PREFACE

PROJECT AT A GLANCE

OBJECTIVE OF THE STUDY The main objective of this study is to gain practical significance of management theories and what extent it has been successfully implemented in the organization

Getting basic understanding regarding company

Studying finance activities

Various techniques used by the company for Business activities METHODOLOGYIn order to accomplish the objective following are the ways by which the data information is collected:- PRIMARY METHOD Day to day operation of the company.

Interviewing the management staff

By interacting with the management staffs of accounts and finance department SECONDARY METHOD Facts and figures made available by the company Referring different books

Documents &figures made available by the staff members

LIMITATIONS Time period for training is short to go into the depth to understand and analyze all the aspects Sap is not user friendly it is difficult to understand

Due to security reasons they would not furnish much detail to me which I needed in the study.

TEXTILES INDUSTRYThe Indian Textiles Industry has an overwhelming presence in the economic life of the country. Apart from providing one of the basic necessities of life, the textiles industry also plays a pivotal role through its contribution to industrial output, employment generation, and the export earnings of the country. Currently, it contributes about 14 percent to industrial production, 4 percent to the GDP, and 17 percent to the countrys export earnings. It provides direct employment to about 35 million people, which includes a substantial number of SC/ST, and women. The textiles sector is the second largest provider of employment after agriculture. Thus, the growth and all round development of this sector has a direct bearing on the improvement of the economy of the country.

Textile Industry is providing one of the most basic needs of people and it holds importance by maintaining sustained growth for improving quality of life. It has a unique position as a self-reliant industry, from the production of raw materials to the delivery of finished products, with substantial value-addition at each stage of processing; it gives a major contribution to the country's economy.

Indias cotton textile industry has a high export potential. Cost competitiveness is driving the penetration of Indian basic yarns and grey fabrics in international commodity markets. Small and flexible batches of apparels can be manufactured in India and can provide a larger variety of casual wear and leisure garments at significantly lower costs.

The government will encourage the establishment of world-class integrated textile complexes and processing units. A scheme for setting up integrated apparel parks has been initiated. This will enable the ready-made garment industry to set up modern units with excellent infrastructure. Rapid implementation of the Textile Upgradation Fund Scheme aimed at providing an impetus to the modernization of textile and jute industries is a priority with the government. India has natural advantages which can be capitalized on strong raw material base - cotton, man-made fibres, jute, silk; large production capacity (spinning - 21% of world capacity and weaving - 33% of world capacity but of low technology); vast pool of skilled manpower; entrepreneurship; flexibility in production process; and long experience with US/EU (European Union). At the same time, there are constraints relating to fragmented industry, constraints of processing, quality of cotton, concerns over power cost, labour reforms and other infrastructural constraints and bottlenecks.EXPORTS OF TEXTILES The textile products continue to play an important role in total export basket of the country.

During the year 2005-06, the share of textile exports including handicrafts, jute, and coir in Indias total exports was 16.63 per cent. India's textile exports have registered strong growth in the post quota period and the textile exports grew from US$ 14 billion in 2004-05 to US$ 17 billion in 2005-06., recording a growth of 21.77 per cent. Therefore, the government has fixed a higher target of US$ 19.73 billion for the year 2006-07.The growth trends have continued in 2006-07 the textile exports have shown a growth of 15.59 per cent in dollar terms and 20.54 per cent in rupee terms over the exports during the corresponding period in the preceding year.

INTRODUCTIONINDIAN PETROCHEMICALS CORPORATION PVT LTD (IPCL) is located in a beautiful sprawling campus of about 115 acres at village Kharadpada,Silvassa in the Union Territory of Dadra & Nagar Haveli. Nearest railway station is Vapi and airport is Mumbai. IPCL is the largest company in the world and largest in Asia engaged in the business of Texturing partially oriented yarn (POY) to produce polyester textured yarn (PTY) in 1994. It has been now merged in IPCL. The name of SIPL (SILVASSA INDUSTRIES PRIVATE LIMITED) has been now changed to IPCL Silvassa Complex from 27th Sep 2006. IPCL is spread over 131 acres of land and has capital layout of Rs 272 crore and annual turnover is Rs 1000 crores. IPCL has a state of the art plant with a human force of around 2042 The company has total regular 1066 employee, which is further categorized into supervisory (211) and non-supervisory (836). There are 995 contract labours. It has capital base of Rs. 650 crores. The company is rated as one of the leading professionally managed, well-governed companies with highly motivated qualified personnel. All functional areas are integrated with advanced application.

It is financially managed and advised by Reliance Industries Limited (RIL). The Board of Directors of Indian Petrochemicals Corporation Limited (IPCL) have approved the merger of Apollo Fibres Ltd (AFL), Central India Polyester Ltd (CIPL), India Polyfibres Ltd (IPL), Orissa Polyfibres Ltd (OPL), Recron Synthetics Ltd (RSL) and Silvassa Industries Pvt Ltd (SIPL) with IPCL

INDIAN PETROCHEMICALS CORPORATION PVT LTD (IPCL) is the largest of its kind in Asia engaged in texturing of Partially Oriented Yarn (POY) of polyester in a wide range of product mix e.g., Crimped, textured, Roto- Micro & super set yarn in various deniers. It is the 1st largest company of its kind in the world with 158 machines backing off a Korean Company.

SALIENT FEATURES OF IPCL It has online Tension monitoring system (OLT) for continous monitoring of textured yarn quality.

It is installed with latest state-of-art texturing machines and ultra modern robot controlled Auto Packing System (APS), technically advised by CAMEL ROBOT, Italy, and all under one roof. It has recently installed SAMURAGHI Packing system of Italy for Jumbo export bulk packing.

It has a developed system known as BOBIN TRACKING SYSTEM (BTS) for online monitoring the finished product. It dose the online monitoring from bobbin to trolley and finally to pallet.

In IPCL customer satisfaction is of prime concern. Based on routine communication with customer survey the customer needs and expectation is determined and documented. All the data obtained from customers are processed and converted into customer requirements are fulfilled for enhancing customer satisfaction.

Meaningful automation & 100% computerized front All machine are modified to inverter operations Measured length-doffing system incorporated Fully equipped laboratory for R&D and QA Full fledged R&D team of highly qualified engineers with 05 pilot machines TQM & QC activities in force

Six Sigma is under implementation Eco-friendly operation Cash project under implementation Connected with SAP and LEGACY system

Fully equipped laboratory to test essential yarn characteristics Barcode system for easy identification of material Research and Development cell for developing new products

ORGANIZATION CHART

OUR LOGO

CODE OF CONDUCT

Code of ethics and business responsibility Be prompt

State purpose and review agenda

Everyone contributes constructively

Pay attention

Be courteous

Focus on topic

Summarize issues and decisions

Assign actionsVISIONTo continuously grow on a sustainable basis and be the largest, the most innovative, the most profitable and the most admired polyester texture yarn producer in the world

MISSIONTo be amongst the global leader in textile, with utmost concern towards ecology, stakeholders and society.

QUALITY POLICYWe at IPCL Silvassa Complex are committed to total customer satisfaction in terms of quality and services for the entire range of our products. Our continued commitment to excellence and innovative efforts helps us to stay ahead as a market leader.Quantifiable Objectives

ParametersTexturising

(Plant -1)Texturising (Plant -2)

Efficiency Level98.5 %98.0 %

Production of 1st Quality Packages95.0 %95.0 %

Total Hard Wastage0.28 %0.35 %

MACHINE Breakdown %

( Mechanical )0.05 %0.18 %

MACHINE Breakdown %

( Electrical )0.05 %0.15 %

Based on above main Quantifiable Criteria necessary framework is provided for reviewing and establishing the Quality Objectives in Indian Petrochemicals Corporation Limited It is communicated and understood within organization and reviewed for continuing suitability.

HEALTH, SAFETY AND ENVIRONMENTAL POLICYAt Indian Petrochemicals Corporation Limited, Silvassa Complex ( IPCL Silvassa Complex) , Occupational Health, Safety and Protection of Environment are of prime concern and an important business objectives. IPCL Silvassa Complex, having role in providing competitive goods and services in the Polyester Yarn market in India and abroad, is conscious of its responsibility towards creating, maintaining and ensuring a safe and clean environment, reduce Health and Safety hazards through application of technology and safe work practices for sustainable development.

In particular, we are committed to

Comply with relevant laws and regulations as well as take any additional Measures considered necessary.

Follow a systematic approach to environmental management plan as well as Occupational Health and Safety Management Plan in order to achieve continual performance improvement, Prevent pollution, maximize recycling and reduce wastes, discharges and emissions, minimize occupational health & safety risks.

Conserve natural resources by their responsible and efficient use in all our operations.

Systematic education of company employees & Contractor personnel for observing safe work practices & establishing continual improvement .

Pre-employment and periodic medical check up of employees for early Identification of occupational health hazards.

Make this policy available to the public.

Our objective in implementation of this policy is long run sustenance and growth of our business by continually improving business process, profitability, enhancing satisfaction of all interested parties and proactive compliance with applicable HSE regulations.

PERSONNEL POLICY It is the aim of the company to get the right talent available in the country to man the various functions and provide them with good working environment to get the best results. A filament is a highly specialized and competitive business in the international arena in which the company has to complete with giants established in the field. The companys objectives are to be a significant player in the domestic market and establish an international image in selected areas.

The guidelines under these policies are:

1. To strive for optimum utilization of human resources and creating an

Environment which is conductive to higher productivity and quality;

2. To achieve excellence in implementing the statuary and Non-statuary welfare programmes for employees of the company; 3. Implementation of HRD Policy of the company;4. To train and develop the employees of the company in relation to HRD Policy and ISO- 9001, ISO- 14001 & ISO- 18001 towards achieving Goals and objectives of the company;

5. To achieve perfection in educating employees of observing and implementation safety precaution and devices to safeguard men, machine, materials and property of the company;

6. To operate within the framework of standing orders of the company and with in spirit of laws of land.

HUMAN RESOURCE DEVELOPMENT POLICYThis policy of human resource development at IPCL will be based on the firm Commitment that Total Customer Satisfaction in terms of Quality &Services. Hence, a strategy of customer satisfaction and technology supported by competent human resource network will give the company and its products the necessary competitive edge in the Domestic and International market.

OBJECTIVE The Human Resource developmental efforts at all levels of working, will be guided as per the following:

1. Strengthening of prevalent congenial atmosphere by ensuring the active involvement of the people in the policies, procedures, processes and systems.2. Enhancing the spirit of camaraderie through mutual trust, self-respect and collaborative team efforts;

3. Generating a climate of openness and proper information sharing by active listening and communication skills;

4. Setting in motion the efforts towards achieving business profits, speed, Simplicity and self-confidence. SOCIO-CULTURAL ACTIVITIES AT IPCL

Periodically holding medical camps for blood donation, Polio Camp, Eye & Skin Treatments for Employees & Surrounding Villagers. Ambulance donated to Red Cross

Nearby schools adopted for computer education

Tribal Womens Education

Sneh Sutru Magazine

BIRDS EYE VIEWName of the company

: Indian Petrochemicals Cooperation Limited

Year of Incorporation

: 1994

Constitution

: Private Limited Company.

Board Of Directors

: a) Mr. Shiva P Chakravorty (chairman) b) Shri C. Bose (Managing Director)

c) R. Santhana Raman (Director)

Bankers

: HDFC Bank

Dena Bank

Syndicate Bank

SBI

ABN Ambro Bank

Auditors

: Chaturvedhy & Shah.ACCREDITATIONS ISO 9001:2000 - QMS certified

ISO 14001:2004 - EMS certified

OHSAS 18001:1999 - certified

TQM & Quality Circles

Six Sigma activities across all functional areas

Eco - friendly operations

Du Pont certified and accredited Lycra Lab.

OekoTex certified ProductsAWARDS & ACHIEVEMENTS

Best Housekeeping award from Baroda Productivity Council.

First prize in inter -industry safety poster / slogan competition in D&NH.

Winner in inter industry cricket tournament for continuous last 3 years.

Received Certificate of Excellence for CASH project in 2005-06.

Received appreciation from D&NH administration for providing excellent fire services in D & NH.

LOCATION

A) Factory/ Works

: Silvassa Industries Pvt. Limited

342, kharapada, Naroli

Near Silvassa

Union Terrotiory of Dadra & Nagar Haveli

Pin code 396 235

B) Registered Office : Silvassa Industries Pvt. Limited

T-5, Vikram Chambers,

Opp, Mahila Milan Mandir, Ashram Road,

Ahmedabad 380 009C) Corporate office

: Silvassa Industries Pvt. Limited

Shree Ram Mills Premises,

Ganpat Kadam Marg,

Worli, Mumbai 400 013ORGANISATION OVERVIEW

Product

: Polyester TexYarn

Plant Commissioned

:1995 Sept

Licensed production capacity

:300 KTA

Installed Production Capacity

: 140 KTA

No of Texturising Machines

:158

Share in the Indian market

:12 -14 %

Exports

: 25 - 30 %

Turnover FY 2006-07

:1192 Rs. crs

INFRASTRUCTURE Site Location

: Silvassa

Located in Zero Pollution area :128 Acres

Built-up Area

:120,000 M2

Air conditioning capacity

: 6,300 TR

Power connected

:33 MVA

Power tariff

: 2.95 Rs

Compressed air capacity

: 95,000 M3

PRODUCT PROFILE Process :

Texturising Raw Material

:

POY ( Partially Oriented Yarn)

Final Product

:

Textured & Twisted Yarn

Basic Products :

Crimp, Tex, Intermingled

Customers : Bhiwandi, Surat, Kanpur, Udaipur, Amritsar and Many Export Countries : Turkey, Belgium, Switzerland, Canada, Japan, Mexico, & Bangladesh

Specialty Product : Lycra Covered, Melange, Bi-shrinkage, Thick & thin, etc.

End Use : Suiting, Shirting, Saris, Jeans, Knitting & Dress Material.

MANPOWER BRIEF Supervisory

: 211

Non- Supervisory

: 836

Contract Labours

: 995

TOTAL

: 2042

POLYESTER UNITS Allahabad Unit, Uttar Pradesh

Barabanki Unit, Uttar Pradesh

Dhenkanal Unit, Orissa

Hoshiarpur Unit, Punjab

Nagpur Unit, Maharashtra

Silvassa Unit, Union Territory of Dadra and Nagar Haveli

MANUFACTURING FACILITIESCapacities of Polyester Units

Name of Polyester UnitInstalled Capacity MTA

Silvassa Unit, Union TerritoryPFY141,000PTT - 600

SUBSIDIARY COMPANIESA) Recron Polyester LimitedB) Synergy Synthetics Limited

ORGANIZATIONAL STRUCTURE AT IPCL

TRAINING SPOTPLANT LOCATION

PLANT I & PLANT IITEMPLE & ADMIN BUILDING & FINANCE DEPARTMENT

GUEST HOUSE

ERP (ENTERPRISE RESOURCE PLANNING)

ERP an Enterprise Resource Planning is a packaged business software system, that integrates all the functions such as planning, manufacturing, distribution, shipping, accounting etc. into a single system, design to serve the needs of each different department within the enterprise. It is a complex piece of software that enables a company to manage the efficient and effective utilization of its resources (Material, people, plant, equipments etc). Thus ERP surely brings significant changes to how a company does business, as it tinkers with the workflows, and alters long-standing processes.

IPCL PURPOSE FOR USING ERP PACKAGE

To automate the workflow and integrate various departments of the enterprise. To share common data & practices across the entire enterprise. To make the employees more outward focused towards customers, suppliers & business partners rather than worrying about internal processes.

To provide the backbone for further extending the functionality through bolt on & other solutions, such as product lifecycle management, supply chain, e-commerce. To yield significant non-tangible benefits such as visibility of Information, smooth processing with adequate controls & enhanced integration.

SAP (SYSTEM APPLICATION PROGRAMME)

SAP can be introduced as 4th largest independent software supplier, founded by five former IBM employees at Germany in 1972. It is available in 14 different languages and implemented by more than 7500 customers all over 90 countries in the world. Founded in 1972 as Systems Applications and Products in Data Processing, SAP is the recognized leader in providing collaborative business solutions for all types of industries and for every major market.

SAP is the third generation set of highly integrated software modules that performs common business functions based on multinational leading practices. It takes care of any enterprise, however diverse it may be in operations, spread over the world geographically. SAP understands that the only industry that matters to you is your industry. That's why there's no such thing as a generic industry solution from SAP. Sap solution sets are based on an in-depth knowledge of the processes that drive your business, whether small business, a midsize company, or a large enterprise.

COMPONENTS OF SAP

FI :Financial Accounts

SD:Sales & Distribution

PP:Production Planning

MM:Material Management

QM:Quality Management

PM:Plant Maintenance

HR:Human Resource

IPCL PURPOSE FOR USING SAP Global Basis Faster Speed Flexibility for Changes (Business & IT) Alertness Reach New Opportunity

Knowledge Sharing

Creativity Focus SAP R/3

IPCL uses SAP R/3 for controlling its whole system. SAP R/3 is SAP's integrated software solution for client/server and distributed open systems. SAP's R/3 is the world's most-used standard business software for client/server computing. R/3 meets the needs of a customer from the small grocer with 3 users to the multi-billion dollar companies. SAP PROCESS MODEL

FUNCTION OF SYSTEM DEPARTMENTTo provide solutions for hardware problems and to make new softwares as per the requirement of different department. The entire unit of IPCL is computerized. SYSTEM department controls each unit in IPCL. System department is divided into two parts.

1. Hardware Department

2. Software Department

3. Network Department (which is within hardware department)

HARDWARE DEPARTMENT

Hardware means those physical components to which we can touch and feel like monitor, keyboard, mouse etc. It supports various departments of IPCL by solving their problem, provides Personal Computers to various department or users and checks the configuration of the computers, which are received from the vendors. Repair the computers do troubleshooting and requested software installation. Switches are used to connect servers to nodes so that data can be stored and accessed by the concerned users. these switches are located in each and every department i.e. POY Godown, YOI A, YOI B, YO2 A, YO2 B, System, Administration department etc.

MAIN FUNCTION

Solve problems related to printers and PC

Operation of LAN through a device called switch

Operation of WAN through leased lines. SOFTWARE DEPARTMENT

Software means those components to which we cannot touch or feel. We can only see it. The software department basically performs the function of Software Development

Software Maintenance

Software Modifications

To develop various soft ware for better communication and prevent error and to make the work easy and store the data. Certain software developed is sticker printing, pay roll, doffing schedule, material store, POY issue and receipt system, etc.

Previously in IPCL all the software were developed using FoxPro language, but now the scenario has been changed due to incoming technology. Now all the software have been developed using Visual Basics. The various software applications used are as follow:

1. APS Lines/Pallet Scanning/Jumbo

2. APS TR/SAP unload

3. APS- Reports

4. Weigh Bridge

5. Budget Tracking System

6. MIS

7. POY System

8. Help Desk

9. OLT- Client

10. Payroll/ESS/IT

11. ISO Documentation System

12. Database Administration

13. Server Administration

14. Waste System

15. Contractor System

16. QMS

17. System Analysis and Design

18. Label Printing System

19. BACK UP Management Systems, etc. NETWORK DEPARTMENT

At IPCL we use LAN, WAN and Lease Line for network connectivity. The speed of these varies accordingly. Here various topologies are used.

Software, Database used in IPCL (Silvassa)

Visual Basic: Visual Basic is a product of Microsoft and is an object oriented Programming Language in which it is easy to develop windows based applications.

SAP: SAP is the leading Enterprise Information and Management Package Worldwide. Use of this Package makes it possible to track and manage in real-time, sales production, finance accounting and human resources in an enterprise.

SQL server: In SIPL, SQL server is used as database to store information. SQL server is product of Microsoft. PROCESS APPROACH FOR SOFTWARE SECTOR

FUNCTION OF UTILITY DEPARTMENT Supply compressed air at required pressure to roto machines, pneumatic instruments such as splicer and APS.

Supply cooled air in the plant so as to maintain good working condition.

Supply water for drinking purpose for cooling tower etc.

SECTION Compressor (For balancing Air for PLANT -1 and PLANT -2 there are 29 compressors at present ) Total 8 compressors

2 Ingersol rand centrifugal type of compressors

6 Atlas Copco screw type of compressors.

Chiller (Total 9 Chiller is there to provide cooling facility to PLANT 1 and PLANT 2) Total 6 chillers

4 blue star chillers

2 Trane chillers

Water system (For providing cooling system.) Raw water plant (toilets etc.)

Drinking water plant(for drinking)

Soft water plant (for machinaries)POWER DEPARTMENT

The main source of power supply for SIPL is Gujarat electric board.

They supply 66 kv power .the power section uses two types of motors to manage power.

LT MOTOR AND H T MOTORSHT converts 66 KV power to 6.6 KV by using power transformer. The total capacity of power transformer is 55 mva. There are four transformers in switch yards, out of them two are 15 mva and other two are 12.5 mva LT motor convert 6.6kv to 430vVolts by using distributed transformer.

There are 16 distributed transformers present in the plant used in switch yard, out of them two are 15 mva and other two are 12.5 mva.

DISTRIBUTION YO1 having four numbered from 1 to 4

YO2 is having four numbers from 4 to 8

PLANT 2 having four numbered from 9 to12

Utility having four numbered from 13 to 16

Total unit of power consumed each day is 6, 42,500 KWH

PLANT I & IIIn PLANT II only two types of machines are used, One is Barmag FK6-1000 and another is Barmag AFK.

S.NoType of MachineNo. of Machine

1Barmag FK6-100012

2Barmag AFK36

Total48

The total Barmag AFK machine is 36. Out of this twelve (12) machines are manual and rests of 24 machines are automatic. By manual we mean that one of the function or operation is done manually. In manual machine when the bobbins are required diameter and weight it gives indication. The indication is given by lightening of red light. At that time the worker has to come and break the yarn and load another POY for further texturing of doffing. Whereas in the case of automatic machine when the bobbin is of required weight and diameter the machine will automatically break the yarn and the yarn would come in the tray. As soon as the bobbin comes in the tray another tube take it place and textured yarn starts wrap on it. In PLANT II raw material POY is issued directly to the machine. There is no facility of godown. There is no separate department for packing as packing is done near the machine. This helps in reducing the error of mixing different bobbins of having different merge number in the box. In PLANT II there is no weight and vision system in the packaging department as the machine only does the weight and diameter measurement. Thus these machines are more advanced. They perform various functions, which machines of Plant I cannot do. In Plant I Barmag AFK machines have been bought from IRELAND whereas Barmag FK6 machine have been bought from Baroda. Preventive maintenance of the machine is done after every 45 days. The length of the tube on which POY is loaded varies but generally it has the diameter of 69mm. The engineers of production department by taking the rpm of the machine calculate the time taken to accumulate the PTY of required weight and diameter. This time is set in the machine and soon as this time is reached or spent, the automatic or manual breaking of yarn is done and new tube takes its place with concluding texturing of next POY is done. The various parameters set in the machines are as follow-:

POY Denier

POY Merge

Speed

Oil RPM

Batch No.

Paper Tube

Doff Time

Doff weight

Doff diameter

Air Pressure

comparative study

S.NoParameterPLANT IPLANT II

1Goodown It has separate godown and on requisition yarn of required merge number is allotted to the concerned department.No facility of godown. POY of required merge number is allotted directly to machine.

2Material GroupYesNO

3Type of MachinesSDS 700

SDS 1200

Barmag FX-900

ICBT

Murata

AlidharaBarmag FK6-1000

Barmag AFK

4AdvanceLess advance machines. More advance machines

6Time taken in productionMore time taken in production as there are various steps.Less time taken in production as cascading of many steps take place.

7Weight and vision systemIt is done after doff has came out of the machine. It is separate from the machine.This is inbuilt facility in the machine. As soon as the doff takes the required size and weight automatic or manual breaking of yarn is done.

8WasteIn this there is more wastage Due to automation less wastage.

9 Size Big and old plantSmall and new plant

10Denier Generally PTY of less denier is madePTY of heavy denier is made

ORGANOGRAM

STORE DEPARTMENT

This is one of the most important departments. It stores all the material except raw material POY and finished material PTY. All the various requirement of the department are fulfilled or satisfied here. The various functions performed by the store department are as follows-:

1) Stores stationary items like note books, registers, cards, used by various departments

2) Stores machine parts

3) Sends the machine parts for repairing to the concerned vendor

4) Issues the new machine parts to the concerned engineer or department

5) Keep the data of goods available, goods demanded and goods allotted to concerned person or department

The Engineering section consists of two, one is receipt and other is issue.

The engineer takes sample from the store section of goods demanded and check whether it is of required quality or not. If it is of low grade quality than the whole goods is returned to the supplier.

RMS- WORKING PROCEDURE IN BRIEF

A) To make availability of all Raw Material & Packing

Materials required by Production Department.

B) Receipt, Storage and issue of all incomings.

Minimum, Maximum, & Order levels are maintained by RMS and purchase request is raised for the material below re- order level. On receipt of the material the quantity is verified with purchase order & supplies Challan / Invoice and the material is unloaded. Q.C. Department is intimated along with intimation slip to pick up batch wise sample for analysis. The material is shifted to its designed area with proper tagging for its further trace ability. As and when the material is required by the production Department it is issued as per FIFO system.

POY STORE

The process of yarn starts from POY store. It is the store where supplier of POY dispatches their raw material. This store performs various functions right from generating and dispatching the invoice and giving the required POY to concerned plants. It keeps the record of which plant needs POY of which type or merges number. As soon as they get the raw material which has been marked as critical stock or the stock in demand of specified Denier/Filament they send it soon as they receive to concerned department so that the process remains continue. Denier varies from 30 to 330. A denier can be defined as weights in grams of 9000 meters. There are various suppliers from where we get POY. These are as follow-:

S.NOSuppliers

1RIL, Hazira Plant

2RIL, Patalganga

3CIPL, Nagpur

4RSF, Allahabad

5AFL, Hosiarpur

6RIL, FDC

The truck, which comes to SIPL with POY, loaded at that time the truck number is noted. After passing through the first gate the trucks weight is weighted with POY at the second gate. This truck after dispatching the raw material at store comes back to the gate. At that time again the trucks weight is weighted without POY and then he has to show the receipt in order to exist SIPL. The raw material obtained is either used as job (for Reliance itself) or for IPCL. If it is for job (RIL) it is recorded as 927 and registered as SI52 and STJW where as if it is for IPCL it is recorded as 101 and registered as SI01 and SCST. Generally 70% of raw material comes from RIL, FDC in order to decrease the sales tax. When it comes from RIL, FDC sales tax imposed is 1% and when raw material comes from RIL, Hazaria Plant the sales tax imposed is 4%. For IPCL type various entries entered are as follow

Challan Number

Excise Group

Reporting Number

Freight vendorFor job type, where the finished goods would be used by RIL, the various entries entered or recorded are as follow-:

Delivery Quantity

Truck depot number

Document posting date

Thus in this way purchase order and goods receipt is made and its print out is taken and kept for further reference. The raw material comes in various packages or form.

S.NOTYPE of PACK DISCRIPTION

1RUContains 36 tubes of 665 Kg

2CARTOONContains 4 tubes of 74 Kg

3EXPORTContains 30 tubes of 560 Kg

4JUMBOContains 45 tubes of 664 Kg

MATERIAL GROUPThe marketing department gives the data to Material group regarding which type of yarn and of what quantity is to be produced. After receiving the data the material group change or set the hardware parameter of the machine in order to produce the required type and quantity of yarn. So as per requirement the material group takes yarn from warehouse to buffer area. The work is done in three shifts named as shift A, shift B and shift C. FUNCTIONS OF MATERIAL GROUP Decide the POY requirement for 24 hours of all the machines Raising an issue to warehouse for the quantity required for each merge under the specific account head.

Stocking the material in the buffer area

Allocating the loading of material to loaders

Cross checking the loading of POY on particular machine in order to prevent mix up of different deniers

Scanning of the barcode on the machine creel

OTHER ACTIVITIES OF MATERIAL GROUP Records of the no. of POY loaded for each merge and source.

Record the no. of POY without tail end & collection of unworkable POY and sending it back to respective sources.

Collections of bottoms of each merge.

Collection of the cutting and stripping waste of POY and recording the same.

Flowchart for material issue to user department from stores

Steps for repairing jobs in Engineering Stores

ORGANOGRAMWare House Manager

INTRODUCTION

Warehouse Department is the place where finished goods are stored that is finished yarn (PTY) is stored. The PTY after being released by packing department is sent to warehouse department. This department checks the goods received. It has to take care that boxes on the pallet are of same batch number or not. After that it is the responsibility of warehouse to load the truck with PTY and send it to concerned department. If there is no order it will be stored in warehouse only. Thus from here the final dispatch of the finished goods starts. The main function is to receive the material from lag area and store it in the ware house and dispatch the same as per requirement stated by marketing department.

SECTIONS1) Receipt system

2) Dispatch system

RECEIPT SYSTEM Receiving the material from lag area through transfer note. Updating the transfer note in SAP system and assigning the location to the material. Stacking the pallets as per the location of SAP system. The location is from FA to FO with an avg. of 40 rows in each.

The location FZ is used for storing downgraded material.DISPATCH SYSTEM Receive the order from marketing department. Check the availability and location of the material. To make a material pick- up- note (MPN) through SAP system so as to free the location and dispatch the material as per MPN. Cross checking the quantity and no. of pallet according to MPN. Make the invoice and dispatch the material

POY GODOWN

It receives the material under different accounts.

Accepts the material by checking the same and entering in SAP system.

Locates the material in the godown as per free location available through SAP system.

File the packing list of the material received and invoice of the material account wise.

Issue the material as per the requirement of material group(through SAP system)

Prepare the stock report daily.

Other activities of POY GODOWN

Returning of the pallets and jumbos.

Sending of the scrap material.

Returning the POY that is unworkable on the machine.

Reuse of the POY paper tube after getting it checked

INTRODUCTION

Production is considered to be the backbone of an industry. It is the step-by-step conversion of one form of materials into another, through chemical or mechanical processing, to create or enhances the utility of the products or services.

Production is at the center and all other activities revolve around it. It deals with decision making related to production processes, so that the resulting goods or services is produced according to specifications. Therefore to run production, we require service activities which make sure that the manufacturing activity can go on and control to make sure that it goes in right direction.

TEXTURING

It is the process where yarn is inserted in bulk with the help of heater and twisting units. It is the process to strengthen a texturing yarn to work properly in future process. At IPCL we have two plants named as Plant I and Plant II. There are total 158 machines at IPCL. Plant I comprise of 110 machines and Plant II have 48 machines. The table below shows the type of machine at Plant I. It produces 380 tones of textured yarn per day and about 100000 packages are packed daily. It exports 30% of its production to European countries. And remaining of is used for domestic purpose. The main work done here at this plant is Texturing. Textile products are sold under the brand names of Only Vimal, Harmony, Reance, RueRel and V2 (pre-cut, pre-packed products). The flagship brand ONLY VIMAL is India's largest selling brand of premium textiles. In a survey conducted by The Economic Times, it was voted as 'India's most trusted Fabric Brand'.

IPCL efforts in research and development has resulted in several new products and processes, such as fluorescent shades on polyester fabrics, extended laundering colourfast fabrics in dope-dyed fibres, water and oil repellent finishes on polywool and Lycra stretch fabrics, wash-fast and flame-retardant fabrics.ORDER PAYMENT CYCLE

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STEPS

1. POY Loading:- It is the first step to the PTY production. So it should be carefully done Otherwise unnoticed error would create more problem in end. Every machine has two sides A and B. There are total 108 positions on each side. New machine have total of 240 machines. Therefore 9 creels are used to load the one side of the machine. Each creel has 24 tubes. It should be noticed that POY of same merge number should be used on the same machine to produce yarn of same quality.

2. Creeling and Threading-: Creel the whole machine up with yarn, ensure that each supply package is correctly aligned in relation to the yarn guide tube and that it clears the baffle plates .Pre thread the creel as far as the first pig tail guide situated prior to yarn cutters.

3. Creeling Supply Packages-: In placing the packages on the creel page careful handling is essential in order to avoid damage to the yarn mass. While the packages being handled, it is convenient to locate the leading ends of the yarn and to leave them in an accessible position Take off discs should be used on packages to prevent snags on the end of the supply tubes if it is not perfectly smooth. Doffing is performed without interruption to the draw-texturing zone and therefore does not involve re-threading.

4. Process Specification Development-: The development of optimum process specification on high-speed draw texturing equipment is complex and many factors influence the choice of the final process parameter. This section outlines the basics method of specification development and discusses the effect of varying each process parameter as well as giving typical setting for each parameter. The development of a process specification is broken down into three stages, which must be completed in sequence to avoid complex integration. Before the specification development procedure is begin a starting specification on needs to be established. This allows yarn to be process so that tensions levels can be measured and product quality examined.

It is the principle department whose main function is to produce the textured yarn at targeted efficiency.

Checking that the machine is loaded with specific POY and ready with other accessories like jet in case of roto product.

Receive the batch no. to be given to the final product, from the process control department.

Decide the paper tube colour to be used.

Collect the sticker from the system department for that particular denier, machine and product.

Sticking of stickers on P/T and fixing it on the machine and keep it ready for yarn threading.

Start the yarn threading on machine after getting clearance from process control department.

Take a short doff after completing yarn threading.

Deciding doff duration as per diameter of 218 mm

Taking the doff as per time and release the same to PC department with proper identification i.e. yarn card and stickers on each trolley and paper tube.

Yarn card and sticker cross checking by dispatcher

Entering the same through trolley barcode scanning in BTS or TTS system whichever is applicable.

Other activities of Production Do splicing of tail end of running POY with end of reserve POY.

Machine loading in case of clearance after breakdown.

Enter the doff weight and mode of packing in the batch master system.

To clear the textured package within 24 hrs for the material which is running for exhaustionYarn Path through the machine

Creel

Creel pipe

Cutter

Input roller

Primary Heater

Cooling plate

Spindle unit

Inter mediate roller

Secondary Heater

Out put roller

Oiler Roller

Traverse guide

Winding drum

PRODUCTION PLANNING

It receives the information regarding the type of the product and quantity of the product to be produced by marketing department.

In accordance with the production department plans for the availability of the machine.

In todays environment production plays a very important role as concern to the development of company.

PROCESS OF PRODUCTION PLANNING

The production planning start with the preparation of budget.

Devising manufacturing method and sequencing of process.

Set the plant layout.

Estimate material and manpower requirement.

Preparation of MPS and CRP. Periodically improvement of quality.

Daily production is made on the basis of three important aspects.

1. MONTHLY PRODUCTION PLAN.

2. SHORTAGE LIST.

3. POTENTIAL OREDERS EXPECTED.

Monthly production plan is prepared by the unit head, on the basis of which the daily production plan is prepared by H.O.D. (Prod). Subsequently, when they get the shortage list, production plan is again updated and at last it is put in to action. FACTS AND FIGURES There is one operator on each machine for the activities listed in the production flow chart.

Apart from that there is 1 dispatcher for a group of 20 machine who leads the team of contract personnel whose function is to see that dirty and damage packages are not delivered to PC III department.

The dispatcher also collects the waste at the end of each shift and reports the same to the engineer along with the no. of trolley and packages released to PC III section.

One more operator is there to look after the batch close system and other general activities.

MATERIAL HANDLING

Material handling is simply picking up, moving and laying down of material through manufacturer. It is helpful in movement of raw material, part of process, finished goods, and packing materials, disposal of scraps and even transportation of workforce in the plant. Proper material handling facility reduces production cost by reducing time and energy etc.

MATERIAL HANDLING EQUIPMENTS

Fork lifter.

Wooden pallet.

Belt conveyer.

Roller conveyer.

Hand trolley.

Electric hoist.

Pipelines.

Stacker.

INTRODUCTION The main function of Process control department is to decide the machine parameters for different types of yarn through trials and monitor the quality of the product as well as to control the process by preventing down gradation of material through necessary corrective action and analyze the reason for breakage and take corrective action accordingly.

The process control department has three sections.

PC 1 ( Co ordinates with YO1 Production)

PCII (Co ordinates with YO2 & YO3 Production)

PCIII (Arranges for releasing of the material from YO 1,2 & 3 on either OLT,TKD or TYT bases)

The main function of the PC department is: -

Inspection of raw material

POY

Coning oil

Paper tube

Product control through

OLT (On Line Tension) System

TYT (Textured Yarn Tester)

TKD (Tube Knitting and Dying)

There are four numbers of machines at present. The process control department has three sub departments PC 1, PC2, PC3.

General works done by PC department Machine Auditing

Machine Checking

Export Box Checking

PROCESS CONTROL I & II

Take trials with different machine parameters and type of products.

Send the packages for laboratory testing

Check the lab results with the specified requirements and norms.

To change the parameters if required and finalize the same through lab results analysis.

Give the batch no. through batch master system.

Checking the actual machine parameters once again and give clearance for production.

Grading of the packages produced as per OLT.

Entering the downgraded packages in a register in order to analyze repetition of the fault on particular position.

OTHER ACTIVITIES OF PROCESS CONTROL. As said earlier that one of the main functions of PC is to control the process and for that it is very necessary to ensure that actual machine parameters are same as those set.

DATA BOOK OPERATOR He checks and ensure that the machine speed and parameters are same as those set He is allotted a group of 20 machines whose parameters should be checked with in 3 to 4 days. Apart from that he follow up the positional fault memo from APS and QA lab faults and rectifies the same with the help of line fitter. MACHINE MONITORING OPERATOR He checks for the reason for the breaks and prepare the report Reasons for the break. POY problem Splicing break

Bottom break

Guide worn out

Others.

Apart from that he checks the yarn path of non OLT machines.

Snap study of non OLT machine every two hours.

FACTS AND FIGURES There is one data book operator for a group of 20 machines. (A Shift only)

One PC operator.

One machine monitoring operator.

OLT operator for group of 20 machines (All shifts)

PROCESS CONTROL III The main function of PC III is to receive the material produced by production and release the same to APS department based on either OLT, TYT or TKD.

Thus material flow will be as flow as follows.(for OLT base)

Stripping of the material.

Releasing of the material.

Stripping of 50 mts is done.

Along with stripping the material is checked for low nips, dirty, damage, and single yarn in double or double yarn in single.

If any abnormality is found same is informed to the prod. Dept. through memo.

INTRODUCTION

Quality is the totality of features and characteristics of a product or service that bear on its ability to satisfy stated or implied needs. It is a sense of appreciation that something is better than something else. It changes in a lifetime from generation to generation and varies by facts of human activity. Quality means focusing on production of increasingly better products and services at progressively more competitive prices.

Today, companies have no choice, but to implement total quality management programs, if they are to remain solvent and profitable. Total quality is the key to value creation and customer satisfaction.QUALITY OBJECTIVES

To establish and continuously upgrade the standard of raw material and keeping the suppliers informed of our requirements as well as their short comings.

To upgrade and develop new process to meet the customer requirements.

To ensure availability of competent manpower and to further enhance their skills and competence.

To maintain the consistency in manufacturing by producing right product in first attempt.

To enhance the timely delivery to customer.

To enhance corrective and preventive action activities at functional level.

PROCEDURE OF QUALITY DEPARTMENT

Quality process involves the understanding of who the customer is, what his needs are, and how these needs can be satisfied. Thus, Quality process comprises different steps, through which complete satisfaction is provided to the customer. Quality operation is a process and inspection of raw-material, semi-finished products, and finished products.

The sample of raw-material is tested in the lab before the material is entered to the stores department. After that if it is approved by the quality department a log tag with O.K mark is put on the material and then send for production and if it is not approved then it send back to the supplier.

When the production process is completed with the approved material, the finished product is tested by the QC department and if the finished product is not according to the standard quality it is again handled to the production department. This is called Pro-active method.

FUNCTIONTo ensure that the quality produced is upto the required standards and according to the norms lay down. Moreover the material used in the process should also be as per the norms.

SECTIONS1) PHYSICAL TESTING LAB. Paper Tube

Weight

Dimension

Compression strength Corrugated Box, Centre Plate Etc.

Weight

Dimensions

Printing defects

Puncture resistance

Bursting strength

Bopp Tape

Holding Strength

2) CHEMICAL TESTING LAB Oil pick up percentage

Properties of coning oil.

Viscosity

% Volatile impurities & % moisture

Density

PH of drinking water.

Distillation of water (for use in battery)

Dyeing of tube Knitted hose

PURPOSE

To see that only inspected material used in process. Use only conforming process material for quality analysis, identifying and holding non-conforming process material and then releasing after proper analysis. The final product conforms in all respects to product specification and for non-conformity material it is only dispatched after suitable gradation or identification. The test for quality is done on the material as per specified sampling plan. This is applicable for both incoming as well as in-process material. The variation inspection and testing procedures, which can be carried out by QA for various materials, are as follow-:

1) Coning Oil Testing.

2) ply testing

3) Box testing

4) Compress testing

5) Printing testing

6) Box weight

7) Testing of wooden Platte

8) Testing of denier of YARN

9) Testing of Elongation and tenacity

10) Bursting testing

There are various instruments used in the Quality analysis Lab. For the purpose of measuring Denier, tenacity, twist elasticity and nodes in a given or fixed length of yarn.

EXAMPLE:

Testing/ Approval procedure for the Paper Tube

Sampling-: The total 10 samples to be drawn first as well as CS, dimensions and weight.

Approval procedure-: If test of first samples are below our standards in any one or more parameters are down

If two readings are within 0-5% down and average is ok as per our standards the result is Accept.

If two readings or more are down and average is upto 95% of our standards then Re-test.

If two readings or more are down and average is below 95% of our standards the sample is rejected and is categorized as low-grade product.

INTRODUCTIONThe entire APS computerized and for software related problems deepens on SYSTEM departments. The APS system that has been installed here is supported to be the most modern equipment to be installed in the industry. This system has been acquired from

CAMEL ROBOT, a Company based in Italy through its India agents the Novell Industries. The Installation of this machine has led to faster packing & dispatch Rate, thereby making the plant truly fully automated. The last part of the system that has been installed at IPCL, i.e., after the installation of the barcode scanner has been directly installed by Novell Industries. This means the weighing scale to calculate the Net Weight of the box, the automatic top flaps closer, the strapping machine, and the automatic centering devices & the pallet has been installed by Novell Industries.

They made two types of packages according to use

1. Domestic

2. Export

The main function of this department is to packing the material received from PCIII so as to provide empty trolley to production. The bobbin after inspected by process control department is sent to packing department for packing. Here two type of packing is done.

1 Auto packing

2 Manual packing

A brief description on various units of APS system which is essential for easy going of the entire system given as below

1) Chain accumulating conveyor for loaded trolleys

2) 2 Robot to Unload packages from trolley to disks conveyer

3) Re-circulating disk conveyor to transport packages through system

4) Automatic weighing and vision systems for individual packages on disks

5) Weighing scale Controller

6) Manual inspection is done after passing from weighting and vision system

7) After the manual inspection of the bobbin it is further passed to Wrapper machine for covering the bobbin with the plastic bags

8) Automatic buzzer for individual packages on the disk

9) Automatic Feeder for wooden pallet

Modes Of Packing1) Jumbo

2) Boxes

Types Of jumbo & boxes1) Neutral

2) Semi-neutral

3) Recron

The boxes listed above are single Decker boxes which contain 6 Pkgs. /box Colour of the boxes1) Brown.(for job material)

2) Green.(for own material)

3) Blue.(for R &D material)

The boxes listed above are double Decker boxes with Texlene Trademark printed on it (12 Pkgs. /box).

Flow chart of packing material through camel robot.Trolley

Trolley conveyor

Unloading Robot

Weight systemManual Inspection Station

Wrapping Machine

Auto packing robot Manual filling

BTS scanning. BTS scanning

Box inspector

Gross Weigh Scale

Cartoon Labeller

Taping MachineStrapping Machine Vacculift Lag Area

For Domestic packing

Sticking of domestic stickers.

Packing as per grade by SAL checker.

On to conveyor

Gross weigh scale.

Carton labeller

Taping Machine.

Strapping Machine.

Vacculift

Lag AreaWarehouseFACTS AND FIGURES No. of checkers = 18 (A&B)

No. of Knotter = 02

No. of trolley pusher=02

Box inspector = 02(1 in C)

Data Entry operator = 02(1 in C)

Box labeler = 02 (1 in C)

Target for each checker =1500 Target for packing = 63,000/day (on an avg.)

Production capacity =49,680 ( considering 12 hrs doff and 216 spindles on each machine)

Packing capacity on Camel robot = 4500 5000/shift

Packing capacity on salmoraghi= 5000 -5500/shift

LAG AREA

The main function of the lag area is to store half pallets and supply full pallets to the warehouse through transfer note.

Receives the boxes from packing

Stacking the boxes as per address

Transferring the full pallets to wrapping station

Scanning of the pallet no. and the boxes on the pallet

Transferring to Warehouse through transfer not.

INTRODUCTIONMaintenance is concerned with day-to-day problem; keeping production facilities and equipment in proper operating condition. To achieve a high rate of industrial productivity, it is necessary to maintain productive facility properly. Everybody knows that machines break down; parts wear out, equipment and other facilities detioriate. As a result productivity fails to make its full contribution, if these are not operating efficiently. For this purpose all the manufacturing concerns follow some maintenance routing to keep all productive assets in efficient working conditions and minimize ideal equipment time.

PURPOSE OF MAINTANANCE DEPARTMENT

To keep all the production facilities in proper working condition.

Allowing machines and other facilities to operate at their optimal capacity.

To replace the critical parts before they fail.

To contribute a great deal to safety of man power and spoilage of a material.

PROCEDURE OF MAINTENANCE DEPARTMENT

The purpose of maintenance department is to maintain the machine and avoid breakdown for smooth functioning of production department. The department maintains stock of frequently required spares part to overcome the breakdown of machine. There are three types of maintenance carried out by the department.

1. Routine Maintenance

2. Preventive Maintenance

3. Workshop Maintenance

FUNCTION To keep the machine in good mechanical condition through preventive maintenance and routine check up as well as to minimize the no. of idle position due to mechanical fault.

PREVENTIVE MAINTENANCEPreventive maintenance is plan maintenance, according to which the timely checkup of machine is done. Under this maintenance, they prepare yearly plan. Firstly, they inform production department that they want to take particular tank or machine for maintenance and so they want it empty, with the help of which both the department can carry on their work.

FUNCTION

It should be carried out on the machine with in 33 +/- 7 days

The PM duration is monthly, quarterly, half yearly, eleven monthly.

Buffing of rollers of input, out put and intermediate.

Removal of lapping on all shafts

Cooling plate cleaning

Checking of all the belts and replacing the faulty one

Replacing of damage parts such as worn out guides, discs having cuts traverse guide which are broken.

Cleaning of all machine parts and airing it.

Checking of the bearings in input, out put and intermediate shafts.

Greasing of all the bearings and parts after 4 months.

Changing of the traverse box oil after 11 months. ROUTINE MAINTENANCEDaily oiling and greasing of machine is done in routine maintenance. Routine checkup of tanks and machines are done for smooth production.

FUNCTION To minimize the idle position on running machine.

In case the idle position are more than 03 and that cannot be rectified in running machine then machine is stopped during doff time and idle position are attended.

Rectify the quality related problems Due to mechanical faults.

For this a memo is given by PC department to maintenance.

To Change the gears in case of machine change over and attend the machine breakdown problem.

WORK SHOP FUNCTION To minimize the down time during breakdown by keeping the spares of the machine in good condition.

Machine in workshop

Roller buffing machine

Lathe machine

Welding machine

Presser (Hydraulic and manual)

Drilling machine.

Eccentricity Tester

SECTIONS IN WORKSHOP Roller buffing section.

General maintenance section

Spindle shop

Jet cleaning

Welding

Knitting machine maintenance

PLANT ELECTRICAL MAINTENANCE & INSTRUMENTATION

To prevent machine breakdown due to electrical or instrumentation problem through preventive maintenance and routine check up.

Activities of Electrical Preventive maintenance

Cleaning of primary heaters.

Checking of all NCD, cutters, panel board

Checking of all electrical connections

Checking of all instrumentation related cards (control card for PH, SH, oiler and traverse.)

Checking of all motors for its bearing.

Activities of Routine Electrical MaintenanceAttending the idle positions due to electrical problem such as cutter problems.

Activities of Workshop Overhauling: Change of bearing in motors.

Checking of PRV on PM machine.

Venting of heaters.

Keep the spares such as motors and coupling in ready condition so as to minimize the down time during breakdown.

INTRODUCTIONHuman resource of an organization is considered to be the most vital assets, because it is the people who make other resources moving. They perform various activities in the organization in different functional areas like production, marketing, finance, etc.

Organizations require the service of large number of personnel. Each position of the organization makes certain specific contributions to achieve organizational objectives. Hence, the personnel who occupy the position should have sufficient ability to meet the requirements. This may require a number of functions like manpower planning, recruitment, selection, training and development, performance appraisal, promotion, transfer, etc.Human resource management is concerned with competing for and competing on human resource. Competing for human resources involves recruiting and employing right personnel and competing on human resources involves developing, retaining, and integrating personnel to achieve competitive advantages.

HUMAN RESOURCES PLANNING

HR planning basically deals with forecasting of additional human resources required in an organization in future. Although human resource planning means different things to different people, general agreement exists on its ultimate objectives the most effective use of scarce talent in the interests of the labour and the organization. Human resource planning includes the estimation of how many qualified people are necessary to carry out the assigned activities, how many people will be available.

OBJECTIVE OF HUMAN RESOURCE To understand the nature of employees and how it is a function of all managers in an organization.

To understand manpower planning so that right people are available at right time and at right place.

To understand the issues related to job analysis and the uses for which it is undertaken.

To understand the concept of performance appraisal and its relevance of managers.

To link directing with the human nature in the organization so that suitable behavioural and managerial models are adopted.

To understand how to design incentive system, job, & enhance quality of work life.

PERSONNEL /HRD DEPARTMENT This P/A department has several sections, those are as follows:

1) Administrator department: This department helps staff in various ways. They handle mostly all finance tasks, like accounts, Company purchase/Sales Account Salary Accounts etc. they also control buses services, guest house providing Air and Train Tickets, also entire telephone system is control by them.

2) Security Department: This department is responsible for safety of entire industry. This department is directly controlled by reliance group. There are two types of entry permit photo card and temporary card for visitors there are two type of cards Green and Red.

3) Medical Department: This department provides medical facilities each and every employee of IPCL .They conduct an annually medical test for all employees. They have four staff Medical Officer and a chief Medical Officer, and also provide medical services for any causality with help of Ambulance facility.

4) Fire and Safety: Various activities done by this department are

i) Mock Drill

ii) Noise level monitoring

iii) Safety committee meeting

iv) Safety audit and inspection

v) Siren beam detector checking

vi) Fire door checking

vii) Fire extinguisher checking

viii) Tool box talk to employees

ix) Work permit checking

5) Time Office: They handle each employees attendance. They temporary provide manual attendance register for staff who is new and those who have missed their ID cards.

They divide the entire work into shifts like A,B,C,H,I,G .

Several types of records maintained by time office are:

1) Gate Pass

2) C-Off

3) CMS Card

4) Shift Change

5) Absence

6) Paid Holiday

7) OT (Overtime)

8) Accident and fitness

9) Buses pass Etc.

ACTIVITIES OF TIMEOFFICE Attendance

Leave records

Wages for regular staff Wages for contractual workforce Over time General insurance Group medical policy and group accidental policy OHSAS 18001 ISO 14001 Government records and register Contractual projection and bills Provident fund Gratuity SuperannuationSHIFT AND LUNCH HOURSThe company runs in five shifts. The shift timings and corresponding lunch hours are as below:

Shift Hours Lunch Hours Tea Break

FromToFrom ToFromTo

07:0015:00(A)11;0013:0007:0008:15

15;0023:00(B)19:0021:0016;3016:55

23:0007;00(C)--12:00

04:0000:20

04:20

08:30 18:00 (G)12;0014:0009:30

15:0010:00

15:30

08:0016:30(H)--09:00

16:2009:30

16:35

LEAVEThe following type of leaves is admissible:

1) Sick Leave

2) Sick leave without Pay

3) Privilege Leave

4) Casual Leave

5) Compensatory Leave

All the regular employees working with IPCL are entitled to get leave as per the rate applicable to their category.

EMPLOYEE SELF SERVICE (ESS)

Every regular employee of IPCL has an option of self service system wherein they have the following options:

Office

Attendance- Reliance

Time-Infocomm

Training

Travel

Reimbursement

Employee separation

Payroll

Personal Information

R-Matrix

Appraisals

Skills

Income Tax Benefits

Forms for Download

For Administrator

Every employee has their own password to access the Employee Self Service, where he can access his information from the above mentioned functions and make necessary changes. This information is recorded in the website which can accessed only by the IPCL employees.

WELFARE FACILITIES

IPCL provides various welfare and recreational facilities to its employees, which are

Statuary as well as non-statuary, as listed below;

1) Sports and Recreation

IPCL offers different sports and recreational facilities to its employees, they are:

a. Facility for indoor games - Table Tennis / Carom / Chess / Athletes etc.

b. Sponsor players for indoor/outdoor games.

c. Conduct tournament for indoor/outdoor games.

2) Industrial health and safety

Under this head, various facilities, which are provided by IPCL as statuary and non-statuary compliance for, its employees are:

a. Medical Inspection Room (MI Room).

b. Protective clothing, Shoes, Glasses, Safety Belts etc.

c. Periodic check-up for employees.

3) Social Celebrations

Various social functions are celebrated at site with employees taking part in it:

a. 26th January Celebration

b. 15th August Celebration

4) Canteen

IPCL runs a canteen with facilities of 250 seating for work force and a

different canteen for the officials, where strict vegetarian meals is served for on coupon basis for Rs 10/- and snacks for Rs 5/-

5) Bus Facility

IPCL provides bus facility on subsidized rate for attending duty on shift. Bus

passes is available in the time office.

6) Uniform

IPCL provides uniform and shoes to all employees on yearly basis. All employees should wear their uniform cloth clean and properly tucked.

7) Employees Credit & Co-operative society

Employees Credit and Co-operative Society is being running with 1300 members. To become the member of the society employee should contribute Rs 100/- as membership fee at first then as saving and Rs 5/- as Employee Labour Welfare Fund, every month

PERFORMANCE APPRAISALS

Performance Appraisals is a method of evaluating the behavior of employees while working in the organization, which includes both the quantitative and qualitative aspect of job performance. Performance can be referred to as the degree of accomplishment of the tasks that are assigned to an individual. It indicates how well the individual has fulfilled the tasks assigned to him. It can be confusing stating that performance can only be measured in terms of results.

IMPORTANT ASPECTS OF PERFORMANCE APPRAISALS Performance appraisal is the systematic description of an employees job relevant strengths and weaknesses.

The basic purpose is to find out how well the employee is performing the job within the organization.

It is a systematic process which tries to evaluate the performance of an individual working in the organization.

Appraisals are arranged periodically within a definite plan.

It is a continuous process in every large organization.

PURPOSE Performance appraisal aims at attaining the different purpose they are

To create and maintain a satisfactory level of performance.

To contribute to the employee growth and development through self training and management development programs.

To help the superiors to have a proper understanding about their subordinate.

To guide job change with the help of yearly ranking system.

To facilitate fair and equitable compensation based on performance.

To facilitate for testing and validating selection tests interview techniques through comparing their scores with performance appraisal ranks.

TECHNIQUE OF PERFORMANCE APPRAISAL AT IPCL

Key Results Areas (KRA)

In IPCL, department wise performance and knowledge about various aspects needed in the department is effectively checked.

Here there are two types of KRAS

Team KRA

Individual KRA

The KRA carries 1000 points which is marked by 10 options been provided.

1-5 options is the team KRA- it is very particular to the department, it varies department wise. This carries 400 marks.

6&7 options are similar for all departments which involves the performance diary and special projects. This carries 400 marks with 200 marks for each.

8-10 options are the individual KRA which involves IR, Safety etc. this carries 200 marks.

According to the marks gained the rating is done department wise. The grades are given as under:

EXCELLENT

VERY GOOD

GOOD

AVERAGE

BELOW AVERAGE

According to the ratings individual is given some incentive allowances once in a year as per the position of the individual.

Even some promotions can be expected.

The time period of KRA rating is April - march.

The rating is termed as OMEGA rating.

MOTIVATION

Various benefits are provided to the employees for motivating them. These are as listed below:

Uniform with shoes.

Medical facilities- self, wife and two children( group medical policy)

Individual accident policy (Group personal accident policy)

Ten paid public holidays where meals are provided for the company with sweets

Sports activities conducted with prizes.

Flag hoisting on Independence day and Republic day.

Planting

Polio, Blood camp, Skin camp

Summer Vivah

Hospital development

FOR NON- SUPERVISORS Attendance incentive

Production incentive

Top ten attendance performance awarded

RECRUITMENT AND SELECTION

Recruitment is the process of finding and attracting capable applicants for employment. The process begins, when new recruits are sought and ends when their applications are submitted. Recruitment is concerned with the identification of sources from where the personnel can be employed and motivating them to offer themselves for employment.

Recruitment is the process concerned with the identification of possible sources of human resource supply and tapping those sources.

The Company hires workers on contract basis. In case of staff, whenever any vacancy is created in the company, first of all the company tries to fill it by promoting the employees within the company, or otherwise they use the external source for recruitment. For the external recruitment, an application is submitted to the HO (Mumbai) by the department head and if HO approves it the company starts their selection process.

SOURCES FOR RECRUITMENT

Internal source External source

---- Promotion ---- Advertisement

---- Transfer ---- Labour contractors

INTERNAL SOURCE

The company fills up the vacancy by employing the existing employee for the required post through promotion or transfering them from other units.

EXTERNAL SOURCE

The company recruits and selects the employee from external sources that is through advertisement in the newspapers and hiring employees through contractors.

PROCESS

PERSONNEL REQUISITIONS

The recruitment process starts when the personnel department receives the requisition for recruitment from any department of the company. It contains all the details about the position to be filled, qualification required from the candidate, terms & conditions of employment, & time by which the candidate has to appear for the appointment.

APPLICATION POOL

The process starts with the collection of various applications. All the applications are collected by the company on the basis of criteria placed by them.

SCREENING OF APPLICATIONS

Screening is done to weed out totally undesirable or unqualified candidates at the outset. The applications received from the applicants contain information regarding their personal bio-data, achievements, experience etc. Based on the screening of applications only those candidates are called for further process of selection.

INTERVIEW

After screening of applicants is done, the company conducts a personal interview of the applicants to find out overall suitability of candidates for the job. It also provides opportunity to give relevant information about the organization to the candidates

APPROVAL FROM HO

The applications of the selected candidate are send to HO (Mumbai), who is then approved by them. The head office further decides the authority, responsibility & pay of the candidate. PLACEMENT

After all the procedure is completed, initially the candidates are placed on the job on probation basis for six months. During this period, they are observed deeply, and when they complete this period successfully, they become the permanent employees of the organization.

PROBATION PERIOD/ TRAINING PERIODProbation/Training is the trial period, which a new employee has to undergo before the individual & the organization accept each other. The various terms and conditions are applicable during the Probationary/ Training period.

1. The Probationer/ Trainer is entitled to get the salary as per the grade in which he is appointed.

2. The training period is of one year and Probation period is of six months, which may be subjected to extension of three months if the performance of the employee is not found satisfactory. However, on successful completion of the probationary period or training period, the employee is confirmed in the services of the company or comes to probation as the case may be;

3. The Probationers/ Trainees services may be terminated by the company at the end of the probationary/ Training period without assigning any reason thereof;

4. The Probationary/ Trainees will be subject to the standing orders & rules and regulations of the company , which are in force and framed by the company from time to time;

5. The Probationary /Trainees has to work in any department /office / branch office as required by the company;

6. The appointment of the probationer /Trainer is subject to his medical fitness certified by the Companys Chief Medical Officer.

FINALIZATIONOnce the candidate has gone though the training and the probation period he is finally chosen for the work with the necessary incentives to be provided

TRAININGEvery organization needs to have well trained and experienced people to perform the activities that have to be done. If the current or potential job occupant can meet this requirement, training is not important. But when this is not the case, it is necessary to raise the skill levels and increase the versatility and adaptability of employees. Inadequate job performance or a decline in productivity or changes resulting out of jobs redesigning or a technological breakthrough requires some types of training & developmental efforts. As the job becomes more complex, the importance of employee development also increases. In a rapidly changing environment, employee training & development is not only an activity that is desirable but also an activity that an organization must commit resources to if it is to maintain a viable and knowledgeable work force. Training & development constitute an on-going process in any organization.

IMPORTANCE OF TRAINING

Training Programs helps to remove the Performance deficiencies in employees. This is particularly true in case of

1) The deficiency is caused by a lack of ability rather than lack of motivation to perform

2) The individual involved have the aptitude and motivation needed to learn to do the job better

3) Supervisors & Peers are supportive of the desired behavior

There is a greater stability, flexibility and capacity for growth in an organization. Training contributes to employee stability in at least two ways. Employees become efficient after undergoing training. Efficient employees contribute to the growth of the organization. Growth renders stability to the work force. Training makes employee versatile in all jobs. Flexibility is therefore assured. Accidents scrap & damage to machinery and equipment can be avoided or minimized through training. Even dissatisfaction, complaints, absenteeism and turnover can be reduced if employees are trained well. Hence, Training is an investment in HR with a promise of better returns in future.

The Entire Training Process can be outlined as below:

TRAINING PROCESS FLOWCHARTTOP MANAGEMENT/ DEPARTMENTAL HEAD/ T & D HEAD

T & D HEAD

TRAINER

T & D OFFICER

HOD/TRAINER

T & D OFFICER

The Training Needs Can Broadly Be Classified Under Following Heads: 1) Induction Training2) Mandatory Training3) Competency Assessment Training (SDM)4) Need Based Training PURPOSE OF TRAINING

Development of all cadres

Career Progression

Succession Planning

Multi-discipline skills

Own discipline, Cross functional, soft and conceptual skills

Building expertise and multiplying it across company : Uniformity in practices across sites.

To bridge losses due to

Retirement

Attrition

To meet additional demands as a result of growth of the company.

K S A K Knowledge - requires to know, to perform

S Skill - has to be proficient in, to perform .

A Attributes - soft skills / conceptual & behavioural traits, to perform

KSAs ( for a Job/Position ) are classified as Own Discipline / Function created for the Job / Position

Cross Discipline borrowed from KSAs created for the other disciplines

Soft Skills borrowed from a common pool created by HR

HSEF Related relevant for HO ? ?

Location specific - created for the Job / Position

Others

INTRODUCTION

Marketing is typically seen as the task of creating, promoting & delivering goods & services to consumers & business. It is a societal process by which individuals & groups obtain what they need & want, through creating, offering & freely exchanging products & services of values with others. Business plans are becoming more customer & competitor oriented, better reasoned & more realistic than in the past. To be successful the firm needs to look for competitive advantages beyond its own operations into the value chains of its suppliers distributors & customers.

IPCL has an extensive network of sales offices, representatives, and distributors that are constantly striving to reaffirm the commitment of every sale and complete support thereafter. They share with their customers, the enormous wealth of their experience and knowledge gained over the years. The company not only supports their present, but also helps to build their future in the businessThe companys service centers are equipped with the modern techniques and procedures for total customer support. Every stage of production is being closely monitored and tested ensuring consistent quality to their customers.

OBJECTIVES OF MARKETING DEPARTMENT

Marketing department not only deals with retaining the existing one, but also attracting new customers. The marketing objectives are as follows:-

To increase awareness among the customer about the product.

To provide quick and widely available service to their customers.

To understand the service output levels desired by the target customers.

To initiate and respond to price change.

To gather information about present market situation and measure market demand.MARKETING PROCESS

Marketing department at the end of every month gets the PTY requirement from each region and thereafter find pout the best possible product mix/sales mix to be run for given PTY Machine plan. Monthly production plan is prepared by marketing head considering customer order in hand, pending order and future requirements.

PRICING POLICY

Pricing policy is been set by the producer, to establish a price list and schedule of discounts and allowance, that is equitable and sufficient to the customers. The pricing policy of IPCL is set up by its Head Office.

TURNOVER OF THE COMPANY

Although the company faced heavy pressure of stiff competition from national and international quarters, the sales of the company continued to register growth. Production at the newly set up plant at Silvassa grew substantially, to compensate for the sagging performance at the manufacturing plant in Mumbai. The annual turnover of IPCL is 1000 crores and above.

EXPORTS

The exports of the company grew by 10% as compare to the pervious year, however the management is pursuing much higher goals to achieve exponential growths in the coming years.

EXPORT YIELD %

SALES AND DISTRIBUTION

Sales department and the warehouse department are both always interlinked whenever the warehouse is used for the storing of finished goods.

Order generation process in the company The sales representatives, marketers, and other employees of the head office of the company collect the orders from the market and pass those orders to the sales and distribution department.

The sales and distribution department notifies the specifications made by the customer and checks the availability of the stocks as per the specifications and then finally decides the date of delivery.

This delivery date is then conveyed to the customer, and if accepted then the order is then recorded for completion within the delivery date accepted.

ACTIVITIES OF THE SALES AND DISTRIBUTION DEPARTMENT The sales and distribution department looks upon to deliver the goods to the goods to the customer on the promised due date.

The sales and distribution department calculated the stock to be manufactured or the stock to be generated from the pending orders and thus plans for future production cycles to be carried out.

It checks the deliver dates getting near and asks the warehouse department to pass on this order quantity of the goods to sales department.

These goods are then prepared to be loaded in to the vehicle through it has to be transported to the customer or the delivery site, whatever may be the case.

The transportation vehicle is decided after estimating and considering the quantity, weight, and size of the goods.

A local transporters vehicle may be chosen if the quantity is small enough to hire a full vehicle.

But if the quantity or size is large enough that a vehicle is required to be hired then a carrier or a container is chosen.

The loading supervisors are responsible for the proper and safer loading of the goods in the vehicle.

SUMMARYThe sales and distribution department looks upon supplying the goods

(a) Demanded by the customers if its consumer goods.

(b) Demanded by the zonal distribution centers if the company has a wider market

(c) Demanded by the further processing if its linked to a sub assembly storing center.

It reports the production planning department for the stock required to be produced in the near future to meet the customer needs at the promised date of delivery and to maintain the planned level of stock in the warehouse.

INTRODUCTION

Research and Development means large-scale investment to support innovative ideas. R&D Laboratories attach great importance to the smooth integration of quality testing, production methods and packaging systems of newly introduced products. R & D activities are monitored by the new version of ISO 9001 : 2000 quality management system.Research and Development centre of IPCL is playing a key role in maintaining its technological leadership by quickly responding to customer and market. It is manned by a larger team of highly qualified and experienced technocrats. They have well equipped library facilities to update reference material, periodicals, current journals and standards of Indian and International origin.

RESEARCH & TECHNOLOGY

IPCL considers R&T as an integral part of its strategic management. Its R&D Center, at Vadodara, established even before commencement of commercial operation, is a forerunner in petrochemical research. The vision of R&T is "...from licensing technology to developing technology, from being an intellectual property user to intellectual property creator" through Research in Hydrocarbon chain, Polymer and Hybrid Material Applications and, Technology Development. In order to cater the needs of Research & Technology, several areas of research encompass Polymers and Materials Sciences, Catalysts and