Laxmi Percision Screws Ltd. Rohtak

INDUSTRY PROFILE

Put simply, anything which joins together two things is a fastener – a broad and collection terms for nuts, bolts and screws-which keeps separate assemblies of any engineering system together in a predetermined position. Fasteners is one of the joining methods, the other notable being welding and riveting. While the latter farm permanent joints, fasteners can be undone when required, mostly for repair and reconditioning.

Fasteners can be broadly classified into two categories depending upon their tensile strength, mild steel (MS) fasteners and High tensil (HT) fasteners are used across abroad spectrum, mostly in general application; they are produced by the SSI and unrecognized sector, using lather and by rolling.

On the other hand, HT fasteners which are elatively technology intensive are manufactured by a few units in the organized sector via the cold hardning (a form of forging) Process HT fasteners can be classified into standard (available of the shelf) and specialized (made to specific design).

Fasteners have two types of head : hexagonal and socket heads Socket Head Screws (are also known as allen Screws or grub screws by machines) are used mainly for industrial application in textiles, machine tools, pumps etc. and also in erecting transmission towers.

Objective of LPS

The main objective of LPS is to provide customer satisfaction or we can say

That making things according to customer demands.

The other main objective of the company are:

· To position himself in the Market

· To increase productivity

· To innovate new things

· To double the export and bring foreign currency

· To get maximum profits

· To increase the performance of employees

· To develop technical and administrative skills

· Optimum utilization of human on resources

Products List

1. Bolt & Nuts For Automobile

A. Engine Parts:

Ø Con Rod

Ø Cylinder Studs

Ø Counter Head

Ø Rocker Arm

Ø Engine Mounting

Ø Main Bearing etc.

B. Chasis Parts:

Ø Wheel Bolts

Ø Wheel hub Bolts & Nuts

Ø Axle Bolts/Pin

Ø Flanged bolts

Ø Collar Bolt

Ø Shock Absorber Mounting Pins etc.

2. Fasteners

A. Constrution Parts (Friction Grip) :

Ø Bolts and nuts for Agriculture Industry

Ø Bolts and Nuts for Industrial Machinery

B. Cold formed parts for Automobile :

Ø Piston Pins

Ø Switch Body

Ø Ball Joints

Ø Gear blanks

Ø Rocker shaft etc.

There are mainly two types of products

A. Standard Fasteners:

Ø Socket head cap screw

Ø Low head socket bolt

Ø Shoulder Bolt

Ø Button head

Ø CSK

Ø Hex wrench keys

Ø Dovel Pin

Ø Nuts

Ø Friction Grip Bolts

Ø Track shoe bolts

Ø Stainless steel hex head

Ø Stainless Steel Socket Head Cap Screws

B. Special Fasteners

There are the products that are made on special order

Ø Round Head Bolts

Ø Hand Bolts

Ø Axle Bolts

Ø Connecting ROD Bolts

Ø Counter Weight Bolts

Ø Wheel Bolts

List of Main Market of LPS

A. DOMESTIC (USER INDUSTRIES)

Ø Automotive

Ø Aviation

Ø Heavy & Light Machinery

Ø Hydraulic/Pnematic Pumps

Ø Machine Tool, Jigs & Fixture

Ø Rilways

Ø Refrigeration & Air Conditioning

B. INTERNATIONAL (COUNTRY)

Ø Australia

Ø Germany

Ø Hong Kong

Ø Japan

Ø Singapore

Ø South Korea

Ø Sweden

Ø Switzerland

Ø United Kingdom

Ø United States of America

Vision of LPS

MOTTO: Total customer satisfaction a market leaderdhip.

TARGET: Annual growth of 30% out of which export should

Contribute up to 50%.

PLAN: To continuously upgrade process technology

& develop new products.

FUNCTION: System oriented approach.

PEOPLE: The driving force behind it.

List of Certificates

1. A2LA

2. NABL

3. ISO9002

4. QS 9000

5. ISO/TS 16949

6. ISO 14001

Major Competitor of the Company

Ø Sunderam Fasteners of TVS Group

Ø UN-BRAKO And Guest Keen Williams

Ø Panda Togun Limited

Ø Sterling Tools

Ø Precision Partners

Various Department of the Company

Ø Marketing Department

Ø Accounting Department

Ø Sales Department

Ø Export Department

Ø Production Department

Ø Purchase Department

Ø Personnel and Administration Department

Ø Design and Drawing Department

Ø Manufacturing Department

Ø Maintenance Department

Ø PPC Department

Ø Quality Department

Ø Standard Department

Ø Tool Department

Ø Lab

LOCATION OF THE PLANT

The company is situated on highway No. 10 Hissar road in District Rohtak (Haryana). L.P.S. Ltd. Is nearly about 5.00 K.m. from bus-stand and 3.00 K.m. from railway station. The company has got excellent manufacturing facilities and conditions. Manufacturing plant extending over a space of about 25-30 areas.

INTRODUCTION

Founded in march, 1968, LAXMI PERCISION SCREWS LTD is one of the leading manufactures and suppliers of High Tensile Fasteners such as Bolts, Screws, Nuts and similar parts for automobile and other industrial sectors.

We have grown steadily over the past 38 years on the strength of our in-house technological developments and innovations coupled with our reputation as the company with strong commitment to customer satisfaction and quality improvement.

We understand what we have to do for our customers. We assure that we will do our best to make or products safe and reliable for our customer’s assembly line.

We promise to improve our products to meet the ever-increasing expectations of our customers and are always obliged for their continued guidance and patronage.

L.P.S

(DESCRIPTION OF SYMBOL)

The hexagon is a symbol of precision. When interpreted as a nut it symbolized craftsman ship and unending productively, the workers and the people related to LPS are represented by the view of hexagon nut. In the symbol the circle represent the co-process, understanding, dedicating towards the workers work or duties like in a quality circle, LPS is the name itself (LAXSHMI PRECISION SCREW) in self explanatory or explaining the keenness every worker or employee to produce a precise product.

FUTURE PLAN

L.P.C. is well on the way to consolidating its future leadership with a rising corporate with an annual growth rate of 40%. LPS is planning to achieve a turnover of Rs. 250 crores in the year 2005-2006.

· Its future plan includes continuous investment in research & development.

· More concentraction on Hard Currency markets of USA, UK, Japan and Europe with the objective of doubling the exports and to bring invaluable foreign exchange for the country.

· On the corporate agenda is a massive expansion programme, which includes diversification into chemicals and engineering.

· To improve quality in design and manufacture through implementation of ISO-9002 system.

PLANT LAYOUT AND LINE BALANCE

The layout may be designed to reduce increasing production costs that gradually evolve from piecemeal or to introduce an entire new process. Re-layout strikes for the maximizing production flow and labor effectiveness.

The overall objective that is of facilities layout is to design. A physical arrangement that most economically meets the required output quantity and quality. It is necessary to consider the first cost in relation to continuous production costs attend both current and levels of demand.

The plant layout means the disposition of various facilities (equipment, material manpower etc.) and service of the plant within the areas of site selected previously. Plant layout begins with the design of the factory building and goes up to the location and movement of the worktable.

DRAWING DEPARTMENT

In this department different dimension of the drawings of the products are calibrated which the Customer Company sent. If the product is the standard component then it is prepared as the standard otherwise it is selected that which machine is suited to it and slight change in the dimensions are made if required. The changed drawing of the component is send back to the Customer Company for the approval. If the drawing is suited to its working modes then the Customer makes a change, and this process is repeated until the drawing of the product is selected.

If the drawing of the component is selected as a standard component then it is prepared as a standard one and MASTER WORK ORDER sheet of yellow color is used, and if the product is prepared as a special product then MASTER WORK ORDER sheet of sky blue color is used as shown.

The function of production department is to effectively plan and regulate the operations of that part of enterprise which is responsible for actual transformation of raw material into finished products. The production activities in L.P.S. are looked after by Works manager who is responsible to report the general manager.

For efficient production, the department has being divided in to various units such as PPC department, Quality Control department, Heat Treatment department etc. All the departments are part of production department and responsible for regulating all the workers of production department.

The production system is a part of a longer system of a business firm.

The production system can be viewed as a frame work or skeleton of activities within which the creation of values can occur.

At one end of the production system are the input and the other end are outputs. Connecting the outputs and inputs are a series of operation or processes storages and inspections.

The production system is applicable for both production of components and production of services also.

The production any component can be viewed in terms of a production system. For example, the manufacture of Fasteners in value such as inputs, wire, machines, workers, tool, etc. After these inputs are acquired, the several operations are performed which are necessary for the formation of bolts. By these operations the inputs are converted into outputs such bolts, screws, nuts etc. After finishing operations, a final inspection occurs. Then outputs are held in the stock rooms until they are supplied to the customers.

Factors affecting scheduling:

These factors are given there under:

1) Customer’s demand.

2) Customer delivery date.

3) Stock already lying with dealers.

4) Stock already lying with the firm.

5) How much time available and how much time is required for manufacture.

6) Availability of machinery and other facilities.

7) Availability of raw material.

8) Availability of manpower.

Feasibility of economic production/batch size.

HEAT TREATMENT

Heat treatment is an important operation in the manufacturing process of machine parts and tools. It may be defined as an operation of heating and cooling of metals in the solid state to include certain desired properties into them. Heat treatment can alter the mechanical properties of steel by changing the size of the grain of which it is composed, or by changing its microstructure. It is generally employed for the following purposes:

1) To improve machinablity.

2) To change or refine grain size.

3) To relieve the stress of the metal induced during cold or hot working.

4) To improve mechanical properties. E.g. tensil strength, hardness, ductility, shock resistance etc.

5) To improve magnetic and electric properties.

6) To increase resistance to wear, heat and corrosion.

7) To produce a hard surface having ductile interior.

The operations used in the company are:

1) Hardening

2) Tempering

HARDENING

Hardening is a heat-treatment process necessary to impact hardness to any component. This treatment consist of heating the steel to a selected hardening temperature (austenitizing temperature), and holding it at this temperature, followed by cooling or quenching at a rate fast enough to devlop the desired hardness. When the steel is austenitized, its lattice structure is a face-centered cubic. The reason for heating and holding the steel in the austenite range is to dissolve carbide cementite into a matrix; then the steel is quenched. At this stage, the trapped carbon causes a shift in atoms to form a body centered tetragonal structure. The shift of atoms and trapped carbon creats a stressed lattice structure. This stressed structure, called martensite and is hard and brittle. It is responsible for the high hardness of the steel. The hardness finally achieved depends on how much carbon was available and how much of it is dissolved, the temperature adopted and the rate of cooling. It is subsequently tempered to reduce the induced quenching stresses caused by the formation of martensite.

HARDENING TEMPERATURE

The hardening temperature to be employed depends on the chemical composition, carbon content and section thickness of the steel. The temperature employed for hypoeutectiod steel will be in the range of 20-50 degree Celsius above Ac3 (upper critical temperature), and for hyper eutectoid steel 30-50 degree Celsius above Ac1 (lower critical temperature). If a steel containing, for instance, 0.5% carbon (ferrite and pearlite structure) is heated to a temperature below the lower critical temperature Ac1, it will not change the original structure of the steel containing pearlite and ferrite.

SHAKER HERRTH FURANCE is used for the hardening purpose.

1^St Zone temperature---820-900 degree Celsius

2^nd Zone temperature---860-900 degree Celsius

Gas generator temperature---950-1060 degree Celsius

Gas and Air fuel ratio- 1:8-1:15

OPERATIONS BEFORE HARDENING

It is most important that the component to be hardened should be free from scales, grease, oil etc. in order to achieve the desired hardness. Hence, such components should be cleaned thoroughly. Components having holes, particularly tool steels, may be packed with clay, asbestos and steel inserts wherever necessary, so that no hardening can occur in the holes. Special attention may not be required where holes are relatively large and tools should be quenched in such a manner that the internal surface of the holes harden completely.

DEGREASING TANK is used for this purpose having the concertration of KM 04 30-40 gm/litre, NaOH 120-140 gm/litre.

The temperature in the degreasing tank must not exceed to degree Celsius and must be above than 40 degree Celsius.

HOLDING TIME IN HARDENING BATH

The time taken to reach the hardening temperature depends on several factors such as the heating equipment and the hardening bath. The rate of heating in salt bath is considerably faster than it is possible in a furnance with atmosphere because heat transfer from a liquid to a solid body occurs at faster rate. When the desired hardening temperature is reached, sufficient soaking time is given.

Soaking time of 3 sec. Is given for piece having 1 mm dia. And soaking period of 50 sec. Is given for a bolt having length of 3.5” and dia ¾”.

QUENCHING

After the component is held at the hardening temperature for a desired length of time, it is taken out for cooling, or quenching, in order to obtain a hard martensite structure. The rate of cooling must be controlled, so that the formation of soft pearlite or bainite is prevented.

The medium sed for quenching depends upon the chemical composition of the steel, the hardware required, permissible degree of distortion, and the complexity of the component. Water, oil, brine, molten salt and polymer quenchents are some of the quenching methods are:

1. direct quenching

2. martempring

3. austempring

4. delay quenching

5. time quenching

6. die quenching

TEMPERING

When steel is hardened it acquires the structure of tetragonal martensite and a certain amount of retained austenite . Steel in this condition is hard, brittle, highly stressed and liable to devlop quench cracks, particularly in too steels. Thus steel in the ‘as-hardened’ condition are of limited usefulness. To overcome this, the hardened steel should have a potential tendency to pass into a stable condition. But this equilibrium or stable state cannot be achieved at room temperature because of low mobility of atoms. As the temperature rises, the mobility of atmos increases due to accelerates diffusion rate, and this result in a structural change of hardened steel to give rise to a stable state. This, in effect, is the process of tempering. By tempering, ductility can be increased, and hardness and strength decreased. In the majority of structural steels, the purpose is to obtain a combination of high strength, ductility, and toughness. Thus, the tempering process, after hardening, makes the steel more useful by providing a stable structure.

STRUCTURAL CHANGES ON TEMPERING

Tempering consists of heating the steel to some temperature below the critical range (Ac1), and holding it for the desired length of time and subsequently cooling it in air. Investigations by various physical methods have established that as the temperature is increased, the hardened carbon steel passes through for stages.

1. At a temperature between 80 and 200 degree Celsius, a carbon rich transistion product known as carbide is precipitated from the tetragonal martensite reducing the lattice to cubic ferrite. This reaction is called the first stage of tempering. During this period, de the release of carbon, the martensite lattice contracts volume. The carbide that forms in martensite during the first stage of tempering is designated as epsilon carbide.

2. At a temperature between 200 and 300 degree Celsius, the retained austenite is decomposed into a bainite-like product, a state of aggregation similar to tempered martensite; and this transformation is called second stage of tempering. At this stage, there is an increase in volume if steel.

3. At a temperature between 300 and 400 degree Celsius, there is the formation and growth of cementite from the carbide precipitation during the first stage and second stage of tempering. It is marked by a considerable decrease in volume and overlaps the austenite decomposition reaction of the second stage.

4. At a temperature between 400 and 700 degree Celsius the growth continues and spheriodization of cementite takes place.

5. At still higher temperatures, the formation of more complex carbides takes place in steel in which strong carbide forming elements are present. This process designed as the fourth stage.

INDUSTRY PROFILE

Put simly, anything which joins together two things is a fasteners-a broad and collection terms for nuts, bolts and screws – which keeps separate assemblies of any engineering system together in a predetermined position. Fasteners is one of the joining methods, the other notable being welding and riveting. While the latter farm permanent joints, fasteners can be undone when required, mostly for repair and reconditioning.

Fasteners can be broadly classified into two categories depending upon their tebsile strenth, mild steel (MS) fasteners and High tensile (HT) fasteners are used across abroad spectrum, mostly in general application; they are produced by the SSI and unrecognized sector, using lather and by rolling.

On the other hand, HT fasteners which are elatively technology intensive are manufaxtured by a few units in the organized sector via the cold hardning (a form of forging) Process HT fasteners can be classified into standard (available of the shelf) and specialized (made to specific design).

Fasteners have two types of head : hexagonal and socket heads Socket Head Screws (are also known as allen Screws or grub screws by machines) are used mainly for industrial application in textiles, machine tools, pumps etc. and also in erecting transmission towers.

CLEANING OF METALS

Cleaning operations are performed both preparatory to finishing operations and after finishing operations. They are primarily used to remove dirt, oil, oxides, scale, and other harmful ingredients that ultimately affect the life of the product. The unwanted surface contaminates that generally exist may broadly be classified into six groups:

1. Pigmented drawing compounds.

2. Unpigmented oil and grease.

3. Chips and cutting fluid.

4. Rust and scale.

5. Polishing and buffing compounds.

6. Miscellaneous surface contaminants.

Depending on the selection of cleaning process, it may be classified as:

1. chemical cleaning

2. mechanical cleaning

CHEMICAL CLEANING

Chemical Cleaning Such As

1) alkaline pickling

2) acid pickling

3) emulsified solvent cleaning

4) electrolytic cleaning

5) vapour degreasing

6) Ultasonic cleaning, are generally used to ensure clean parts and surface before the finish is applied. They may be used individually or in combination, depending upon the material to be cleaned and the effect desired.

ELECTROPLANTING

Electroplanting may be described as a process of covering a surface or object usually metallic with a thin adherent coating of the same or other metal by electrolysis. The form and details of the original parts are retained.

Essential elements of planting process are cathode, anode, electrolyte and direct current at low voltage. The articles are connected to cathode bar, and on the anode bars are suspended plates of metal being deposited.

In LPS large rotating drums having holes containing nuts/bolts are connected to cathode usually 10-15 volts.

The technique of electroplanting is basically the same for all metals, although there are certain formly only to clean surface, the need for through cleaning of the parts to be plated is of fundamental importance. The cleaning or polishing operation may, therefore, require any one of the following steps:

1. removal of all oil, grease or organic material by immersing the parts in hot alkaline solution, and lastly by rising in clean water: and

2. removal of surface irregularities, scale and oxide by picking or by use of a file, abrasive wheel, or wire brush. The work piece must then be polished and buffed to ensure adhesion or to obtain the desired appearance.

PRE TREATMENT

This is basically the clearing and activation of the products so as to get an adherent deposits (I,e. Oil removal etc.) on the products.

PLANTING

The product are mainly zinc plated, depending upon the requirement of the customer. This is done to improve the corrosive resistance of the material. Electrolyte used during planting is solution is combination of (Zinc metal + Zinc Chloride + Boric Acid).

Zinc Metal = (25gms to 35 gms)/ lts.

Zinc Chloride = (100 gms to 120 gms)/lts.

Boric Acid = (30 gms to 35 gms)/lts.

During planting Zn plate is positive charge and material to be plated is negatively charged. Planting tank is combination of two electrodes one of which is consumable i.e. Anode and electrolyte.

POST TREATMENT

This is done to increase the corrosive resistance of the steel. The process is called passivation. According to the requirement, Zn plated or phosphated (black finishing) products are dipped into the respective passivation solution. The product is kept for 1 minute in the solution and dried after wards.

Different colours imparted during passivation

Colours Solution

Yellow Nitric Acid + Sulphuric Acid + Sodium Dicromate

(8ml to 10ml)/lts. (55ml to 60ml)/lts. (330gms.)/lts.

White Nitric Acid + Ginthon Oil 550

(4gms to 6gms)/lts., (8ml to 10ml)/lts.

Green Olive 862

(120ml to 140ml)/lts.

Black Kempass 66A+Kempass 66B

(90ml)/lts (90ml)/lts.

QUALITY CONTROL AND INSPECTION

Inspection means comparing materials product as performance with standards. Whenever products are manufactured, some will be the outside the limits of allowances provided. All the required specification are stored – out, and rest are sent for remark as either scrapped. It stops the wrong production and thus time and money wastage due to rejection can be effectively controlled. To maintain the desired accuracy and quickens special devices are used.

OBJECTIVES OF INSPECTION

a) To detect error in the manufacturing system and to prevent the production defection items.

b) To save the manufactured products and defect rejected products, thus maintaining the quality of the product.

c) To take information of these methods, responsible for falty production.

d)

FUNCTION OF INSPECTION

1) inspection of raw material

2) inspection during manufacturing

3) metallurgical and metallographic inspection

4) purchase part inspection

5) Finish good inspection

6) Tool inspection

TYPE OF INSPECTION

Ø Dimensional inspection

Ø Testing of mechanical properties

Ø Surface finish inspection

Ø Performance testing

The inspection is done commonly at two places, stages stage inspection and final inspection, but sometime patrol inspection is also done to check the effectiveness and efficiency of the machines. Thus patrol type of inspection is done to manufacturing of components.

INSPECTED METHOD

In a respective type of manufacturing inspection should be done at several placed.

Ø Process inspection

Ø Sampling inspection

Ø Batch sampling inspection

Ø Final inspection

PROCESS INSPECTION

Process inspection the inspection of the component during the manufacturing. It also referred as inspection is to prevent scrap, rework, reduce operation levels and detect hidden defects and to attain a higher quality of finished products.

SAMPLING INSPECTION

In sampling inspection sample is taken and analyzed for machined and totaling faults. Stage inspector performs this type of inspection. This inspection helps in detecting only fault that may be in machine’s tooling. Thus report also benefits the operator by letting him know his quality of work.

BATCH INSPECTION

This type of sampling is generally concern parts there have been removed from the shoo door and sampled accordingly to statistical methods based on past experience.

FINAL INSPECTION

Final inspection is done at the end of all the operations being performed. All the parameter are checked again. Thus inspection is very critical and all the parts are screened and combed any faults which might have crept in during manufacturing.

QUALITY CONTROL

Quality control means degree of perfection achieved. It is not absolute but it can be judged and realized by comparing with some standards.

OBJECTIVES

To see that the products being manufactured are in tolerance limits. To take necessary steps, so those products, which are not up to the standard, don’t reach to the consumers.

ADVANTAGE

Quality of the product is improved and thus more consumers are attracted with the effect quality control, scrap, rejection and re-working are minimized and thus avoiding wastage, which reduces the cost of production.

Reputation of the company is enhanced by good quality of its products.

RESPONSIBILITIES OF Q.C. DEPARTMENT

1) To allow sale of products of uniform and required specification.

2) To reject the defective goods and shield the consumer from defective items.

3) To correct the rejected goods if possible.

STAGE INSPECTION

In stage inspection components come in let and are checked by stage inspectors. The components are check functionally and dimensionally. Different gauges for different dimension are used to reduce the inspection time.

PARTIAL INSPECTION

In this inspection, the components are inspected in the machine itself during their manufacturing. This type of inspection helps as follows:

a) Reduce Scrap

b) Better control on dimensions

c) Time saving

d) Man power saving

STANDARD ROOM

In standard room calibration of instrument is done periodically.

CALIBRATION

A process in which we compare the performance of T and MI of unverified accuracy of the T and MI of the verified accuracy to detect any deviation.

Instruments color coding system is utilized for the calibration of instrument for every month. The instruments in which tip is coated with the month’s color code than this will indicate that the instrument is calibrated in that month. If any instrument is coated with red color, it means that the instrument is “out of order”.

Colour Month

WHITE JAN/JULY

GREEN FEB/AUG

BLUE MAR/SEP

YELLOW APR/OCT

BROWN MAY/NOV

PINK JUNE/DEC

RED SCRAPE

Various standard instruments used for calibration in the standard room of L.P.S. industry are as follows:

1. Slip Gauge Box (‘0’ Grade)

2. Slip Gauge Box (‘1’ Grade)

3. Floating carriage dia. Measuring machine

4. Dial calibration

5. Torque wrench tester

6. Electronic comparator (E.C)

7. Surface roughness tester

8. Profile projector

9. Roundness tester

10. Contracted

11. Pitch machine

12. Wear check plug (W.C.P) etc.

PACKAGING

In the modern world most of the goods are available in the packages. The packaging protects and preserves the goods and offer convenience in transport, handling and sales also. The goods in packaging should retain their original form, shape and properties, the packages should be convenient and attractive.

A primary package is the one, which come in contact with the product. Therefore, the selection of the material plays a vital role and it should be compatible with the product to be packed. The main function of a transport package is to give the required protection to the packaged commodity against incidental hazards during transportation handling and storage. The fundamental factors affecting the design of a package are:

a) Product characteristic

b) Modes of distribution

c) Marketing distribution

The technical consideration that influence the package design are hazards during transportation, such as shocks and vibrations, transmitted to the product during transportation by rail, road, sea and air.

Hazard during handling, such as impact due to drop, compression and puncture.

Hazard during storage (for e.g. the greater the tacking height in a warehous, more the need for strong and rigid package to withstand compression) and, Hazard due to climate change.

The packing should be of best quality and be produced at competitive costs. Various materials used for packing are plastics, metals, glass, wood and paper (including corrugated packaging)

Now mechanical packaging times are employed and fully automated high-speed production systems are being introduced. Traditional packaging materials like tin and glass are being forced to give way to plastics and paper the whole concept is to give the consumer the most economical packaging material.

PACKAGING SYSTEM

There are three major elements in any packaging operation

1) The package

2) The packaging machinery

3) The operating and maintenance personnel

MAINTAINANCE DEPARTMENT

Basically, the reason for operating a maintenance- engineering group is to attended the day to day problems of keeping the physical plant machinery, buildings, services in good operating conditions.

SCOP

Although in practice the scope of the activities of maintenance engineering department is different in each plant or in institution and is enhanced by plant size and type, company policy and industry-wide and sectional precedent, its possible to group these activities into that are assigned to the department for the reason of expediency, know how as precedent.

PRIMARY FUNCTION

1) Maintenance of existing plant equipment

2) Maintenance of existing plant building and groups

3) Equipment inspection and lubrication

4) Utilization generation and distribution

5) Alternation to existing equipment and building

6) New installation of equipment and the building

SECONDARY FUNCTION

1) Store keeping

2) Plant protection

3) Waste disposal

4) Salvage

5) Other services just like property accounting pollution and noice control

The maintenance-engineering department seems to be cure for many other odd activities that no other single department can handle. Although its human increases the scope of one’s department, care must be taken not to dilute the primary responsibilities of the maintenance are to handle their secondary services.

PREVENTIVE Vs. BREAKDOWN MAINTENANCE

Preventive maintenance has long been recognized as extremely important in the reduction of maintenance cost and improvement of the equipment reliability. In practice, it takes many form, two major that should control the extend of a preventive program are first, the cost of program compared with the carefully measured reduction in total repair costs and improves equipment performance, second the percent utilization of the equipment maintained. If the cost of preparation for a preventive inspection, the justification is small. If on the other hand, breakdown could resuit the severe damage to the equipped and a for more costly repair, the scheduled inspection time should be considered. Further more in the average plant preventive maintenance should be tailored to fit the function of different items of equipment. Conversely preodic inspection of small electric motors and power transmission can easily exceed the cost of unit replacement at the time of failure.

PREVENTIVE MAINTENANCE

One of the most important tool in minimizing down time, whether as not a conventional preventive maintenance program is possible is called ‘PREVENTIVE ENGINERING’. Although this would appear to be the application of common sense of equipment design maintenance engg. It’s the field which is neglected often maintenance engineers are so busy handling emergency repairs as in other day to day activities that hey found no opportunity to analyses the cause for breakdown which keeps them so fully occupied while most engineers keep their eye open in details such as better packing longer wearing and improvised lubrication systems, true preventive engineers goes further then this and consists of actually setting as idea specific amount of technical man power of analyze accidents of breakdown and determine where the real effort is needed, then through redesign substitution changes and specification or other similar means reduction the frequency of breakdown and cost of repairs.

A special group acting as a cost of reduction unit can handle these, or it can be included as one of the function of the maintenance engineers. It should be emphasized however that this type of the program required intelligent direction to ensure that time and money are expanded in the areas where the most returns likely a particular pump, operating under usual conditions, shows a high incidence of failure but because of simplicity of design and repairs has a low total maintenance cost and if it were the one of its type in the plant, as intensive investigation for maintenance cost reduction would be difficult to justify on the other hand, a simple component such as capstan bearing on a spinning machine, although having a low unit replacement cost, can fail so often and on so many machines that the total cost per year would earn too many thousand collars. Here an investigation can controlled on the reason for failure of one nit could be extremely profitable. Effective engineering can result only when it is recognized, as independent activity is search nature.

Research and development

The company’s R & D efforts continue to be dictated by the need for market orientation.

In the face of stiff competition in order to maintain the profit margin, the focus is on developing products of increased value addition. Accordingly manufacture of seams, track bolts, automotive and fastener components like steering knuckles, gudgeon pin, starter motor, pinions are being planned. The fully computerized five-station part former and bolt washer assembly machine presently under installation and commissioning/ordered would facilities this. Stainless steel fasteners and fasteners which are percolated with micro capsulated anaerobic thread cocking adhesive are being considered as value added products.

Special products machines and CNC turning centers are being added to the manufacturing facilities to increase productivity and consistency in quality of special fasteners, especially for the automotive applications.

Since the tool from the considerable part of the manufacturing cost, in house heat-treatment of the tools has already started. Plans are being drawn up to introduce vacuum hardening, organic treatments and other tribological coating to improve the tool life.

In order to cut down development cycle time for special fasteners in the automotive industry which is the largest consumer’s for company’s products technical collaboration is being entered into with a leading manufacturer of automotive fasteners in the world the company’s efforts on the whole should meet the today’s customer’s requirements, namely, zero defects, low cost, just in time delivery and short development cycle times.

PERSONNEL DEPARTMENT

The activities of personnel department are:

1) Recruitment

2) Training/ Placement

3) Welfare activities

4) Welfare actions

5) Industrial relations

RECRUITMENT

It is based upon the workload foa a predetermined target and is done with the consent of the managing director. The qualification standard for each post is laid down as approved by the M.D.

GENERAL POLICY

According to the company all the promotions vacancies are fulfilled, through internal recruitment. Usually recruitment from outside is for the workmen grade category administration department and trainees in the technical department.

RESERVATION

For the persons of project area and the state in which the project is situated are given some preferences for recruitment for the posts of lower grade. All the unskilled workers can be recruited from the project area and first preference is given to the persons displaced from the project are a provided they satisfy all other conditions.

In the case of skilled workers, clerks and other staff member whose scale of pay are comparatively low and whose basic qualification and experience and equal, preference can be given on the priority as mentioned above. The vacancies are also notified to the local employment exchange and they sponsor candidates belonging to the state.

In the case of medium level technical and non-technical posts having high salaries, recruitment is done in all Indian Bases

TRAINING/PLACEMENT

The company has different types of training programs. Trainees are trained to improve the basic skill and work knowledge on the basic machine. After the basic skill and work knowledge on the basic machine. After completion of the two years training, the specialist’s trainees are posted as Forman and two increments.

PROMOTION GIDELINE

In almost all cases the vacant posts are fulfilled from the concerned section/department. The promotion guidance laydown a method of determining the eligible employee who is considered for placement to higher post by promotion principle. The promotion shall only be to the next higher post in the wage section. Promotion shall be considered only if there if there is vacancy in next higher post. For engineers, the vacancy will be fulfilled based upon test interviews. Promotion of the employees will be considered only when they have secured a minimum period of eligibility in the lower post. Change of trade on promotion will be permitted in exceptional cases on the basis tests and interviews. Promotion of employee should be considered one month after the date of increment in the lower scale. Promotion will make on the merit and seniority basis.

WELFARE ACTIVITIES

As per factory act following are the welfare activities for worker and staff:

a) STATUTORY ACTIVITIES

1) Provision of toilets

2) Provision of drinking water

3) Separate washing facilities

4) Sitting facilities inside the factory

5) First-aid and medical facilities

6) Subsidized canteen facilities

7) Rest room and lunch room

8) Apartment of welfare officers

For every 2000 employees there will be one welfare officer. For every additional 500 employees, One additional officer is posted.

b) NON-STATUTORY ACTIVITIES

I. Transportation facilities

II. Quarters/Housing

III. House building allowance scheme

IV. Uniforms

V. Recreation activities

VI. Death relief

STUDY OF PLANT INCENTIVE AND LABOUR WELFARE SCHEME INCENTIVE SYSTEM

The workers are encouraged to achieve more production through a cash incentive scheme. The amount of cash incentive is directly proportional to increase production and different amounts are prescribed for each category of workers according to certain slabs fixed for the monetary incentives, however, changes from time to time.

LABOUR WELFARE SCHEME:

The following labor welfare schemes are in operation in the company:

1) WELFARE ITEMS

As per policy of the company, welfare items like shoes, socks, raincoats, leather jackets, winter uniform, towels, goggles, caps, glass tumblers and coffee mugs are procured centrally by the company and are distributed to the workers as per norms fixed for each item.

2) SPORTS ACTIVITIES

The company has made adequate arrangement for providing recreation to the workers by encouraging sports activities among them. Sports kits and other material is pressured by the company for distribution among the interested workers. There is arrangement for indoors as well as out-door games. Competitions even at state level are organized and workers participation is encouraged and ensured by extending all help, financial and otherwise. There is regular system of issuing circular for participation in various games/sports, among the workers.

3) FAIRS & FESTIVALS/CULTURAL ACTIVITIES

The company arrangement community celebration of major fairs and festivals like Gurupurab, Janmashtami, Ekadsi, Diwali and new year day, etc. in a benefiting manner.

4) TOURS

Trips to different places of educational places of educational and recreational interest to the workers are also arranged by the company from time to time.

5) WELFARE TRUST

A welfare trust known as the L.P.S.’s employees welfare limited is also running for the various welfare activities of the employees.

6) WORKERS EDUCATION SCHEME

To provide facilities to the workers and their families in the field of education, company runs schools nearby and provides transport at subsidized rates to the children pursuing higher studies away from the company’s complex.

Other welfare activities include arranging for blood donations and family planning camps for the benefit of the workers, and providing facilities for postal life insurance. Death Relief fund is also being mentioned.

CONCLUSION

During my training, I found the program very informative. I learnt different aspects of the manufacturing of fasteners and the industrial environment in general. I learnt how the different department work and put their concert effort in the realization of the goals of the organization. It certainly would prove my first step towards a lasting industrial career.