AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM

1.1 INTRODUCTION An organization is an entity where two or more persons work together to achieve a goal or a common purpose. If there is an organization, then there must be some people who work as a whole for a common purpose, so there must be defined purpose. If an organization does not have any purpose, it will not survive in the long run. To achieve the purpose by using people, the processes are needed. Organization is a group of people working together for achieving a common objective which is already defined by the organization. To run the organization properly without any wastage of resources a proper structure and hierarchy is to be properly defined in an organization. The organizational study was conducted at RUBCO Rubberized Coir Mattress Division, Poothukuzhi, Kottayam. It started its operation in 2001 November. The project realized with an investment of Rs.280 Millions. The manufacturing plant is among very few in the country to employ advanced Austrian Machinery, sourced from DOA, Austria. Rubber is a polymer consisting of Hydrogen and carbon and is elastic in nature. It is found in the fluid of some specific plants but it can also be produced synthetically. Naturally, rubber is produced by the process of tapping of the plant called Hevea Brasiliensis. Around 3/4th of the national rubber is produced in Kerala. So rubber has become the backbone of our economy. Due to the bad impact of globalization the overall market of rubber fell down in Kerala, that time instability in price of rubber was one of the major problem that farmers faced in the market. The farmers were not getting fair price for their effort, but this problem has come to an end since 1997, because the Kerala state rubber co-operative limited came into existence in this year for the purpose of exporting the infinite possibilities of rubber. It literally means that Kerala state rubber cultivator. RUBCO is incepted with prime objective of effectively utilizing the abundant rubber resources of Kerala. In a short span, RUBCO has successfully introduced a wide range of fast moving rubber based product. Today the RUBCO group is manufacturing rubber footwear, casual shoes, cycle tyre and tubes, two and three wheeler tyre, rubberized coir mattress process and rubber wood based furniture, block rubber (ISNR) and pale latex crepe, apart from natural rubber trading.
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AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM

1.2 OBJECTIVES O THE STUDY

To have an understanding of the profile of RUBCO Mattress division and its various activities. To acquire the knowledge regarding the functional as well as the managerial aspects of the company. To find out the problem and to put forward some suggestions. To get an idea about the organizations various departments. To familiarize with the various activities of the company. To get feel of actual working environment and to get the acquainted with it. Learn and enrich by observations and by implementation of my knowledge. To learn and maintain good relationship with the organization.

AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM

1.3 SCOPE OF THE STUDY This study is about the major functioning of the RUBCO Rubberized coir mattress division, Pampady. This study mainly based on the details collected from each department. Each and every activity of the department functions are studied carefully with the available data. This study is beneficial to the future mangers as they are put into real life situation. A study on allthe department can help to improve the process and there by overall improvements in the companies performance can be made.

1.4 LIMITATION OF THE STUDY The main limitations of this study are, Time limit: To understand an organization and its working the period of one month is not at all enough. So that time was the most important limiting factor in the study.

Lack of data: Some of the data are treated as confidential hence the researcher could not get the details of the same.

Lack of comparative data: The details of other companies related to the same business was not available to take comparative study 1.5 REASONS FOR SELECTING THE COMPANY For select this company because they are engaged in active performance in production service and marketing. The prime consideration is the study is its tremendous growth during the past few years. The major departments are Finance, marketing, Purchase, Production and planning, Maintenance, Quality control, human resource and Exports.

AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM

1.6 RESEARCH METHODOLOGY Research in common parlance refers to search for knowledge. One can also define research as a scientific and systematic search for pertinent information on a specific topic. In fact research is an art of scientific investigation. The advanced learners dictionary of current English lays down the meaning of research as a care full investigation or inquiry especially through search for new fact in any branch of knowledge.In short, the search for knowledge objective and systematic methods of finding solution to a problem in research. RESEACH DESIGN A research design is the arrangement of condition for condition and analysis of data in a manner that aims to combine relevance to the research purpose with economy in procedure. In fact, the research design is the conceptual structure within which research is conducted. A research design constitutes the blueprint of the collection, measurement and analysis of the data.

Primary Data: It refers to the first hand information which is original in character that an investigator himself collected from the respondent.Primary data required for the study where generated from individuals, structures, questionnaire and also from the discussion made with people Having formal and informal interview and discussion with managers and official staffs. Personal visit to plant.

Secondary Data: The secondary data are those which have already being collected by some one else, so which have already passed through the statistical process. The main source of secondary data collection is Data collected from published records and unpublished sources. Official records. Office manuals. Department manuals.
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2. INDUSTRY PROFILE

AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM

2.1 INDUSTRY PROFILE Rubberized coir mattress segment is a high competitive. This segment having more than 50% of the market share in the mattress industry. They have more than 45 odd brands and over 200 different models. The major players of the industry are Kurlon, Duroflex, and Sunidra. The birth of rubberized coir industry is quite amusing and interesting. Prior to the year 1960 people hardly had any idea of this novel and high quality of product. In those days the world famous car manufacturer M/S Volks wagon of Germany, were using the horse hair as cushion filling material for their car seats. As the production increased from100 cars per day to 300, there was a depth of raw material. This necessitated a suitable alternative products for rubberization and which could suite to their specifications. Of various alternatives tried like Sisal fiber, Jute fiber, the coir fiber was decidedly found to be the best. This was the beginning of the rubberized coir industry. It is nearly four decades old. It was in 1964 M/S bharat Motors of Chennai established its manufacturing unit. After nearly one decades of its introduction, Government of India recognized Rubberized coir mattress as a healthy and hygienic product. Slowly many state Government recognized rubberized coir as Wealth from Waste and advocated the use of rubberized coir mattress in various activities such as hospitals, health, clinic etc. through issue of government circular. Other type of Mattress Cotton mattress Form mattress Spring mattress Cotton mattress: Cotton mattress mainly targets lower income groups. This is priced very low. The cotton mattress industry has a market share of 50%. Form mattress

AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM

Form mattress segment comes as next place after rubberized coir mattress industry. This industry have market share of 9 to 10% this industry mainly targets customers belonging upper income and upper middle income group. The major players are MM form, sleepweell.

Spring mattress This industry targets consumers belonging to the upper income group. Major players are Spring well, sealy, Kurl-on.

Growth During Last 4 Decades From a handful manufacturers, during early 60s this product got some market recognition in early 70s. in the next 3 decades over one hundred manufacturers have entered rubberized coir field. Today rubberized coir products are increasingly used in many industries notably in transport industry like railways and buses, packaging industry (pharmaceuticals, heavy engineering, electronics etc), hospitals, theaters and auditoriums. The basic raw material for Rubberized Coir industry is the brown coir fiber and the natural latex rubber. Over the last decade, the brown coir sector has registered a tremendous growth.

2.2. WORLD SCENARIO There are three major players in the mattress industry and are as follows. Sealy corporation: It is the major manufacturer and it got the name from the place it started, sealy, Texas. King koil Founded in 1988, king koil has over a century of experience crafting high quality, affordable bedding both the united states and through out the world.

Simmons Bedding Company

AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM

Simmons bedding company is a major manufacturer of mattress and is one of the oldest companies in the united States, for over125 years.

2.3 INDIAN SCENARIO The rubberized coir mattress market of India is estimated to be highly fragmented with little brand loyalty. The major players are;

KURL-ON LTD: Kurl-on ltd, a Manipal group Company came into existence in 1962. Kurl-on Ltd is the brand leader in the mattress industry has acquired major market share in the branded mattress segment.

DUROFLEX Duroflex is the largest exporter of sleep and comfort product from India, started its operation in 1963.

CENTUARY MATTRESS: Centuary Fiber Plates private ltd started its rubberized coir plant at Hydrabad in 1988 under the brand name CENTUARY. Centuary is the first mattress manufacturer with ISO 9001-2000 series and ISI certification.

2.4 .STATE SCENARIO In India, the coir industry has developed very well especially in Kerala where they produce Retted Fiber. Green husks of coconut are immersed in the salty backwaters for 10 to 1 months. The main players are DUROFLEX DUROFLEX is the leading mattress manufacturer in India which started its operation in 1963. It is the largest exporter of sleep and comfort products from INDIA.
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EASTERN SUNIDRA Eastern mattress Pvt Ltd.is a park of Keralas renowned business conglomerate the Eastern Group of companies. RUBCO Kerala State Rubber Co-operative Ltd(RUBCO) was set up in the year 1997. Its prime objective is to effectively utilizing the abundant rubber resources in Kerala. The Indian coir industry has a diversified structure, reflecting the broad range of r aw materials and value added products involved. In the industry provides at least part time employment to an estimated 40000 persons. At the beginning of the value chain are approximately 300 fibers millers with usually less than 10 employees and an estimated 500 suppliers of coir pith, or dust. There output is either purchased or direct export or undergoes manufacturing for twine, mats and brushes rubberized coir mattress and pots, geo textile and pith products. Product, which are technically more demanding or better suited for mass production, such as high end twine, brushes, rubberized coir and erosion control blankets are predominantly produced in larger facilities, employing more persons. Now, rubberized coir mattress industry the competition is more and more, the demand for the product is in growth stage. So the only the quality mattress industry can survive in the competitive World.

v. Future Of The Industry

now in rubberized coir mattress industry the competition is more and more the demand of the product is in the growth stage. So only the quality mattress industry can survive in the competitive world.

RUBCO GROUP Kerala state rubber co-operated ltd(RUBCO) situated in Kannore. Kerala state is promoted by the government of Kerala to promote rubber industries in the part of our country.

AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM

Today India enjoys 4 the position in the production of natural rubbers(NR) and the small state of Kerala contributes 92% of its so it has become the backbone of our economy. Due to the bad impact of globalization the overall market of rubber fills in Kerala and the instability in price of rubber was one of the major problems that the rubber farmers faced. The farmers were not getting fair price for their effort. But this problem came into an end since 1997 as the Kerala state rubber cooperative ltd. (RUBCO) came into existence and here started a series of possibilities for the utilization of rubber in multifarious sphere and fields. Since its inspection in 1997, RUBCO has travelled a long way. It has entered into various Rubber based industries.

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3.COMPANY PROFILE

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3.1.

ABOUT RUBCO

Kerala State rubber co-operative Ltd(RUBCO) was set up in the year 1997, with the objective of effectively utilizing the abundant rubber resources in Kerala. RUBCO has in short span, redefined the way the co-operative movement in Kerala. Today from a single unit company RUBCO has grown into Rs. 280 crores conglomerate with well diversified operations and a market presence extending beyond boundaries of Kerala. Kerala State Rubber co-operative Ltd(RUBCO), is situated in Kannur, Kerala state, India is promoted by the provisional Government of Kerala to promote Rubber based industries in this part of our country. Today India enjoys 4th position in the production of Natural Rubber(NR) in the world. Among the total production, small state of Kerala contributes 92%. So the rubber has become the backbone of our economy. Due to the bad impact of globalization the overall market of the rubber fell down in Kerala that time instability in price of rubber is one of the major problem that the farmers facing in the market. The farmers were not getting fair price for their effort. But their problem came into existence. In this year on the purpose of exploring the infinite possibilities of rubber. Since its inception in 1997, RUBCO has travelled long. It has entered into various rubber and rubber wood based industries like Hawaii chappal with reputed Malaysian technology, cycle tyres and tubes, Rubberized coir mattress, conventional and procured tread rubber, Block rubber(SMR), Pale Latex crepe, Casual shoes etc. for at least over 16 decade with a vision to become a Global leader in the production of natural Rubber and innovative product development, RUBCO adopts the best ad latest process in the production. In their slogan it self they had mention that RUBCO means RUBBER and RUBBER means RUBCO

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VISION To ensure brand leadership in all manufactured and marketed. MISSION To develop brand equity and to ensure professional co-operative image through a systematic working procedure. RUBCO group has involved in a wide range of business such as; Foot wear Furniture Cycle tyre and Tube Rubberized coir mattress Natural Rubber Virgin coconut oil

PROJECTS IN PIPE LINE RUBCO Hawaii chappal unit introduced three models; New projects for Coconut Based Products Virgin coconut oil Activated carbon Coconut spray dried milk powder Packed tender coconut water Coconut water concentrate

Plant for casual/ sports shoe on progress Unit for automotive rubber components to be established RUBCO is in the process of setting up a project for the manufacture of tyres and tubes for two/ three wheelers, passenger cars, heavy duty trucks and light commercial vehicles. The project will be located in the proposed industrial growth center being

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Organizatioanl Goals and Objectives Goal: The organizational goal of RUBCO-RCM Division is to make RUBCO a leader in the market of Rubberized coir mattress. Objectives; Maximize the capacity of utilization of the existing. To increase the profitability of the company and to maximize generation of surplus to enable RUBCO to finance its diversification projects. To execute production on time in accordance with the market demand of the product and make available them to the distributors. To maintain and improve the existing cordial relationship between employees and the management. To ensure strict quality control and ISI standards of products complete in the global market. Ro maximize cost reduction. To introduce new varieties of mattress as to increase the wide range of mattress catering to diverse segments of the market. HISTORY OF THE ORGANIATION Kerala State Rubber co-operative Ltd, (RUBCO) has in short span, redefined the way the co-operative sector functions and set the pace for the co-operative movement in Kerala today. RUBCO was set up in the year 1997 with the objective of effectively utilizing the abundant rubber resources in Kerala. RUBCO has also entered into technical alliances with the world leader in the respective field, sourcing from them State-of-art technology. Substantial investments in modern manufacturing facilities, coupled with well Organized market activities, have been RUBCOs products earn a reputation for quality and significant market shares. RUBCO is the largest exporter of Natural Rubber in the country today. Even in the domestic market, Rubco is a major supplier of natural rubber to all leading tyre companies in India. RUBCO is also a Government intervention agency towards market stabilization and has been serving the farming community directly and indirectly to get reasonable price, arresting drastic fall in price during the peak production periods. Natural rubber trading has being a blend of social obligation and commercial practicability led by a professional management team and ably
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supported by a committed work force. RUBCO is now poisoned to enter a high growth phase, with served new interactive that will take the group on a path of diversification and expansion. Rubber holds immense potential for a wide variety of commercial uses which is yet to be fully

Other Divisions Of RUBCO RUBCO Footwear Division RUBCOs footwear division manufactures a range of quality casual rubber footwear. The plant manufactured under the renowned Malasian technology RUBCOs footwear range presently comprises of three leading brands RUBCO Hawaii, RUBCO Rainbow and RUBCO classic RUBCO Cycle Tyre & Tube Division The plant has an annual installed capacity of 3 Million tyre and tube. RUBCOs range of cycle tyres & tubes has advanced features such as high non skid depth improved wet-skid resistance and traction property and more mileage and puncture resistence. RUBCO Huat Wood Pvt.Ltd The furniture manufacturing plant has a processing capacity of 40000 Metric tones per year. The product are being exported to UK, USA, Japan and many other countries across the globe. RUB WOOD, the furniture range, comprises of dining tables and chairs, designer Wardrobes, futons kitchen cabinets and computer and office furniture and is available in the choice of designs and finish. RUBCO Sreekandapuram Latex Pvt Ltd The company manufactures Block rubber (ISNR) and pale Latex Crepe(PLC). RUBCO is in the process of expanding the scope of operations of this unit in line with market trends. RUBCO Sales Inernational Ltd RUBCO sales international(RSIL) is a public limited company promoted by RUBCO to spearhead the sales and the marketing activities for RUBCOs entire range of product in the domestic and international market.

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Administration and Management of RUBCO The administration and management of RUBCO vests in the Board of Directors consisting of fifteen members as follows. Nine directors are elected by n class shareholders from among themselves. Two directors elected by B class shareholders from among themselves. CHAIRMAN: Mr. E. Narayanan He is a veteran co-operator and is holding various positions as chairman in central and state level co-operative organization. MD: Mr. Jacob D Mathew He has more than 25 years of experience as CEO in corporate sector. Other directors. Sri. V.N Vasavan Sri. George Mathew Sri. V Azeez Sri. Paneeri Mukhundhan Sri. M.V. koman Nambiar Sri. S.N. Chandran Sri. K.Manoharan Sri. V.P.Sadhasivan Sri. K.S.Gopi Sri. Jacob D Mathew

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4.ORGANIZATION STRUCTURE

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AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM

ORGANIZATION STRUCTURE Organization structure is the structure of the relationship among positions and the jobs created for the purpose of accomplishing the objectives of the enterprise. It represents the pattern of the relationships among the components of an organization. They are: The form of the structure The functions to be performed The human aspects This pattern of relationship governs duties and activities of persons who are depend upon each other for accomplishing the objectives of the enterprise. An organization structure should be designed to clarify who is to do what tasks and who is responsible for what results, to remove obstacles of performance caused by confusion and uncertainty of assignment, and to furnish decision making and communication networks reflecting and supporting enterprise objectives. The companys organizational structure is diagrammatically represented by an organization chart (a diagram representative of the hierarchy of an organizations personnel). The organization chart shows the line of responsibility between the various departments of the company.

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ORGANIZATION STRUCTURE

GM

Quality control &Assur ance officer

Administ rative cum personel officer

Account Officer

Purchaase Officer

Mechanical Maintenance Engineer

Electrical Maintenance Engineer

Productio n Manager

Custo mer Care

Assistant

Electrical Supervisor

Steno Qualit y Super visor

Mechanical Supervisor Accou ntant Store Keeper Sales& Shipping Officer Work Shop Technician Security

Electrician

Junior Clerk

Shift In-Charge Production Planning Officer

Supervisor

Workers

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AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM

5.PRODUCT PROFILE

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AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM

PRODUCT PROFILE I. PRODUCT PROFILE OF RUBCO RCM DIVISION Rubco manufacturers a wide range of mattress catering to diverse segment of the market. The range consist of

Heaven

A premium model that provides unmatched sleeping comfort is available in 3 inch and 4 inch thickness. Also available in customized dimensions and thickness for large quantities. Heaven Plus A luxury model that is elegant as well as comfortable which is 5 inch thickness. Hitech

A hitech model with an accent of finish and luxury available in 5 inch thickness.

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Hitech Pillow

Superior quality mattress finished to world class standard is available in 7 inch thickness. Dosth

An economy model that offers true value for money is available in 2 inch and 3 inches. Dosth Plus Safal

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A regular mattress that combines comfort and durability is available in 3 inch and 4 inches. Heal

This quality product is suitable for uses in the hospital. It is available in 3 inch and 4 inches thicknes Yathri

An elegant mattress mean for hotels, hospitals, tourist resort, etc. Yathri combines superior sleeping comfort with perfect back support enabling a relaxed healthy sleep layer of rubberized coir and latex enhance the comfort which soft and elegant quilting adds a luxurious feel for use in hospitals is available in 3 and 4 inches thickness. 9.30 pm

It is economy model available in 3 inch and 4 inch thickness. Dreams 50:50

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Relif

Relif Matterss is other product its thickness 4 inch and density 3.5 inch, 90 kg/m2. Renova
.

Product Category: Rubco Sleeping System Thickness: 6 Material: Rubberized Coir Blocks Density: 3.5 90 Kg/M3 Upholstery: 100 Density 1 Rebonded PU foam sheet pasted on the bare block.10mm 13 density PU Foam pasted at the bottom side

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AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM

Traveler

Traveller matters is 51 mm thickness material: Ruberized coir material Density: 60 kg/m2 Upholstery : 5mm 9 density p u foam pasted both sides. Cotton cloth pasted over border side.

Other product from factory.

Cushions

Mats

Eco soft pillow Pillow cover Rexin Pillow Soft Touch Pillow
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AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM

6.GENERAL MANAGEMENT PRACTICES

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A. THE PLANNING PROCESS

1.
FINANCIAL PLANNING

CAPITAL INVESTMENT BY BOARD OF DIRECTORS

LOAN FROM BANK

I NITIAL

WORKING CAPITAL FOR RAW MATERIALS , LABOR SALARY

&

OTHER EXPENSES LIKE ELECTRICITY .

2. LABOUR PLANNING

I NCENTIVES ACCOMMODATION TRANSPORTATION F OOD PROVIDENT FUND MEDICAL I NSURANCE HEALTH INSPECTION . (P ERIODICALLY )

3. PRODUCTION PLANNING

AS PER THE REQUIREMENT (DEMAND). MATERIAL SCHEDULING BY INCREASING THE SIZE OF THE RING USED IN THE LOOM . WORK SCHEDULE FOR BAG ORDER, MAINLY MENTIONED THE FOLLOWING DETAILS , SERIAL NO, WORK ORDER NO, ITEM, Q UALITY, COMPLETION DATE , DISPATCH DATE . PLANNING OF PURCHASING RAW MATERIALS FOR THE MONTH JULY WILL BE TAKEN ON J UNE. TAPE PLANT o RAW MATERIALS USED PER DAY. o T OTAL MATERIAL USED FOR PRODUCTION. o WASTAGE HAPPENS IN PRODUCTION.

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B. DECISION-MAKING PROCESS DECISIONS TAKEN BY BOARD OF DIRECTORS . MAINLY DECISIONS TAKEN FOR RAW MATERIALS PURCHASING. AND ALSO DISCUSS THE VARIATIONS IN THE RATE OF THE MATERIALS PURCHASING. C .INFORMATION SYSTEMS

RAW

MAINLY INFORMATION GETTING THROUGH TENDERS & E -MAIL. TAKING ORDER THROUGH E-MAIL. VARIATIONS IN RAW MATERIAL PRICES SHOULD PASSED THROUGH EMAIL . D. COMMUNICATION SYSTEM o GROUP MOBILE SYSTEM . o I NTER COMMUNICATION . o DIRECT COMMUNICATION. o LETTER o I NFORMATION REGISTERS . (EACH SECTION WISE ) E. GENERAL STRATEGIES OBEY ALL INSTRUCTIONS OF ORGANIZATION D UTIES & RESPONSIBILITIES . o PUNCHING SYSTEM o REPORTING THE TOP MANAGEMENT AT ANY EMERGENCY CIRCUMSTANCES . (E.G. DURING NIGHT HOURS ) o AND IF ANY MAINTENANCE IS ORIGINATED, THAT SHOULD ALSO INFORM IMMEDIATELY . F. CONTROL SYSTEM o SECURITY o CCTV (CLOSED CIRCUIT TV) G. ORGANIASATION MANUAL A well equipped advanced manufacturing technology under one roof controlled by ERP system throughout all departments.

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H. DUTIES & RESPONSIBLITES OF THE TOP MANAGEMENT:

1. SENIOR MANAGER
CO-ORDINATION WITH ALL THE MANAGERS AND MD/DIRECTORS . PREPARE MONTHLY PRODUCTION PLANNING AND TARGETS. ENSURE THAT ALL FUNCTIONS OF BRMSCO ARE PROGRESSED AS PLANNED AND AS REQUIRED BY THE DIRECTORS . ENSURE THAT PRODUCTION TARGETS ARE MET . ENSURE THAT ALL PURCHASES ARE DONE ON TIME AND ECONOMICALLY . ENSURE THAT ALL DELIVERIES ARE DONE AS PER CLIENT REQUIREMENT AND AS PER SCHEDULE . ENSURE THAT QUALITY OF MATERIALS AS PER PURCHASE ORDER . EMPLOYEE S WELFARE AND SAFETY IS ENSURED. ENSURE THAT PROPER LIAISON WITH VARIOUS CLIENTS AND GOVERNMENT AUTHORITIES ARE DONE AS REQUIRED BY CONCERNED MANAGERS . ENSURE THE COLLECTION ESPECIALLY FROM THE CORPORATE ORDERS . UPDATE THE COSTING OF PRODUCT AND INFORM THE CONCERNED IMMEDIATELY .

2.

HUMAN RESOURCE MANAGER MANAGE ALL MAN POWER RELATED ACTIVITIES . LIAISE WITH LOCAL AUTHORITIES AND POLITICAL PARTIES. ENSURE THAT PROPER RECORDS ARE MAINTAINED REGARDING EMPLOYEE WELFARE . MAINTAIN SALARY RECORDS. I N-CHARGE OF COMPANY SECURITY. ORGANIZE BOARD MEETINGS . MANAGE CANTEEN ACTIVITIES AND LABOR ACCOMMODATION.

3. FINANCE MANAGER
S UPERVISE ALL ACCOUNTS FUNCTIONS . ENSURE THAT PROPER ACCOUNTING PRACTICES ARE FOLLOWED. ENSURE THAT ALL TAXES ARE PAID ON TIME AND AS PER LAW . PROPER SALES TAX AND EXCISE DUTY RECORDS SHALL BE MAINTAINED . F OLLOW UP ON PAYMENTS FROM CLIENTS . LIAISE WITH AUDITORS AND BANK.
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COLLECTION AND ISSUE OF C FORMS. ENSURE THAT COST ESCALATION CLAUSES OF ALL CONTRACTS ARE PROPERLY FOLLOWED UP . PREPARE MANAGEMENT REPORT ON CASH FLOW . ENSURE THAT BANK PAYMENTS ARE DONE ON TIME AND WITHOUT INCURRING PENALTIES . MONTHLY OUTSTANDING COLLECTION STATEMENT TO BE PREPARED AND INFORM /CONTACT THE CLIENT FOR PENDING PAYMENT . PREPARE MONTHLY INCOME AND EXPENDITURE STATEMENT WITH SEPARATE HEAD WISE .

4. SALES MANAGER
PREPARATION OF TENDERS FOR SALES. ENSURE THAT ALL TENDERS FOR PP BAGS FOLLOWED UP AND RESPONDED. MARKET THE PRODUCT AND OBTAIN SALES ORDERS. PREPARE SALES TARGETS AND ENSURE THAT SALES TARGETS ARE ACHIEVED. ENSURE THAT PRODUCTION WORK ORDERS ARE ISSUED AND DELIVERY DATES ARE MET . ENSURE THAT PRODUCT QUALITY IS MAINTAINED BY PRODUCTION AS PER CLIENTS ORDERS . F OLLOW UP WITH CLIENTS FOR PAYMENTS AND SALES PROMOTION ENSURE THAT GOOD WORKING RELATIONS ARE MAINTAINED WITH CLIENTS . DAILY MONITOR THE STOCK AND ORDERS .

5. PURCHASE MANAGER
CARRY ALL PURCHASE ACTIVITIES OF THE COMPANY. ENSURE THAT ALL RAW MATERIALS ARE PURCHASED ON TIME AS PER THE REQUISITIONS RAISED BY PRODUCTION , MAINTENANCE AND OFFICE. ENSURE THAT ALL STATIONARY ITEMS ARE PURCHASED AS REQUIRED . ENSURE THE PURCHASES ARE DONE ON A COMPETITIVE BID BASIS AND MOST ECONOMICALLY AT THE OPTIMUM PRICE . I NVENTORY CONTROL ENSURE THAT ALL REQUISITIONS AND PURCHASES ARE THROUGH ERP AND PROPER APPROVALS ARE OBTAINED . ENSURE THAT PAYMENTS ARE DONE AS PER THE TERMS OF THE PURCHASE ORDER AND CHECKING OF GRN. STOCK CONTROL TO BE CHECKED WITH PRODUCTION MANAGER AND INVENTORY TO BE MAINTAINED .
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6. PRODUCTION MANAGER
T O ENSURE OPTIMUM MACHINE UTILIZATION SO AS TO ATTAIN PRODUCTION TARGET . MAN POWER ALLOTMENT AS PER THE REQUIREMENT. ENSURE STATISTICAL QUALITY WORK. WORK EXECUTION AS PER THE REQUIREMENTS OF THE CLIENTS . CONTRACT EMPLOYEE S WAGES REPORT . DAILY FABRIC AND BOBBIN STOCK CHECKING . WORK ORDER ANALYZE BEFORE THE EXECUTION . ENSURE THE QUALITY ASSURANCE.

7. MANAGER MAINTENANCE
DAILY MONITOR POWER FACTOR, ENERGY UNIT , DG AND DIESEL CONSUMPTION CHECKING. T O ENSURE ALL THE MACHINES ARE ENGAGED AS DAILY MAINTENANCE , MONTHLY MAINTENANCE AND PREVENTIVE MAINTENANCE . T O CHECK ALL THE RUNNING MACHINERIES , TROUBLE SHOOTING AND RECTIFICATION . ERECTION AND COMMISSIONING (LOOMS ) AND OTHER MACHINERIES AS AND WHEN REQUIRED . DAILY UPS OVERLOAD CHECKING . MACHINE WISE LOAD CHECKING. T O ENSURE ALL THE MACHINERIES ARE ON WORKING CONDITION . T O ATTEND THE ENTIRE BREAK DOWNS AT THE EARLIEST WITHOUT AFFECTING THE PRODUCTION . T O ENSURE PLACEMENT OF INTENT FOR SPARE PARTS IN ADVANCE . MAINTENANCE REPORT TO BE PREPARED AND SUBMIT THE SAME DAILY TO THE MANAGEMENT .

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7.DEPARTMENT PROFILE

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FUNCTIONAL DEPARTMENTS Departmentalization is the method of arranging activities to facilitate the accomplishment of organizational objectives. The organizational process of determining how activities are to be grouped is called departments. These departments show the horizontal differentiation in an organization. The main departments are 1. Administration cum personnel department 2. Finance and accounts departments i. ii. Stores department Purchase department

3. Production department i. ii. iii. iv. v. vi. Production (main plant) Production (furnishing) Production development Production planning and control Lab and quality department Engineering department

4. Marketing department

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A. ADMINISTRATIVE CUM PESONNEL DEPARTMENT Human Resource Management HRM is the process of acquiring, training, appraising, compensating employees and attending to their labor relations, health and safety and fairness concern. In other words HRM is the people concern dimension in management. Since every organization is made up of people, acquiring their services, developing their skills, motivating them to the higher level of performance and ensuring that they continue to maintain commitment to the organization are essential to achieve organizational objectives. This is true regardless of the type of the organization, government, business, education, health, recreation and social action. The main functions are: Conducting job analysis Planning about needs and recruiting job candidates Selecting job candidates Conducting orientation and training program for new employees Managing wage and salaries Providing incentives and benefits Appraising the performance Communication with employee (interviewing, counseling, discipline) Training and developing managers Building employee commitment

Human resource is the greatest of all resources RCM division have the total strength of employee and staff of Rubco RCM factory is 218, out of which permanent are alone will come up to 147. It is a high to manage this large resources. For that efficient functioning of administrative cum personnel department needs special mention. The department comes under administrative cum personnel officer

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STRUCTURE OF HR DEPARTMENT

.
A.P.O

STENOGRAPHER

Jr. Clerk

TIME OFFICER

SECURITY WING

RECEPTION

RESPONSIBILITIES OF HUMAN RESOURCE MANAGER a. The human resource manager is responsible for the manpower planning recruitment, selection, training compensation, package, performance appraisal maintaining, discipline harmonious relation training, optimum use of HR achieving the targeted production etc. b. He is responsible for providing advices and guidance or assistance to the officers and staff working in the unit of control of General Manager in the matter connected with performance appraisal discipline harmonious relation training optimum use of human resources achieving the targeted production. c. HR manager is responsible for the creation of posts pay scale and other required sanctions from managing director chairman for filling up manpower requirements from time to time. d. HR manger shall be responsible for complying with various labor legislation. e. Hr manager is responsible for formulating HR policies and interpretation of different labor laws. f. The HR manager is responsible for preparation of wage and salary bill and passing to finance department for disbursement.

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.A(i). The Functions of Administrative cum Personnel Department The functions of administrative cum personnel department can be divided into two heads. Administrative function Personnel function

ADMINSTRATIVE FUNCTION Liaoning with government and local bodies. Correspondence with various government and non-government organization. All the internal and external mail, letter and memo, registered item handled by this department. Security A well equipped security forced is provided for safeguarding everything inside the factory complex. Monitoring the daily inwards and outwards dispatch.

PERSONNEL FUNCTION MANPOWER PLANNING The main object of manpower planning in Rubco RCM division To ensure optimum use of human resource employed. To determine further recruitment level To forecast further skill requirements that will serve as a basis for training and development programmers.

MANPOWER PLANNING PROCESS Following are the steps involved in manpower planning at RUBCO RCM division o Analysis of current system o Forecasting the time horizon of the plan o Reconciliation of action plan

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JOB ANALYSIS Job analysis is the procedure through which a HR manager has to determine the duties of the positions and characteristics of the people to hire for them. RECRUITMENT Recruitment is the process of searching right persons and stimulating them to apply for job in the organization. Rubco RCM division follows a centralized system of recruitment at head office level. Only recruitment of casual workers is directly done by RCMs division in itself SELECTION Selection is the process of differentiating between applicants in order to identify and those with a greater likely hood of success in a job selection is concerned with picking the right candidates from a poll of applicants. Selection is a negative in its applicants as its seeks to eliminate as many unqualified applicants as possible in order to identify the right candidate. In RUBCO RCM division selection of employees are done at two levels at the workers level are at managerial level. The workman are divided into 3 levels based on their skills. They are: Skilled workers Semi skilled workers Un skilled works JOB DESCRIPTION Job description is preparing for a number of different purposes in an organization. The area follows: To define the responsibilities of the job To review the organization structure and distribution of duties with the organization for a the job evaluation. To provide information about a post to be filled recruitment or selection purpose. INDUCTION The main function of induction process at RUBCO RCM is to make the worker understand the relevance of his or he in the overall organization in the set up, apart from the general orientation programmed concerning all aspect of the company

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operation given by personal department specific induction programmed are also conducted depending upon necessity

EMPLOYEE REMUNARATION AND COMPANSATION At RUBCO RCM employees are remunerated well considering its year of inception was just 3 years back. The average wage of permanent workers is more than 150per day allowances. The wage is given on a monthly basis. The employee compensation for accidents happening in the factory is also handled by personnel department.

TRAINING AND DEVELOPMENT Training is a learning activity, which is directed towards the acquisition of specific knowledge and skills for the purpose of an occupation or task. Development can be considered as any learning activity, which is concerned more with career growth than immediate performance. The factory rigorously follows its training and employee developing activities focusing on up its training and employee development activities focusing on up gradation of technical and behavioral skill. The training officers of concerned programs include both internal as well as external training personnel. External agencies include personnel from worker educational centers as well as from professional training agencies. Internal training includes both in house training and on the job training. The development programmers for top manage are done by head office which is mostky external.

EVALUATION OF TRAINING PROGRAM Evaluation is done to determine whether or not the objectives and content of the training courses are consistent with the aim and current needs of the company and whether these objectives being reached in the most effective and economical manner. Evaluation of training program is conducted through internal assessment, evaluation is based on measuring the performance of employees before and after training periods.

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PERFORMANCE APPRAISAL Performance appraisal is a systematic and objective way of judging the relative worth or ability of an employee in performance his job. The performance appraisal in RCM division of RUBCO is normally conducted for: a) Identifying employees for further increment in salary or position. b) Determining training needs for further improvement s in performance. c) Motivating employees by indicating their performance level. d) WELFARE EMPLOYEES All employees in the organization are covered under the employees state insurance scheme. Festival advances are given to the employees on the occasion of notified festivals. Annual bonus/incentives are paid out to the employees as per the company rule. Drinking water Latrines and urinals. Canteen Transportation HEALTH AND SAFETY Safety- company is very much aware of the safety needs of the worker. RUBCO RCM division has a very good safety policy in which it was envisaged to make it an accident free organization. The company has identified the probable area of accidents and the worker working over there are given extra training and proper caution boards displayed at accident prone areas. First aid facilities are provided in the factory for all employees. Health- Health is wealth for employees as well as for managers. RUBCO RCM division has done enough measures to ensure mental as well as physical health of employees. Precautions are taken to avoid dust in factory complex.

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INDUSTRIAL RELATION Administrative cum personnel department looks after the key area of union and management relationship. The department has set in place on effective system to speedy sort out any difference and disputes. The department gives updated reports on the labor situation to the head office time to time.

EMPLOYEE RETENTION Most of the employees are young who are gaining experience at RUBCO. So after going enough experience they may opt for other companies. So in order to retain them and build loyalty towards the organization administrative cum personnel department has drawn clear cut plan and are working towards the plan by implementing it on a step by step basis.

ABSENTEEISM Absenteeism rate in RUBCO is normal only. More than 94% attendance are maintained. Management has initiated many steps as the absenteeism in coming down.

GRIEVANCE REDRESSAL A very grievance redressal system is there in the factory. An employee ha s full freedom to take up any grievance with his immediate supervisor, who tries to solve it to the extend possible. If the employee still feel aggrieved, then he can take up the a matter with the next higher authority up to the level of administrative cum personnel officer.

TRADE UNION The trade union in RUBCO RCM division is Rubco union. In the factory there exists a good and healthy relationship between management and trade union. The union is lead by C.I.T.U.

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FINANCE AND ACCOUNTS DEPARTMENT

B. FINANCE AND ACCOUNTS DEPARTMENT I. Financial management

Financial management, also to as corporate finance or managerial finance, emerged as a distinct field of study at the turn of 20th century. Finance theory in general, rests on the premise that the goal of financial management should be to maximize the wealth of shareholders. Finance is the lifeblood of the business of the entire organization. Accounts department at RUBCO RCM division is responsible for all financial decision in the division, which involve decision regarding financing, investment and working capital. All financial activities in the division routed through the accounts department. The accounts department RUBCO RCM gets fund from financial department of head quarters. The stores and purchase department also comes under this department. II. Finance Management Department

Finance refers to the application of skills in the manipulation is the use and control of money. The finance in the modern business world is the life blood of the business economy. We cannot imagine a business without finance because it is a central point at all business activities. Responsibilities of financial manager III. Financial planning Raising of necessary funds Disposition of profits Tax planning Internal audit Profit planning Financial Functions Passing and settlement of all miscellaneous advances. Perform all works connected with insurance coverage of fixed asset. Keeping personnel file of employees relating to salary computation and annual increment.
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Prepare profitability trend reports and wage analysis. Quarterly and yearly financial report preparation. Making bank statement. Preparation assisting the coordination at all works connected with finalization of accounts. Assisting statutory/ vigilance/ auditors from head quarters. Make internal and external purchase.

STRUCTURE OF FINANCE DEPARTMENT

FINANCE MANAGER

ACCOUNTS

STORE KEEPER

PUECHASE OFFICER

JR. CLERK

JR. CLERK

JR. CLERK

IV.

FUNCTIONS OF FINANCE DEPARTMENT Exercise control over cash Passing and settlement of all miscellaneous advances Performing all work connected with insurance of fixed assets Settlement of telephone and electricity bill Keeping personnel files of employees relating to salary computation and annual increment. Preparation and maintain of accounts and book up-to-date, that are required under different acts Preparation of financial statements Over view of internal and external purchase Preparation of profitability trend report and wage analysis
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Preparation of monthly profit and loss account and cash flow statement and present them monthly to top level managers meeting of whole RUBCO Group at RUBCO headquarters.

BANKERS OF RUBCO RUBCO RCM bankers are: District Co-operative Bank, Kottayam State Bank of Travancore PROFITS 2003-2004 2004-2005 2005-2006 2006-2007 2007-2008 2008-2009 - 100 lakh - 145 lakh - 100 lakh - 10 - 50 lakh lakh

- 58 lakh

Financial highlights of the organization

Current assts Drs Finished goods Cash Raw material WIP Total

2004-05 25 20 25 80 65 215

2005-06 60 60 10 40 60 260

2006-07 40 40 8 40 60 188

2006-07 50 30 5 50 40 175

2007-08 40 100 2 70 35 247

2008-09 50 110 6 70 40 276

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MANAGEMENT INFORMATION SYSTEM It is computer based system that provides flexible and speedy access to accurate data. A set of computer based system and procedure implemented to help managers in their crucial job at decision making. The actual process involved collecting data, organizing data discrimination of data and storage of data. These data will be used for managerial analysis and control. It focuses on accuracy of data and takes the user into confidence.

CAPITAL BUDGETING Capital budgeting is done at the beginning of the year itself. The requirement of capital will be specified clearly for the approval during the budgeted year. If any other requirement of capital is faced then proper justification has to be made. If the requirement is seen as on important one of them approve of the capital is sanctioned.

CASH MANAGEMENT Cash management system is one of the key areas in any business. Apart from the fact it is the most liquid current asset can be reduced. Cash is the common denominator to which all current assets can be reduced because that other major liquid asst receivable and inventory get eventually converted in to cash.

FIXED ASSETS Fixed assets are the major working of any company. Depreciation of fixed assets is charged on diminishing balance method. Credit control system A trade credit arises when a company sells its product or services on credit and does not receive cash immediately. A company grants credit to protect it sales from the competitors and to attract the potential customers to buy its product at favorable terms. Credit period allowed is
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60 days to 90 days. It can be extended to 180 days. The collection of credit will be handled over to the factory manager. The company will give the creditors on further extension on one month legal action will be taken against the person or company. If the company has submitted the cheque or person for the credit due and the cheque has bounces or dehorned the company can be take legal action against the person or the company. Trade creditors receivable which the company is expected to collect in the near future.

Planning Funds Planning funds is a careful estimate made by the manager about the total finds required. This is the estimation done by the observation over the physical activities of the company.

Allocation of funds Providing at funds to proper place at proper time is also an important task to be done by financial manager studies the cash requirements of each department and then funds are distributed.

Recording of transaction Each and every transaction that takes place in the company has to be recorded properly for the purpose of having better control over the funds. All the transaction are recorded in journal and then posted to the ledgers.

Cost control The costs are controlled in row material and reduction to expenses as there is limitation of utilization of funds. The company will always have a comparison of budgets and actual. Stock in store Stores department is an auxiliary department of financial department. The major purpose of this department is to be having row material from suppliers to different
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departments and there after verify the bill/invoice to ensure of incoming material and confirm the quality and value with purchase order.

STORES DEPARTMENT Stores department is an auxiliary department. It functions under accounts officer.

STRUCTURE OF STORES DEPARTMENT

STORES DEPARTMENT

STORES KEEPER

STORES CLERK

SEMISKILLED LABOUR

Functions of Stores department Receipt of incoming material. Efficient and orderly record keeping of all material storage. Issue of material against written authority. Stores of material in safe and conventional location. Timely intimation to proper authorities regarding out of stock conditions. Prevention of damages, losses and unauthorized uses etc. Rejected material requirements. Sales return management. Maintenance of accounts.
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Material documents of this department are produced in coordination with the production department. Monthly check and other periodical checks are done to certify the actual inventory value in quantities. There is a separate section for rejected products. Rejected products are stored in stores department itself. Such products are inspected before and after by the quality control department. Such products are sold out as separate sale items. Classification of materials Raw materials Latex Coir Chemicals Cloths Fabrics

General Engineering Materials Electrical items Mechanical items Capital item tool etc

Statutory Items and Furniture Furniture Paper Bill books

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PURCHASE DEPARTMENT This is the department, which purchases the required raw material for the production of mattress. So this department can be said as the backbone of Rubco. The store keeper verifies the material and if it goes beyond minimum required level, he will inform it to the accounts officer and he will pass on the information to the general manager. The general manager then does further action to buy the required raw materials. The main function of purchasing department is to ensure uninterrupted flow of production.

STRUCTURE OF PURCHASE DEPARTMENT

PURCHASE OFFICER

JR. CLERK

JR. CLERK

Purchase Functions: Source identification Source identification involves the identification of suppliers from which purchase are to be made. Source selection Source selection involves selecting the best supplier from different suppliers, which is based on desired quality, price, service etc. Vendor rating

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This responsibility lies with RUBCO head office. Vendor rating is done on the basis of the product, price of the materials and the reports from the production department in case of latex or chemicals.

Receipt of materials Materials are collected by the receipt store and the details will be given to the section for inspection. Number of item passed, rejected and the reason for rejection if any will be specified. Receipts store will then prepare materials receipt report and then send it to the concerned section i.e; purchase and accounts. The original will be retained by the receipt store. CLASSIFICATION OF MATERIAL The materials used in RUBCO RCM division are broadly classified as: RAW MATERIALS Latex, coir rubber chemicals, cloths and qualified fabrics, PU forms and threads. GENERAL ENGINEERING ITEMS Electrical items, Mechanical items, spare parts and capital item tools. STATIONARY ITEM AND FURNITURE Office requirements, paper and bill books, cleaning products PURCHASE PROCEDURE Requisition The power of approving material requisition is with Rubco head quarters. Purchase proposals After the purchase requisition has been approved by the head office, the order is placed. Purchase order After fixing the right supplier, purchase order is prepared and placed with proposed party. The order rate, quantity, delivery schedule and terms of payment will be mentioned.
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Vendor rating The responsibility lies wit the RUBCO head office. Vendor rating is done on the basis of product, price of the material and reports from the production department in the case of Latex or chemicals. Receipt of material Materials are collected by the receipt store and the details will be given to the section for inspection. Number of items passed and reason for rejection if any will be specified. Receipt store will then prepare materials receipt report to be send to the concerned srction. Original copy will be retained by the receipt store.

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PRODUCTION DEPARTMENT

C. PRODUCTION DEPARTMENT RUBCO RCM division ha progressively recorded high productivity and profitability. Production department is equipped with managers and supervisors. The machine used in the production department are of high cost and mainly imported from foreign countries like U.S.A and U.K. it is the largest functional department in RUBCO RCM division. The whole production department comes under factory manager.

Structure of production department

PRODUCTION MANANGER

Production plant

Production furnishing

Product development

Lab and quality department

Production Planning Control

Engineering Department

Raw materials used The main raw materials used for the production of bare mattress are Latex & chemicals Curled coir
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The chemical used with latex are Sulphur Zink oxide Zmbt ZDC Dispersal F China clay B-rods TDQ

Final product from this department The final product from this department is bare rectangle shaped rubberized coir block. Rubberized coir block is resilient and because of resilient of the curled fiber. The purpose of rubber latex is to bond the resilient coir fibers together and impart shape of the product.

Number of workers of this department The skilled workers at this department comes to 33. There are 46 semi skilled and 35 unskilled workers. Casual workers will come to 42. Temporary workers are 12 in number. The production process of RUBCO RCM division consist of following stages:

C.(i). production (main plant) Processing of coir Coir is one of the major raw material for the rubberized coir mattress, which is purchased as bundles (140 bundles= 1 load). This purchased bundle may contain moisture in them. To eliminate this moisture content it is kept in the coir drier machine & and by using steam from boiler it is heated for three days, where specific temperature is maintained. This moisture content in coir is brought down allowable limit of 5% or below.
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PROCESSING OF LATEX ( COMPOUNDING SECTION) The raw latex processing consist of two steps: Ceramic Ball milling

Ceramic ball milling a process in which chemical required for the compounding is grinded with ceramic balls to make it dispersion. There is three ceramic ball milling machine of Rubco RCM factory. Compounding

In this stage the above model chemical dispersion is mixed with latex stirrer machines. Sufficient quantity of stabilizers also added into the above mixture at this stage. SHEETFORMING SATGE The production of rubberized fiber sheets are done by the computer controlled sheet forming machine. The 7 crores investment machine generally called DOA is imported from Austria. This section has under it. o o o o Untwisted unit Distributor and first spraying section Drier and second spraying section Cutting table

Here completely dried and tempered rope are fed into the untwisted unit were the untwisted unit were the ropes are opened up to make it coir fiber and curled coir fiber are thrown by a cyclone into a feeding conveyor. Fibers are opened further with air from compressors and supplied to a sheet former. The second sheet former takes the fiber over and pragmatically produces sheet with partly vertical fiber orientation adjustable width and surface weight. The sheet is sprayed with compounded latex from the top in the automatic spraying section called spraying gun. The sheet is then dried in its passage through the tunnel drier. After drying in its first passage, the sheet is automatically turned over and sprayed with compounded latex on the other side. After the final drying the sheets are cut to the required size in automatic cutting machine. PRESSING STAGE The sheet from DOA machine are piled up and progressed in a continuous roller press to get the desire weight. Then these sheets and the hand sprayed in a
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spraying booth compounded latex these progressed parts are in a hydraulic hot press to active the required dimensional stability. VULCANIZING STAGE The pressed parts are then loaded in a trolley and further processed in a Vulcanize to give the desire resilience to the product. On vulcanization properties such as tensile strength, heat resistance and resistance to ageing of rubberized coir are improved TRIMMING After vulcanization the bare blocks are cut in machine called band saw to form rectangular bed like a block of desired length and width. FINAL INSPECTION After final inspection and checking this bare block are given the furnishing department to further processing.

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STRUCTURE OF PRODUCTION PLANT

Production Department

Coir Ropes

Cenex and Dislodged Latex

Coir Drier

Compounding(latex mixed with chemicals

Untwisting machine

Sheeting plant

Conveyer Drier

Pre-press

Pilling and weighing

Cutting machine

Surface spraying

Hot press

vulcanize

Inspection

Trimming

Sending to furnishing department dispatch

Quality control

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C.(ii). Production (furnishing) Furnishing department comes under factory manager. At furnishing department the bare mattress from production-plant is brought to furnishing department and it is fabricated with Rexene and cloths and packaged and made ready to dispatch. The major machinery in furnishing department is all are imported one. Furnishing department works as per the daily work order given by planning department. According to work order only labor is deployed every day.

Functions of furnishing department Furnishing at different models of mattress, cushions and pillows as per the set standards. Final inspection of mattress, cushions, pillows and other bedding accessories. Labeling, packing and dispatching mattress and cushion. Preparation of furnishing material. Dispatch dispatch of mattress, cushion and pillows as per planning department instruction. Reworking of rejected mattress after referring the condition.

Furnishing process steps Corner cutting Adding Feeding Stitching Quality checking and inspection Labeling

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MAJOR MACHINES USED IN FURNISHING DEPARTMENT

OUILTING MACHINE This machine produces over covering PU from ponds for Heaven, Relief, HiTech, Heaven plus, Hi-Tech pillow top. This machine is fully computerized and imported from UK. It is capable of producing thousands of variety of design.

BOARDER STICHING MACHINE PU form together with the upholstery is feed to this machine where the machine stitches the boarders in which are rolled and passed to the stitching section.

TAPE EDGE MACHINE Quilted tapster with the boarders kept on rubberized coir pad is feed in to the machine, which stitches on the sides, and mattress are now ready for packing.

OTHER MACHINES Corner Cutting Machine Sewing machine Fabric cutting machine Sealing machine Handle stitching machine

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STRUCTURE OF FURNISHING DEPARTMENT

SHIFT IN CHARGE

PRODUCTION SUPERVISOR

PRODUCTION

PRODUCTION

HIGHLY SKILLED WORKERS

SKILLED WORKERS

UNSKILLED WORKERS

SEMISKILLED WORKERS

C.(iii). Product development The product development carried out is concerned with the identification of the most economically feasible method for applying the principle through research. It involves design, redesign and fabrication of new or modified product and testing it to find its usefulness. Product development essentially involves developing product to suit their customers needs and conditions. The purpose is to ensure that it meets the requirement and quality slandered. This is applicable to all product modification of the existing company. C(iv). Production planning and control It is done on the basis of specification or orders placed by RUBCO sales international and based on domestic order placed by authorized distributors. The required quality and quantity is specified through production planning and the production is done according to this planning. Operation planning involves the organization of an overall manufacturing operating system to produce a product. Objective of production planning is to provide a physical system together with a set of operating guidelines for efficient conversation of raw materials, human skills and other inputs into finished goods.

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C(v). lab and Quality Control Development RUBCOs product have domestic and international acceptance due to stringent quality maintenance. A well equipped lab functions at RUBCO RCM division to assure the quality maintenance produced here. This department comes directly under factory manager. The adoption of quality management system should be a strategic decision of an organization. The design and implementation of an organizations quality management system is influenced by varying needs, particularly the objectives the products provide to sustain an dwin products acceptability in the market.

The functions of Lab and Quality Assurance department They are classified into two: Quality assurance function Laboratory function

Quality Assurance Function Strive to achieve international quality standards to the products through various quality inspection models. Ensure quality of raw materials purchased. Ensure the quality online process of production. Supervise the production process at various stages to make sure that quality policy of Rubco is strictly maintained throughout the manufacturing process. Ensure the quality of finished products. Assure quality of packing and selling. Assure quality of transport. Carry out research and development activities with product development department.

Laboratory functions and Quality Assurance Department

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Testing of material this include testing and analysis work of raw materials like Latex and Coir, furnishing materials like cloth, PU foam cotton, blanket, threat etc and finished product. Effluent treatment plant.

The effluent treatment functions also come under lab Testing of sub-contract material Testing of packing and selling Customer relation management

Here lab works in tandem with marketing department Vendor analysis

Effluent Treatment Plant At the effluent treatment plant rubber and latex is separated from the effluents and this water is used for irrigation purpose in the garden at RUBCO RCM factory compound. Personnel in Lab Only shift-in-charge (lab & Q.A) quality supervisor lab and a clerk are the permanent staff. The rest of lab technicians, lab assistance etc. are all temporary employees. Shift-in-charge (lab &Q.A) is at freedom to appointment these technicians, and assistance according to the need.

QUALITY TEST FOR RAW MATERIALS

TEST FOR COIR Moisture content test: The purchase-curled coir may contain moisture from atmosphere. To detect this moisture content test is carried out. The permitted level of moisture in coir is 5% of below.
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TEST FOR LATEX To measure whether the quality of purchased latex meets with the specific standards following test are conducted: Dry rubber content test Total solids test Test for ammonia Volatile fatty acid content test Mechanical stability test

QUALITY CONTROL PROCEDURE To maintain the quality policy of RUBCO and assure the quality of bare mattress block as well as raw material, various quality control procedures and tests are adopted in the lab. They are: Indentation Hardness Test This test is conducted using indentation hardness apparatus. A 10cm x 10cm sample block is taken fro the bare mattress and this block is compressed to 40% of its original thickness by applying a load of 500gm per minute. Flexing Test This test is done to check the internal hardness of bare mattress. The bare mattress block is kept in flexing apparatus and subjected to 250000 times of flexing to check the hardness. Compression Test This test is also done to check the hardness of bare mattress. It si kept in for 22 hours. 3 hours after the release of the load reading is noted from the compression test apparatus under the following conditions. o At atmosphere condition o In hot air oven(70%) Aging Test This test is done to test the durability performance of the mattress. PH Test
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PH test is conducted to analyze the durability performance of the mattress. Sulphate Test To estimate the sulphate content the extract of rubberized coir sheet.

STRUCTURE OF THE QUALITY ASSURENCE DEPARTMNET

Shift in charge

Quality supervisor

Production supervisor

workers

workers

ENGINEERING DEPARTMENT Functions of engineering department: Instrumentation Electrical maintenance Maintenance and utility

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D. MARKETING DEPARTMENTS

Marketing is the foremost function that gives the management hopes for their integrated task through making profits. It is a social and managerial process by which individuals and groups obtain what they need want through creating and exchanging products and value with others. Marketing of RUBCO mattress is done by Rubco sales International ltd (RSIL) at H.O. Kannur. Rubco sales International ltd (RSIL) is a public limited company promoted by Rubco to spear head the sales and marketing activities for Rubcos entire range of products in the domestic and international markets. Within a short span of its inception, RSIL could effectively develop a competent network domestically as well as globally and undertaken the su ccessful launch of Rubcos product. Its efficient and effective marketing strategies helped the organization to build up a very strong brand name.

D(i). Functions of Marketing Department The functions of marketing department are given below; Conducting seminar/ exhibition for the purpose of launching new product to the market and also make the people aware of their existing products. Conducting retailers meet for the purpose maintain cordial relationship between management and distributors dealers, retailers. Conducting consumer survey for the purpose of collecting information from customers for the product development and evaluation of existing position of product in market. Formation of effective marketing competition increase market share launching of new product entering into a new market with different product formulation of sales strategies in order to achieve the target turnover. Formulation of sales strategies in order to achieve the target turnover. Orientation given to leader and distributors to make awareness about the quality of products. Product development is based on the feedback from customers and retailers.

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STRUCTURE OF MARKETING DEPARTMENT

Highly skilled workers

Highly skilled workers

Highly skilled workers

D.(ii). MARKETING STRATEGIES Rubco mattress attained wide market coverage in Kerala within a short period of it being established. Now Kerala market is dominated by Rubco mattress industry. The effective marketing strategy that they have adopted is the reason behind this explosive growth of Rubco. Expansion of existing market into other geographical areas, i.e, now Rubco is the market leader in Kerala mattress industry and they are about to expand their market all over South India in order to attain their target turnover. Planning for introducing new products into market and entering untapped segment is their innovative strategy. Marketing Mix Marketing mix is the set of marketing tools that RUBCO RCM division uses to pursue its marketing objective the target. It is classified as the 4 the Ps of marketing i.e, product, price, place and promotion. FUNCTIONS OF RSIL Gather market information Monitoring of supply chain system Nurturing and sustaining excellent customer relation Helps to achieve product innovation and modification by way of conducting marketing R&D and customer survey. Through better and effective distributors network expansion as well maintains it ensures improved product availability at reduced cost.
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To help the production units to better and improve the quality of output.

RSIL is a separate Department to spear head the marketing activities of Rubberized Coir Mattress product at its factory in Pambady. The sales personnel of Rubco Marketing Department.(RCM) include two Jr. Sales Officer and 6 sales executives. In the highly competitive sector of rubberized coir mattress where there are almost 120 odd as well as half a dozen organized sector players are existing, the marketing Department (RCM) had done an excellent job in making the Rubco almost a market leader in the state within a short span of 3 years. RUBCO mattress has also entered Tamil Nadu with setting up of distribution channel in Chennai and Erode. With the aggressive market expansion plans and the domestic sales turnover of RUBCO Rubberized Coir Mattress are all poised to doubles. As Rubco has entered in to expert deal with some with the European Unions nations and the shipment already flagged off, the current years sales figures may even go up further.

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ORGANIZATIONAL STRUCTURE OF RSIL

Chair man

M.D

Company secretary (administrative officer of RSIL)

GM (RSIL)

Cost accountant (accounts officer of RSIL)

Mktig sales mgr (RCM)

Mktig sales mgr (F&P)

Mktig sales mgr (F&C)

Advt sales promotion dept

Area managers

Jr. sales officer

Sales Executives

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NEW MARKETING INITIATIVES The marketing initiatives other than maker expansion include the function of new innovative products like. Budget matters Foldable matters Mattress protector (comforter) Hi-tech pillow top mattress with 7 inches thickness Latex pillows 1. Pricing The price denotes the value of a product or service expressed in money. Rubcos pricing strategy on its mattress is largely competitor based(going rate price). Rubco charges the price as per Duroflex price. The pricing policies of RUBCO RCM also include The price quoted is inclusive of transportation charges. The margin of distributor is 11% on transfer price and margin for retailer in 20% on MRP in Tamil Nadu. The retailer are at freedom to sell below MRP 2. Promotion To win the battle of competition every manufacturer has to choose a number of promotion tools which can be classified as advertising, publicity and sales promotion. 3. Advertising The advertising of Rubco rubberized mattress is done through Maabozell communication Ltd Ernakulum, an advertisement agency. 4. Packing Packing of the product plays vital role in success or failure of a product. Packing strongly affect the purchase decision. Packing is the covering given to a product to a product for protecting it. On the plastic covering of Rubco mattress contain information regarding its unique 3-D technology.

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5. Exports Exports is not a function of Marketing Department (RCM) at Kannur. This function is done by RCM factory Pambady itself. This year Rubco has started exporting of its mattress to some European Union Countries. Rubco RCM divisions also receives enquiries from Sri. Lanka, U.S.A.and other middle east centers. As Rubco RCM decision strictly follows its quality and product satisfaction of the customer the exports opportunities are plenty.

STRUCTURE OF SALES NETWORK

RUBCO (manufacturer)

DISTRIBUTOR

RETAILER

CUSTOMERS

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8.SWOT ANALYSIS

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SWOT ANALYSIS RUBCO MATTRESS

The evaluation of companys strength, weakness, opportunities and threats is called SWOT 1) Strength Rubco mattress division wide range of different mattress in different range. Relationship between employee and top level management and among dealers and distributors is in harmony. Through effective marketing Rubco products could have acquired wide market acceptance and customer within a short period of being time established. Leadership style that company following is through dedication and coordination. That encourages employees of the organization to work towards their organizational goals. Products with high quality, wide range of products are manufactured which is capable to challenge variable environment condition, goodwill, and customer service, technical advice, marketing intelligence, wide network, and interaction with customers. Effective managerial system is on of their strength. Good financial management system that exist in the organization.

2) Weakness

Higher rice compared to their competitors. Company should conduct more training and development programs to the employees and the workers. Lack of promotional activities abroad Transportation facilities are available but not to the extend as desired.

3) Opportunities Rubco rubberised coir mattress shold plan to enter into foreign markets Rubco rcm division is notyet fully tapped their 100% utilization of existing machine
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capacity so opportunities lies there. The factory can undertake new projects regarding projects diversifications. Opportunity of identifying the regions where introducing more and more quality products. So that structure can withstands the different regional environment.

4) Threats Fluctuating price of raw materials Lack of raw material Increasing competition Taste of customers varies Product differentiation For the past several years company is facing severe competition RUBCO ensure high quality products due to which the price of the product is comparatively high compared to its competitors. So there is possibility that customer can switch to competitors.

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9.FINDINGS AND SUGGESTIONS

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FINDINGS

1. Presence of good industrial relations with local unions and there is greater co-operation management and employees. 2. Wages system is fair in RUBCO. 3. Workers health and safety are given prime importance. 4. A good co-ordination exists between different departments. 5. Labor turnover is very low. 6. Trade union play a vital role as bargaining agents.

SUGGESTIONS

1. 2. 3. 4. 5.

Increase promotional activities could enhance building brand image. More automation should be done so as to reduce the number of workers. Increased production for increased profits. The company has to engage in production of variety products. RUBCO should adopt a strategy that would result in lowering the production and distribution cost than of its competitors to win the market. 6. The company has to engage in production of variety products. It has to add new product line thus widening its product mix ie, cousions and furniture upholstery. That way it can acquire a strong reputation in the single field. 7. The company has to make strengthen their supply chain in other states, in order to tap the target market.

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CONCLUSION

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CONCLUSION

The rubberized coir mattress industry has a great market in India. There are number of mattress manufactures in the market who are struggling hard to make an impact in the mind of customers. Branded and unbranded mattresses are there in the market, unbranded ones are concentrated on the local market. They are mainly giving attention to provide customized product, who cannot afford to branded mattress at comparatively high price. At present, mattress market has become one of the most competitive markets in India, which spend huge amounts of money for advertisement and other promotional activity. RUBCO is a major player in this industry. The internship study is helped to make a valuable conclusion through the analysis of different functional departments of the RUBCO. Presently it is ranked at the top with consideration to quality. The core competencies of the organization can listed as below: Professional management Effective Leadership Cordial relationship between employees and top level management. The company has well established network in industry with sound manufacturing and marketing experience.

The company had adequate resources available for expansion.

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BIBLIOGRAPHY

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BIBLIOGRAPHY

www.rubcogroup.com www.rubcomattress.com www.rubcoindustry.com www.rubcorcm.com

Journal : Rubber AIS vol .17, aug2010

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