trainers offers what comes directly from corporate. It also easy to
develops our communication skills to convey well & personally offering impact in existence.
These programs are helping us to know the industry requirements. Starting from interview
preparation and proving our self to be productive with personality for the organizations from
day one. This practical situation will help use more than theories which we studies. It will
help use to develop our skills through the practical experience. These activities help at the
time of its entry into organizations until we leave the organizations.
2
b) Industry profile :
World latex industry
Asia, dominates the world latex industry producing over 90% of the world output.
However, latex concentrate has been in the grip of price volatility for the most part of time
due to erratic supply, with prices currently ruling high at around US$ 2.2 in the producing
countries.
World supply of latex concentrate has been estimated at around one million tonnes a
year in dry rubber content terms. This comes to about 13% of the global supply of natural
rubber. Of the world output of latex concentrate, over 90% comes from Asia and the rest
from the African and Latin American countries. Centrifuged latex of 60% rubber content is
the largest variety produced in the world. This level of rubber content is optimum for making
many products through dipping, moulding and extrusion. Consequently, latex concentrate of
60% dry rubber content has remained the preferred material of the latex goods manufacturers.
Asia’s prominence
Asia is now the centre-stage of world latex industry. Countries of Thailand, Indonesia,
Malaysia, India and China are rich sources of NR latex and the products made out of it.
Annual output of latex concentrate is substantial, but its global requirement is more
pronounced. Latex products have become part of civilized life, as they offer living comfort,
healthcare and cozy toys for children. These are made in almost all developed and developing
countries. Being a much sought after raw material, latex concentrate has been in the grip of
price volatility for the most part of the time.
Low supply, high price
The price of latex concentrate has been ruling above US$ 2 a kg in the markets of
major producing countries like Thailand and Malaysia for over the past six months. It is quite
remunerative for the producers and processors, but the products manufacturers find it too
good to make finished products at fair price. Even at US$ 1.8 a kg early in January 2010, it
was pricey. Since then the price has moved up and ruled around $ 2.2 in the producing
countries. The fluctuation is obviously the result of inadequate supply. High demand for dry
rubber grades limits the availability of field latex for processing into concentrate. The price
of latex has been going up and down from time to time in tune with the surge and fall in
supply.
3
When the global economy is slowly recovering from the slump, there has been a
general rise in demand for goods and services. The economic downfall of 2008 and the slow
recovery thereafter have made a number of rubber-based products to turn dear, especially in
the healthcare sector. In the midst of such robust demand, outbreak and advancement of the
pandemic Influenza-A (H1N1) in many parts of the world have pushed up the demand further
for products like latex gloves. Global consumption of gloves has been estimated to be at
around 140 billion pieces a year. According to a preliminary estimate, this may grow by 10%
over the next five years. Consequently, demand for latex would rise further.
The position of major producers Thailand, Malaysia and India is briefly examined
here.
Thailand, the topper
Thailand was the world topper in production of latex concentrate in 2009 with
703,817 tonnes in dry rubber content terms, accounting for about 70% of the world output. Of
this, 100,262 tonnes was consumed by the domestic industry and as much as 595,550 tonnes
was exported. Almost 75% of the latex concentrate reaching the world market was from
Thailand.
Many of the major latex consuming companies in Thailand are multi-product
producers. Examples are Sri Trang Agro-Industry Public Company, Thai Rubber Latex
Corporation, Thai Hua (Public) Ltd. Co. and Von Bundit Co.Ltd. They figure among the
leading centrifuged latex producers in Thailand with diversified activities with production of
dipped goods and other latex-based products. As crop from their plantations is not enough for
captive consumption, field latex is procured from other plantations, traders and rubber
producers co-operatives to feed the latex processing units. Such companies make more gains
from the overall activities.
Malaysia, a major importer
Malaysia produced 110,913 tonnes of centrifuged latex in 2009 out of the total
rubber output of 857,020 tonnes. As domestic production of latex concentrate is quite
insufficient to feed the industrial units, a large quantum is imported. Production of latex
goods is an important industrial activity in the country. There are over 160 units in the latex
products manufacturing sector making medical, household and industrial gloves, catheters,
4
latex thread, balloons, finger stalls and foam products. They have fairly large scale of
operation.
Malaysia has been facing significant decline in natural rubber production from 1990.
However, the country wants to maintain its position as a world supplier of rubber and rubber
products. Large quantum of dry rubber and latex concentrate is imported into the country, for
domestic consumption and for export. In 2009, as much as 399,357 tonnes of dry rubber and
402,616 tonnes of latex concentrate were imported. With 110,913 tonnes of domestic
production, the latex concentrate availability rose to 513,529 tonnes.
Two multinational synthetic latex producers, Synthomer of the UK and
PolymerLatex of Europe have set up production plants in Malaysia. Together, they produce
230,000 tonnes of nitrile latex a year. In addition to meeting the Malaysian demand, the rest
is supplied to other countries in the Asian region.
India, significant player
Latex centrifuging is an important segment of the raw rubber industry in India.
Dipped goods, adhesives, carpet backing and the foam mattress segments raise good demand
for centrifuged latex. India is currently the third largest processor of centrifuged latex in Asia.
Import of latex does not normally take place in India as the import duty remains
high at 70%. Nevertheless, there is an avenue to import latex without duty. Products
manufacturing units in the Export Processing Zones can import raw material without duty.
Dipped goods producers in the Zone imported around 4,000 tonnes of latex concentrate in
2009 taking advantage of the duty exemption facility. Generally, units in the Export
Processing Zones import latex only when the domestic price exceeds the world price by a
significant margin.
Latex centrifuging
There are 73 latex centrifuging factories in India. A handful of them function in the
public and co-operative sectors. Rest of the units remains in the private sector. Capacity
utilisation of the centrifuging plants in almost all the units is around 50%. This is mainly
owing to the non-availability of enough field latex for processing. Over 85% of the country’s
rubber crop is processed into sheet rubber. Though capacity utilisation is low, latex
processing units are able to make profitable operation aided by the prevailing very good
price, in excess of US$ 2 a kg.
5
A good number of these units obtain field latex from own rubber plantations. But the
captive supply is quite insufficient for economic operation of the processing factory. Hence
they source preserved field latex from rubber traders, Rubber Producers Societies and from
plantations of reasonably good quantity of latex production. There are also commercial latex
processors who do not own rubber plantations. They utilise commercially available field latex
– mainly from planters who have sizable quantum on offer and from Rubber Producers’
Societies. Over 500 Rubber Producers’ Societies out of the total of 2,277 collect latex from
the member small growers and preserve it for sale to the latex centrifuging units. Each
Producer’s Society has membership of 50 small growers and the society is able to gather a
sizable quantum every week for offer to the processors.
Better price
Several small growers find it advantageous to sell the crop as field latex since the
price obtained is good enough, equal to the price of RSS 5 grade sheet rubber. Sometimes
they get a better price, when latex processors offer a premium to attract enough supply.
Selling the crop as field latex has many advantages. It reduces saves the on coagulation,
washing and sheeting the coagulum and drying the sheets in the smoke house, which takes a
minimum of four days. Transportation of the crop is also not involved as the buyers collect
field latex from the plantation premises immediately after tapping.
There are also 25 creamed latex processors in the country. Creamed latex is mainly
used in making latex foam and latex thread. The creaming units also function profitably as
the price obtained for creamed latex is remunerative. Latex concentrate finds ready market in
India. Its major user is the foam products sector. There are 154 units producing latex foam
and 75 producing coir foam.
6
c) Company profile :
KURIAN ABRAHAM LIMITED
(Latex Unit,Thucklay)
Kurian Abraham group of companies, founded 5 decades back,is the
pioneers and undisputed leaders in the rubber processing industry in India.The foresight,
vision and quest for quality propelled the group to establish itself as the single largest
processors of centrifuged latex and other latex based products for domestic and global
marketing.
The group grow rubber trees, tap ,preserve and process the rubber latex for
consumption in the dipped goods industry.Concentrated Natural Rubber Latex,crumb
rubber ,crepe rubber,examination/surgical gloves are the range of products manufactured and
marketed by the group.
The Concentrated Natural Rubber Latex supplied by Kurian Abraham
Limited ,Latex Unit is used in industries manufacturing inspection /surgical
gloves ,condems,ballons,foams and rubber bands.The gloves,condoms and foam industries
are the major customers of Kurian Abraham Limited,Latex Unit.(KAT)
The KAT unit was founded in 1973 with two centrifuge machines with an
average production of 6 tons per day.Over the last 38 years the unit has undergone
infrastructure expansions and technological up-gradations resulting in today’s production
capacities of 100 tons per day.
The production of CNRL involves collection of field latex from
estates,preservation at the collection points ,transportation to the factory,selection of
AFL(Ammonia Field Latex)lots for centrifuging,filtering in tanks,desludging,centrifuging,
chemical addition ,standardization and packing including marketing.
The important characteristics that contribute to the quality of CNRL are
DRC(Dry Rubber Content),VFA(Volatile Fatty Acid)No.,MST(Mechanical Stability
Time),KOH No and viscosity.On the basis of these characteristic, the CNRL produced and
marketed by KAT are the following grades:
CNRL grade standard
7
CNRL grade super
CNRL grade special
CNRL grade X
CNRL grade 52% DRC
Classified 35% DRC
CNRL grade LATZ
A part of the centrifuging process is subcontracted to an external facility
owned by the Kurian Abraham group.The desludged latex is sent from KAT to the unit that
centrifuges,packs and provides packed CNRL back to KAT for taking into main stock of
finished products.
The finished product CNRL is packed in reconditioned MS drums ,inside
coated with bituminous paint and exterior painted with enamels.The standard quantity in a
drum is 205 litres net.The drum is sealed using tamper proof bung caps.
The standard grade CNRL packed in KAT is under product certification
license of Bureau of Indian Standards since 1992.The ISI marking process helped to
strengthen the quality control activities of KAT and from this base level of quality
management , the organization came a long way in improving the processes and process
controls and thus gaining appreciable recognition as the best reliable quality latex supplier in
India.
d) Product profile
8
The late Mr. Kurian Abraham started Kurian Abraham Private Limited as a
proprietary concern in the year 1955. The firm was engaged in marketing latex. In 1958 a
factory was set up for processing latex. Today KAT is one the largest processors of
centrifuged latex in India with an output capacity of 100 metric tones per day.
Products
Latex
Pre - vulcanized letex
Skim crepe/ block
Latex
KAT's double centrifuged latex and specialty latex grades meet the exacting
requirements of the manufacturers of condoms, gloves, catheters, elastic threads, foams,
balloons, toys, rubberized coir etc. In fact it is the first ever Indian latex processor to receive
an ISO 9001:2000 accreditation as well as the ISO 14001: 2004 accreditation for
environmentally friendly stringent manufacturing practices. Until now, the general
impression was that it is was not possible to get ISO 14001 certification for rubber based
industries as the processing of natural rubber latex is bound to generate large quantity of
effluent. Nevertheless, KA-Latex's steely resolve and commitment for environmentally safe
manufacturing practices and procedures has nullified this myth and proven that even in the
rubber industry ISO: 14001 accreditation is very much feasible.
The company's latex, sold under the KA Latex brand not only has a significant share
in the Indian market but is also exported to countries across the world such as the US,
Europe, South America,Turkey and Sri Lanka.
Pre - Vulcanized Latex
An exciting development on the processing horizon is the introduction of pre
vulcanized (PV) latex in India. KAT is first in the country to enter into a technical agreement
with the world major in PV latex - Revertex of Malaysia to offer world-renowned Revertex
and Revultex grades of PV lattices in India.
Their PV Lattices are distinguished by their long shelf storage life, online process life,
consistency and stability. They have end use applications in gloves, condoms, catheters, baby
teats, continuous sheeting, adhesives, carpet backing, cast articles including theatrical masks
9
and toys. These lattices are specially formulated and tested to perform on modern high speed
manufacturing lines and custom built lines of individual manufactures, with minimum batch-
to-batch variations. They meet all the currently known and impending regulations on cyto-
toxins, carcinogens and proteins - giving the Indian rubber industry an altogether fresh
impetus.
Skim Crepe
Skim Crepe is produced from skim latex. Skim latex is produced as a byproduct
during the preparation of centrifuged latex concentrate. It has a dry rubber content of only 3
to 7%. However, it also has a very low dirt content. Coagulation of skim latex is done by
acid treatment. It is important that the ammonia content is kept as low as possible. The skim
coagulum is washed and milled. This produces sheets between 1.2 and 1.5 mm thick and 24
cm wide. The washing process removes from the coagulum considerable amounts of the
serum constituents which can cause rotting. The sheets are dried in drying rooms for 2.5 to 4
days at 37°C . The sheets are packed as bales and marketed as "skim crepe".
Skim Crepe Block
Skim Crepe Block is made from skim crepe sheets which is made into blocks and
palletised for shipment. These blocks will be properly dried in drying chambers at around 100
+degree centigrade. Properties will be similar to skim crepe except it is more convenient to
transport as well more dried than the skim crepe. The quality is almost at par with ISNR 20
except slightly high nitrogen content.
CHAPTER 2
a) Objectives of the study:
10
To know the organizational framework .
To know how manufacturing process is carried by the company.
To know the functions of various departments.
To know the authorities and responsibilities of each personnel.
To know the working environment.
b) Scope of the study:
The study is being conducted at Kurian Abraham Pvt.Ltd(Latex Unit),Thuckalay.
And this study tell us an overall view of organization and functions carried out by different
departments like manufacturing, maintenance, human resource, accounting & administration,
etc.,.
c) Area of the study:
The study had been undertaken at Kurian Abraham Pvt.Ltd(Latex Unit),Thuckalay
and the respondents were the assistant factory manager and the employees from different
departments like accounts and administration,human resource, testing and laboratory,etc,.
d) Limitations of the study:
1. The primary data collected from limited respondents.
2. Lack of time is a major limiting factor.
WORK ENVIRONMENT
11
Work environment requirements are initially elicited , discussed and finally
determined by a group of top management members,having regard to the need to ensure
positive influence on motivation,performance and satisfaction of employees.
Human and physical factors of environment determined and managed are:
Suggestion system
Personnel safety
Use of protective equipment
Facilities to wash,change,eat and rest
Hygiene and cleanliness levels
Noise and vibration levels
Light and airflow needs
Pollution level in the work areas
CHAPTER -3
DEPARTMENT PROFILE12
A) HUMAN RESOURCES DEPARTMENT
DEPARTMENT CHART :
Responsibilities of HR manager:
Determining competency needs of personnel with the approval of director.
Recruitment of personnel.
HR deployment & induction.
Human aspects of work.
Education & training of personnel.
Maintaining personnel data.
Annual performance appraisal.
Continual improvement of HR process.
Authorities of HR manager:
Prepare education and training plans.
Organize training events.
13
DIRECTOR
HR MANAGER
ASSISTANT
Update training records & personnel data sheet.
Review annual performance appraisals & follow up actions.
Labour welfare facilities:
The labour welfare facilities and fringe benefits provided by KAT to its labours are
quite appreciable such as,
Two sets of free stitched uniform every year
Washing allowance
Provident fund
Medical allowance
Tea allowance for labours
Bonus
Gratuity
Fringe benefits:
Medical allowances.
Loans without interest for motor vehicles
Children education allowance
Family tour.
Working time:
In KAT,the working time varies workers to workers according to the nature of work.It
can be listed as follows:
Machine workers:
i. A shift - 6:00am to 2;00pm(40 workers)
ii. B shift - 2:00pm to 10:00pm(30 workers)
iii. C shift - 10:00pm to 6:00am(20 workers)
Intervals - 10:00am to 10:30am ; 6:00pm to 6:30
Office staff:
9.00am to 5.00pm
14
Lab:
i. A shift- 6.00am to 2.00pm
ii. B shift- 1.00pm to 9.00pm
Others:
i. A shift = 6:00am to 2:30 pm
ii. B shift = 1:30 pm to 10:00pm
Total number of employees:
KAT employed totally hundred permanent workers as 85 male workers and 15
female workers .It also employs temporary workers.There, 24 contract workers are working
currently.
Leave facilities:
KAT provides leave facilities to its workers concerning their personal life.They are
given as follows:
Factory workers:
o Earn leave - 20 days
o Casual leave - 5 days
Office Staff:
o Casual leave - 7 days
o Medical leave - 8 days
Managers:
o Leave -25 days
Female staff:
o Maternity leave - 84 days
Payroll process:
15
Office staff are paid salary on the first working day of every month.Labours are paid
wages as monthly payment on the date of 5.If it is a holiday ,it will be paid on the next
working day.All the payments are made only through bank.The payment details are as
follows:
Staff:
Basic pay
DA 12%
Medical allowance 4%
Provident fund 12%
Labours:
Basic pay
DA 12%
Medical allowance 4.5%
Provident fund 12%
B) FINANCE DEPARTMENT
16
DIRECTOR
GENERAL MANAGER
ACCOUNTS MANAGER
ACCOUNTS ASSISTANT
DEPARTMENT CHART:
Responsibilities of finance manager:
Preparation of budget.
Cash flow management.
Banking.
Expenditure control.
Preparing finance & account’s related reports.
Authorities of finance manager:
17
Reviewing & processing financial sanctions.
Release of payments.
Assets and liabilities:
KAT acquired a very good position in the latex industry. It makes
around 250 to 300 crores of turnover every year .And earns net profit of 6 crores.The
following figure shows the different types of assets and liabilities.
Types of assets:
Fixed assets
* Land (Non depreciable)
* Plant & machinery
* Furniture & fixture
* Vehicles
Current assets
* Debtors
* Loans & advances
* Bank
* Cash
* Stock in trade
Investments
Non tangible assets
* Goodwill
* Miscellaneous expenses
* Technology known
18
Types of liabilities:
Share capital
Reserves & surplus
Current liabilities
Loans & advances
Profit & loss
Investment:
KAT invests its surplus in mutual funds / money market.The investments are made as
temporarily only.Mostly it invests for the period of 6 months.
Sources of funds:
Some times funds are generated through the company’s profit.Mainly they use
shareholders’funds/ directors’ funds / sales funds.
Tax payment:
KAT pays all types of taxes accurately on time such as excise duty,advance
tax,income tax,service tax,sales tax,purchase tax,etc.,.They paid taxes for the year 2010 –
2011 and 2011-2012 as 33.22% and 32.5% respectively.
Working capital management:
As latex is a seasonal product ,KAT needs working capital during the months of
August to February.But,from March to July ,working capital is not needed.
19
C) WORKS/FACTORY DEPARTMENT
DEPARTMENT CHART:
20
DIRECTOR
EDP IN CHARG
E
ACCOUNTS &ADMINIST-
RATION
CHIEF CHEMIST
ASST MANAGER (COMMER-
CIAL)
PRODUCT-ION CHEMIST
STORE IN CHARGE
FACTORY MANAGER
MAINTE-NANCE
PURCHASE ASSISTANT
BRANCH IN CHARGE
DESPATCH ASSISTANT
SUPERVISOR
AUTHORITIES AND RESPONSIBILITES OF FACTORY
MANAGER
Authorities:
1. Approval of purchase order.
2. Approval of capital purchase to amount of Rs.10000 or below.
3. Approval of cash purchases upto Rs.5000.
4. Approval of level ‘c’ documents.
5. Stop production.
6. Changes to production plan.
7. Extend working hours.
8. Approve overtime.
9. Interaction with statutory authorities and other external bodies.
10. Review and disposition of non-conforming products.
11. Resolving customer complaints.
12. Approving cash requirements.
Responsibilities:
1. Overall functioning of factory.
2. Day to day administration of factory.
3. Identifying training needs for those reporting to him.
4. Supervision of activities of assistant manager-commercial,chief chemist,production
chemist,etc.,.
5. Identification of monitoring and measuring devices in co-ordination with chief
chemist.
6. Identification of resources requirement for the factory.
7. Man power planning and deployment.
8. Providing technical clarification in co-ordination with chief chemist.
9. Ensuring achievement of planned production.
10. Ensuring complaint to statutory and regulatory requirements
11. Ensuring safety of personnel and working conditions.
21
12. Ensuring upkeep of factory premises.
13. Human resource management pertaining to factory.
14. On job training to department heads.
15. Disbursement of salaries and wages.
16. Providing information to management pertaining to factory operations.
17. Continual improvement.
Activities:
It includes purchase planning, production planning, statutory compliance, review
and analysis of data(factory level), control of sub contracted centrifuging, etc,.
The works department consists of seven sub departments such as,
a) Production
b) Information Technology
c) Maintenance
d) Stores
e) Commercial
f) Testing & Laboratory
g) Sales & Planning
The department charts and the authorities and responsibilities of each personnel for
each department are as follows:
22
a) Production Department
Department chart:
Responsibilities of Production chemist:
To control the production process.
Timely execution of production plan.
Ensuring cleanliness inside the factory.
Referring to work instructions and specifications.
Identifying training needs for those reporting to him.
Ensuring the fitness of production equipment.
Authorities of production chemist:
Extend the production time to complete the production.
Stop further process in case of production long sheet or daily report.
23
PRODUCTION CHEMIST
PRODUCTION SUPERVISOR
WORKMEN
FACTORY MANAGER
Clear the CNRL for packing.
Approval of indents.
Determining the quality of chemical and other materials.
Responsibilities of production supervisor:
Timely execution of direction from the director.
Adhering to production plan.
Housekeeping.
Packing the correct batch.
Addition of chemicals.
Selection, setup, dilution and additions.
Authorities of production supervisor:
Assigning the personnel for work.
Clear the product for next process.
Quality policy:
Commit to consistently ensure customer satisfaction by exceeding quality levels of known
expectations; employing continually improved processes; and strictly adhering to agreed
delivery schedules.
24
RECEPTION OF FIELD LATEX AT VARIOUS
COLLECTION CENTERS
DESLUDGING
PUMPING TO RECEIVING TANK
CENTRIFUGING
QUALITY CONTROL TESTING
CONCENTRATED LATEX IN STORAGE TANK
SKIM LATEX
PRESERVATIVES
ADDITION OF DAHP(Dry Ammonia Hydrogen Phosphate)
PRODUCTION PROCESS :
25
Aspects of Production Planning
KAT considers the followig aspects for the planning of production.
Market demands details received from Sales & Planning manager.
Availability of raw materials.
Capacity utilization.
Current customer order.
Orders for special products.
Ammendments to production plan may arise due to
* Changes in customer requirements.
* Priorities in order execution
* Exigencies at KAT.
Safety measures:
The equipments provided by KAT to its workers to ensure their safety to prevent
accidents are Gloves, shoes, chappals, acid-gas masks, safety belts, hip ropes, protective
cloth, face shields and helmets.
26
b) Administration & Accounts Department
Department chart:
Responsibilities of A & A officer:
Consolidation of stock and statutory statements.
Maintenance of time card.
Indenting for cash requirement.
Disbursement of salaries & wages.
Assuring statutory remittances.
Compilation of leave statements.
Authorities of A & A officer:
Procuring N forms, cess permit and delivery note.
Issue of stock and cash statements.
Responsibilities of assistant:
27
FACTORY MANAGER
A/C’S & ADMINISTRATIVE
OFFICER
ASSISTANT
Maintaining statutory registers.
Consolidation and dispatch of empty drum statement.
Despatch of all general statements.
c) Information & Technology
Department chart:
Responsibilities of EDP-in charge:
Preparation & consolidation of statements.
Maintenance of records.
Proper control of electronic documents.
Storage and protection of CDs and floppies.
Scanning of virus as per schedule.
Taking the hard copies as per requirement.
Responsibilities of data entry operator:
Correct feeding of data.
Taking the hard copies as per requirement.
28
FACTORY MANAGER
EDP-INCHARGE
DATA ENTRY OPERATOR
d) Maintenance Department
Department chart:
Responsibilities of junior supervisor:
Execution of preventive maintenance.
Check up of generator, DM plant and water softener.
Checking the quality of items purchased.
Authorities of junior supervisor:
Approve the quality of item purchased.
Recommand for repairs/replacements when needed.
Activities:
It includes maintenance of buildings & work areas, utilities , centrifuges and
stirrers, open drum storage yards, sludge pits, open drains, latex storage tanks,computers,etc.,
and AMC maintenance.
29
FACTORY MANAGER
JR.SUPERVISOR-MAINTENANCE
WORKMEN
e) Stores Department
Department chart:
Responsibilities of senior supervisor:
Identifying storage areas.
House keeping.
Insurance of products.
Reverification of stored products.
Maintenance of stocks.
Handling storage resources.
Identifying training needs for those report to him.
Reservation of product.
Maintaining records.
30
FACTORY MANAGER
SENIOR SUPERVISOR
SUPERVISOR
WORKMEN
Authorities of senior supervisor:
Approval of gate pass.
Issue of products.
Initiation of purchase requisition as per Re Order Level.
Dispatch products.
SUPERVISOR –DESPATCH:
Responsibilities :
Despatch of products as instructed by commercial assistant.
Maintaining the stock CNRL.
Identifying the storage area for CNRL.
Protection of CNRL under storage.
Co-ordination with commercial assistant.
Authority:
Load the products.
31
f) Commercial Department
Department chart:
32
FACTORY MANAGER
ASST.MANAGER(COMMERCIAL)
DESPATCH ASST.PURCHASE ASST. BRANCH IN-CHARGE
ASSISTANT FIELD SUPERVISORASSISTANT
ASST,FIELD SUPERVISOR
Responsibilities of assistant manager:
Budgeting the purchase of latex.
Transport arrangement of despatches.
Daily arrangement of schedules for lifting of AFL and general items.
Implement corrective / preventive action.
Identifying training needs to those reporting to him.
Conducting supplier evaluation and identification of new supplier.
Authorities of assistant manager:
Release of purchase budget of latex.
Negotiating the general purchase.
Approving the transport quotations.
Release a purchase order.
Rate of supplier performance.
Commercial department itself includes two sub - departments.They are as
follows:
i. Purchase department
ii. Despatch department
33
i. Purchase department:
Activities:
Provision of resources to the latex supplier through branches.
Demonstration of latex preservation to the approved suppliers through
branches.
Co-ordinating with branch for latex procurement.
Check list for latex load dispatch from branch.
Settlement of payment to the latex suppliers.
Purchase of drums.
Verification of purchasing data and release of purchase order.
Monitoring of purchase order.
Evaluation and approval of suppliers.
Performance monitoring of suppliers.
Reorder level and minimum stock level to ensure materials are available.
Purchase planning.
Important suppliers:
The suppliers of KAT are from different states.Mainly they are from Kerala.KAT
purchases its raw materials from about 250 suppliers.The important among them are:
Velimali estate.
Kavuvalla agencies.
Kundarathala agencies.
Arun agencies.
Arasu agencies.
Woodhope estate.
34
ii. Despatch department:
Activities:
Batch and drum selection for despatch.
Verification of trucks documents & driver license.
Loading and preparation of gate pass.
Planning and monitoring of despatches.
35
FACTORY MANAGER
LAB CHEMIST
CHEMIST
ASSISTANT CHEMIST
LAB ASSISTANT
LAB BOY
CHIEF CHEMIST
g) Testing And Laboratory
Department chart:
It structured same as the R & D department.
36
Responsibilities of chemist:
Preparation of solution used for testing.
Checking of AFL received.
Reporting of testing done.
Maintenance of statutory registers and records.
Authorities of chemist:
Assuring the use of correct test methods and calibrated measuring devices.
Assuring proper testing & timely reporting.
Monitoring the DRC of sources sample and lot sample and reporting of various.
Recording and reporting of test results.
Activities:
Testing color of CNRL.
Testing odour.
Testing total solid content.
Testing dry rubber content.
Testing ammonia,VFA methods, potassium hydroxide, magnesium content, etc.
Preparation of standard solutions.
37
D) SALES & PLANNING DEPARTMENT
DEPARTMENT CHART:
Responsibilities of sales manager:
Generate customers, maintain customer relationship.
Submit offers.
Conduct negotiation.
Accept orders, issue confirmation and work order to factory.
Realization of payment of bills.
Fixing price to the products.
Issue daily dispatch schedule and sole documents.
Correspondence with customers.
Responsibilities of sales assistant:
Preparation of daily dispatch schedule.
Maintaining sales order register.
38
DIRECTOR
SALES MANAGER
SALES ASSISTANT
Maintaining of customer related files, bills etc.
Checking of bills.
Target:
Though latex is a seasonal product,it is a demand oriented product. The target to
produce latex for one year is 1lakh field latex.
Fixing annual sales target:
The manager has to plan and fix the annual sales target at the month of March every
year. The manager has to consider the following aspects while planning & fixing annual
targets.
Actual sales & production of previous year.
Market demand.
Competing market contribution.
Resection rate.
Seasonal crop variation.
Customer Focus:
A customer focus is inherent to the business processes of the organization.The
present requirements of customers are determined and met. The quality of
products ,services,communications and relations,to the extent practicable,is also maintained
at a level that exceeds the customer expectations.
The emerging market trends including the possible future requirements that are
likely to be specified by customers and statutory/regulatory agencies are monitored and
timely actions taken to position the organization with ability to meet such requirements in
future.
Perceptions of customers as to what extent their needs and expectations are
met,are monitored and measured.
39
Methods of overcoming competitors:
KAT is overcoming its competitors by focussing on the following three
areas.
Better customer relationship.
Good customer service.
Quality of product.
No Advertisement:
As latex is a raw material for producing gloves, balloons, etc. there is no
advertisement.
Major customers:
KAT has about 150 customers from various districts,states and also from
nations. Kurian Abraham group itself acts as one of their major customers as it produces
gloves,condoms,rubberband,etc.,.
The other important customers are:
TTK LIG-America
HLL- Trivandrum.
Kurlon.
Suretx.
40
E) ISO 9000 CELL
DEPARTMENT CHART:
Responsibilities of management representative:
Ensuring proper implementation & control of QMS.
Reporting the performance of QMS.
Ensuring promotion of awareness of customers requirement.
Monitor and ensure effectiveness of corrective action.
Reporting of audit results.
Authorities of management representative: Proper issue of QMS documents.
Issue of management review meeting agenda and minutes.
Issue of internal audit schedule.
Responsibilities of the assistant: Maintaining statutory registers.
Consolidation and despatch of empty drum statements.
Despatch of all general statements.Activities:
1) Analysing internal audit results.
41
DIRECTOR
MANAGEMENT REPRESENTATIVE
ASSISTANT
2) Organizing management reviews and follow-up actions.
F) R & D AND QUALITY ASSURANCE DEPARTMENT
DEPARTMENT CHART:
42
FACTORY MANAGER
LABORATORY CHEMIST
CHEMIST
ASST.CHEMIST
LAB ASSISTANT
LAB BOY
CHIEF CHEMIST
Quality objectives of chief chemist:
Determining product requirements including regulatory requirements.
Planned approach to measuring quality including selecting measuring devices.
Use of correct specifications and methods for measuring and monitoring the quality.
Ensuring the release of conforming products.
Quality Objectives of chemist:
Monitoring statutory registers and records.
Ensuring good laboratory practices.
Ensuring use of correct test method and calibrated measuring devices.
Correctness of product characteristic verification.
Accuracy of recording data.
Quality objectives of assistant chemist:
Preventing mistakes in testing.
Right handling of lab accessories.
Ensuring the correctness of test result.
Pre-Vulcanized Latex Technology:
KAT gives greater importance to R & D department.Due to this it has introduced a new
technology to produce pre-vulcanized latex . Pre-vulcanized latex is unperishable one.So that
,the customers can store it for long duration and there is no need for customers to mix
chemicals for their further production.
No Ammonia Latex:
KAT has taken a conscious decision to reduce the amount of pollutants.No ammonia latex is
in research which is meant for non-pollutant latex.Within a short period it will come to
market and will make the environment healthy.
43
CHAPTER - 4
SWOT ANALYSIS:
STRENGTHS :
KAT is a large factory.
ISO 9001-14001 certified.It is the only factory which has been certified for both the
quality and no/less polluting environment.
It has a great scope for export.
It also has a good infrastructure.
KAT has a strong financial position.
No problem if demand is low that it has Customers from its own group of Kurian
Abraham Pvt.Ltd.
WEAKNESS :
High cost of production.
Labour shortage which results high labour cost.
OPPORTUNITIES :
Pre-vulcanized latex technology.
Joint venture with Malaysia.
Infrastructure development.
Foreign customers.
It has an opportunity of labours from North India.
THREATS:
Fluctuation in prices.
Raising cost of raw materials.
Low power generation by government as the industry heavily relies energy resources
like electricity.
44
CHAPTER - 5
FINDINGS, SUGGESTIONS AND CONCLUSIONS
a) Findings :
Kurian Abraham Pvt.Ltd,Latex Unit , Thuckalay is on a steady growth path.It is the
oldest and the most trusted latex unit of our country.
Its in-house R & D facility for advanced product design,development and testing ,
plays a critical role in bringing about a high level of customer satisfaction and reliability of
products.Their fully equipped labs for complete testing of products have enabled to develop
products in compliance with Indian and international standard specifications.
KAT’s in-house research , design & development competencies, world – class
manufacturing facilities , continuous training, skilled labour and professional management
give them edge over competition.
b) Suggestion :
Though KAT provides good welfare facilities to its labours and its
employees, the total number of permanent employees / workers are comparatively low. So, it
would be better to get feedback from the employees/workers to find out their actual
expectations.If there is any default from the management,it can be analysed and decisions can
be taken to rectify them.This will lead to sustain the efficient employees / workers
permanently with them.
45
C) Conclusion :
The organizational study on Kurian Abraham Pvt.Ltd,Latex unit,Thucklay,
has really enabled me to understand the organizational structure of the corporate world to an
extent,the ways and means how it functions.KAT is one of the leading industries in the
manufacturing of latex.
It was found during the study that is indeed a healthy organization with a lot
of well unique functions, the industry basically being an latex industry has a large investment
and a good no.of people working in it,there is a well established organizational structure with
the top level management,the middle level management and the bottom level management.
KAT has introduced good labour welfare facilities which care the needs of
workers and consequently increases the love and affiliation of the workers toward the
organization.
KAT is the only manufacturing industry which owned the pre-vulganized
latex technology having joint venture with Malaysia.
KAT has customers not only from India but also from foreign countries like
China ,USA,etc.,.It also has a good infrastructure and it is strong in its financial position.It is
the largest processor of centrifuging latex in India.Thus,KAT has earned a good name in the
society.
46
APPENDIX
47
48
O
RG
AN
ISA
TIO
N S
TR
UC
TU
RE
Fina
nce
Wor
ks /
Fact
ory
ISO
900
0 C
ell
Sale
s And
Pl
anni
ngR
&D
And
Q
ualit
y A
ssur
ance
Adm
inis
tratio
n &
Acc
ount
sM
aint
enan
ce
Com
mer
cial
Prod
uctio
n
Stor
esTe
stin
g La
bora
tory
Purc
hase
Des
patc
h
DIR
ECTO
R
BIBILIOGRAPHY
COMPANY DOCUMENTS
WWW.OOPPOOTTIL.COM
WWW.RUBBER.COM
WWW.ALLRUBBER.COM.AU
49
O
RG
AN
ISA
TIO
N S
TR
UC
TU
RE
Adm
inis
tratio
n &
Acc
ount
s