CHAPTER III

FUNCTIONAL DEPARMETN

PRODUCTION DEPARTMENT

PRODUCTION DEPARTMENT

PLANT PROCESS

Supplies raw materials

( through suppliers

Stores raw materials

Fabrication Machine shop

Paint department

Quality inspection Quality inspection

Sub assembly

Final assembly

Quality inspection

Stores department
Clutch Plates

Clutch is a part which helps in transmitting power from engine to the gearbox for moving the
vehicle. The clutch is designed for the each model exclusive by NERO AIRFILTERS SPARE
PARTS as per the requirement of the vehicle manufacturer. The quality is tested through latest
R&D machines specially designed to test clutch plates at variable speeds and harsh conditions so
that there should be no problem after the fitment in the vehicle and driving is safe and
comfortable. The quality is so high that the durability and efficiency is comparable to any other
manufacturer in the world. Intermediate friction plate are made of high carbon steel, and the core
plates are made from aluminum, steel, high temperature resistant plastics, or phenol resin based
fiber depending on the design of the clutch. The friction material in wet type clutch is made in
three types rubber based, cork based or paper based and for dry clutch, resin and fiber based
material is used. This friction material is lined on the core plates to generate the torque in the
engine. There are different friction materials for different applications to enhance the quality and
performance of the vehicle i.e. more mileage, more life, high pickup etc. The complete clutch is
made inside the plant so that there should be no defects at any stage; only the raw materials are
bought from outside and checked at the time of procurement. The process involved in making the
clutch is so atomized with integrated production line that there is no possibility of mistake. Fibo
Macro And Micro Spare Parts is producing clutch plates for vehicle starting from 50cc to 650 cc.
FIBO MACRO AND MICRO SPARE PARTS is always working on quality and cost so that it
can provide the best quality at best price in international market. fibo macro and micro spare
parts the specialist in friction material has spent almost 50 years in improving the clutch
technology.

What is the function of Clutch?

In simple words the function of clutch is to move and stop the vehicle without damaging the
engine. The clutch is fitted inside the engine, to stop the power from being transmitted to wheels
clutch plays a key role. Clutch also has a major importance in smooth engaging and disengaging
of gears which ultimately stops engine from getting ruined.

MECHANISM

Transmission in automobiles is a systematically arrangement of parts connecting the engine to

the wheels. The simplest transmissions are manual transmissions, and consist of a system of
interlocking gearwheels; these wheels are arranged so that by operating a lever the driver can
choose one of several ratios of speed between the input shaft and the output shaft. These ratios
are called gears. To allow smooth shifting from one gear to another, a clutch is provided to
disengage the engine from the transmission. A clutch is a mechanism for transmitting rotation,
which can be engaged and disengaged. Clutches are useful in devices that have two rotating
shafts. In these devices, one shaft is typically driven by a motor, and the other shaft drives
another device. The clutch connects the two shafts so that they can either be locked together and
spin at the same speed or be decoupled and spin at different speeds.

WORKING

On most 2-Wheelers, the clutch is operated by the clutch lever located on the left handle bar. No
pressure on the lever means that the Clutch plates are engaged (driving), while pulling the lever
back towards the rider will disengage the clutch plates, allowing the rider to shift gears. These
clutches are usually made up of a stack of alternating plain steel and friction plates. one type of
plate has lugs on its inner diameter that key it to the engine crankshaft, while the other type of
plate lugs on its outer diameter that key it to a basket that turns the transmission input shaft. The
plates are forced together by a set of coil springs when the clutch is engaged.

Racing Motorcycles often use slipper clutches to eliminate the effects of engine braking.

In a car the clutch is operated by the left-most pedal using Hydraulics or a cable connection from
the pedal to the clutch mechanism.
Manufacturing process of a 2 wheeler Clutch Plate

Clutch Friction Disc 2-wheeler

Two Wheeler clutch friction disc also called as friction lining is made up of a splined round
metal part plate covered with friction material (lining) .the Splines in center of the clutch disc
mash with spines on the input shaft of manual transmission. This makes the input shaft and disc
turn together. However the disc is free to slide back and forth in the shaft.

Clutch Friction Disc Cork and Paper Base

Cork base clutch is made up of Heat resistant non asbestos cork and fibers. Grooves are cut into
friction material to aid cooling and releasing Clutch disc. In 4 wheeler clutches the rivets are
used to hold the friction material to both sides of the metal body of the disc.

Paper base clutch friction disc is made up of heat-resistant cellulose based material molded
together. Cellulose is used to prolong life of the clutch and provide more torsional strength.
Paper Clutch friction disc has more life than cork base friction materials as it possess:

 More heat resistant property

 Low wear and tear characteristics
 High endurance

At fibo macro and micro spare parts we make clutch as required by our customers with meeting
international standards in any design and with any friction material technology. Some of the
examples are displayed below:
Break Shoes

Clutch Shoes

DEFINITION & THEIR MECHANISM

A Device for decreasing the Speed of a moving body or for stopping its motion.

Most Brakes act on Rotating mechanical elements & absorb Kinetic Energy either Mechanically,
Hydraulically or Electrically.

Mechanical Brakes are the most common, they dissipate Kinetic Energy in form of heat
generated by Mechanical friction between a rotating metallic drum or disc & a stationary friction
element brought into contact with it by mechanical, hydraulic or Pneumatic means, the friction
elements for drum brakes may be bands or Shoes i.e. Blocks with one surface concave.

It works on a mechanism where the drum Brake is actuated to contact with internally expending
shoes in it, by pressure exerted on Brake Pad/ Lever directed on semi circular brake shoe by a
system of flexible Cables/ rods.

ABOUT

Standard Drum Brakes were invented in 1902 by LOUIS RENAULT. His brakes worked by
using a CAM to force apart two hinged shoes. Drum Brakes are improved in many ways over the
years , But the basic Principle remains 20th century even with the advent of Disc Brakes in
1970s , Drum Brakes remain the standard for REAR WHEELS.

TYPES

There are several types of Brakes used today such as Mechanical Brakes ,Hydraulic Brakes
,Pneumatic Brakes, Electro-Mechanical Brakes etc. ,The Brake Used today Commonly are Drum
Brakes with Mechanical and Hydraulic Systems.

We can categorize Brake Shoes as per vehicle requirements as 2 Wheeled & 3 wheeled.
Depending upon their Friction Material properties Brake Shoes are Organic , Metallic or
Ceramic type & Depending upon their Shoes they can be classified as Aluminium casting &
fabricated shoe.

Most Generally we can categorize Brake Shoes comparing their friction material
composition as:

FIBO has all type of brakes shoes with High Performance meeting with International quality
standards.

At FIBO GROUP we have facilities & a team of R&D People to work out for good &
functionality friction material which is Eco-Friendly. Every New Development undergo full
Property , functional & Endurance check before Production at our labs to avoid any stage failure.

FIBO R&D Team is always dedicated to improve Quality of the products.

Presently FIBO is involved in manufacturing a wide range of Asbestos base, Asbestos Free both
in Rigid and Rubberized friction material Brake Shoes for 2Wheeled as well as 3Wheeled
Vehicles.

MANUFACTURING

At FIBO Group we only procure Raw materials for Manufacturing Friction material and Brake
Shoe Aluminum Part / Fabricated Part, Every operation after that is being carried out in House.
The process flow for the manufacturing is detailed below:

Manufacturing Process
TESTINGS & QUALITY
FIBO Group has a wide range of testing equipments and team of trained personals & technical to
fulfill Customer Requirements for good quality components. Our Specialized testing facilities
include :

 Universal Testing Machine

 Coeff. Of Friction Test Rig
 Profile Projector
 Salt Spray Chamber

With the help of these special purpose machines the simulation testing is carried out to ensure
reliability & Performance of the component produced. The Chase type Coeff. Of Friction Test
Rig can be used as per National & International Standards.

A Team of Qualified Inspectors is involved for Process inspection during manufacturing to

produce quality Products with the help of QC Tools & Techniques. In Our Labs routine checks
for finished components is Carried out to help & ensure the performance.

Brake Disk Pads

MECHANISM

The Disc Brake is a Device for slowing or stopping the rotation of a wheel. A Brake Disc
(Rotor), usually made of Cast Iron / Ceramic, is Connected to the wheel or Axle. To stop the
wheel Friction Material in form of Disc Brake pads (Mounted in a Device called Caliper) is
forced mechanically, hydraulically or electromagnetically against both sides of the disc. Friction
causes the disc & attached wheel to slow or stop.

ABOUT

Disc type Brakes began in 1890’s &Ist patented in 1902, though it took another half Century for
wide adaptation.

Modern style Disc Brake first appeared on low volume in 1949 & discontinued in 1950 due to
design problem .These Brakes offer better stopping performance than comparable Drum Brakes,
including resistance to Brake Fade caused by overheating of Brake component and are able to
recover quickly from immersion.

Unlike a Drum Brake, The Disc Brake has no Self-servo effect and braking force is always
proportional to the pressure placed on the braking pedal or lever. In the beginning Disc Brake
was most popular in Sports cars, since these vehicles are most demanding about Brake
performance. Now Disc brakes has become the more common form in most passenger vehicles,
although many use the Drum Brake on the rear wheels to keep costs & weight down as well as to
simplify the provision for a parking brake.

As the front brakes perform most of the braking effort, this can be a reasonable
compromise.

TECHNICAL

The Disc Brake System Consists of:

 A Brake Disc
 A Brake Caliper
 A Brake Pad Set

Brake Disc

Disc Brake Disc’s are commonly manufactured out of a material called Grey Iron .Specification
for manufacture of grey iron for various applications is as mentioned in standards. Which
dictates the correct range of Hardness, Chemical Composition, Tensile Strength & other
necessary properties for intended use.

Historically Brake Discs were manufactured throughout the world with a strong concentration in
Europe and America. During the Period 1989 to 2005, manufacturing of Discs has migrated
predominantly to China. Today almost 60% of Brake Discs and Brake Drums are manufactured
in China & exported globally.
Caliper
The Caliper is the assembly which houses the Brake Pads and Pistons. Two Type of Calipers are
there.

1. Floating calipers
2. Fixed Calipers

Fixed Type Calipers have Zero movement related to Disc, It uses one or more Pairs of Pistons to
Clamp from each side of the Disc & is more complex and Expensive than a Floating Caliper.

A Floating Type Caliper (also called a "sliding caliper") moves with respect to the disc, along a
line parallel to the axis of rotation of the disc; a piston on one side of the disc pushes the inner
brake pad until it makes contact with the braking surface, then pulls the caliper body with the
outer brake pad so pressure is applied to both sides of the disc.

Floating caliper (single piston) designs are subject to failure due to sticking which can occur due
to dirt or corrosion if the vehicle is not operated regularly. This can cause the pad attached to the
caliper to rub on the disc when the brake is released. This can reduce fuel effiency and cause
excessive wear on the affected pad. Additional heat generated by the constantly rubbing pad can
lead to warping of the disc also.

Piston & Cylinder

The most common caliper design uses a single hydraulically actuated piston within a cylinder;
the hydraulic design also helps multiply braking force. The number of pistons in a caliper is
often referred to as the number of 'pots', so if a vehicle has 'six pot' calipers it means that each
caliper houses six pistons.

Failure can occur due to failure of the piston to retract - this is usually a consequence of not
operating the vehicle during a time that it is stored outdoors in adverse conditions. On high
mileage vehicles the piston seals may leak, which must be promptly corrected.

Brake Pad
The brake pads are designed for high friction with brake pad material embedded in the disc in the
process of bedding while wearing evenly. Although it is commonly thought that the pad material
contacts the metal of the disc to stop the car, the pads work with a very thin layer of their own
material and generate a semi-liquid friction boundary that creates the actual braking force.

Of Course on depending properties of the material Disc wear may Vary, these are the properties
that determine material wear involved trade-offs between Performance & longevity.

Screw

Raw Materials

Screws are generally made from low to medium carbon steel wire, but other tough and
inexpensive metals may be substituted, such as stainless steel, brass, nickel alloys, or aluminum
alloy. Quality of the metal used is of utmost importance in order to avoid

The cold heading machine cuts a length of wire and makes two blows on the end, forming a
head. In the head slotting machine, the screw blanks are clamped in the grooves around the
perimeter of the wheel. A circular cutter slots the screws as the wheel revolves.

cracking. If a finish is applied to the screw, it must be of a compatible makeup. Steel may be
coated or plated with zinc, cadmium, nickel, or chromium for extra protection.
Design

On a single thread screw, the lead and pitch are identical, lead is twice the pitch on a double
thread model, and three times as much on a triple thread. The pitch of a screw is the distance
between two threads (or grooves) from the same point on each thread. It is also more commonly
known as the number of threads per inch or centimeter. The lead of the screw measures how far
it is driven in for each revolution.

The Manufacturing Process

Machining is only used on unique designs or with screws too small to be made any other way.
The machining process is exact, but too time consuming, wasteful, and expensive. The bulk of
all screws are mass manufactured using the thread rolling method, and that is the procedure
described in further detail.

Cold heading

 1 Wire is fed from a mechanical coil through a prestraightening machine. The

straightened wire flows directly into a machine that automatically cuts the wire at a
designated length and die cuts the head of the screw blank into a preprogrammed shape.
The heading machine utilizes either an open or closed die that either requires one punch
or two punches to create the screw head. The closed (or solid) die creates a more accurate
screw blank. On average, the cold heading machine produces 100 to 550 screw blanks per
minute.

Thread rolling

 2 Once cold headed, the screw blanks are automatically fed to the thread-cutting dies
from a vibrating hopper. The hopper guides the screw blanks down a chute to the dies,
while making sure they are in the correct feed position.
 3 The blank is then cut using one of three techniques. In the reciprocating die, two flat
dies are used to cut the screw thread. One die is stationary, while the other moves in a
reciprocating manner, and the screw blank is rolled between the two. When a centerless
 cylindrical die is used, the screw blank is rolled between two to three round dies in order
to create the finished thread. The final method of thread rolling is the planetary rotary die
process. It holds the screw blank stationary, while several die-cutting machines roll
around the blank.

Threads can be cut into the blank by several methods. In the reciprocal method, the screw
blank is rolled between two dies. In the cylindrical method, it is turned in the center of
several rollers.

 All three methods create higher quality screws than the machine-cut variety. This is
because the thread is not literally cut into the blank during the thread-rolling process,
rather it is impressed into the blank. Thus, no metal material is lost, and weakness in the
metal is avoided. The threads are also more precisely positioned. The more productive of
the thread-rolling techniques is by far the planetary rotary die, which creates screws at a
speed of 60 to 2,000 parts per minute.

SPEEDOMENTER
A speedometer is a device used to measure the traveling speed of a vehicle, usually for the
purpose of maintaining a sensible pace. Its development and eventual status as a standard feature
in automobiles led to the enforcement of legal speed limits, a notion that had been in practice
since the inception of horseless carriages but had gone largely ignored by the general public.
Today, no automobile is equipped without a speedometer intact; it is fixed to a vehicle's cockpit
and usually shares a housing with an odometer, which is a mechanism used to record total
distance traveled. Two basic types of automobile speedometer, mechanical and electronic, are
currently produced.

History

The concept of recording travel data is almost as old as the concept of vehicles. Early Romans
marked the wheels of their chariots and counted the revolutions; estimating distance traveled and
average daily speed. In the eleventh century, Chinese inventors came up with a mechanism
involving a gear train and a moving arm that would strike a drum after a certain distance.
Nautical speed data was recorded in the 1500s by an invention called the chip log, a line knotted
at regular intervals and weighted to drag in the water. The number of knots let out in a set
amount of time would determine the speed of the craft, hence the nautical term "knots" still
applied today.

The first patent for a rotating-shaft speed indicator was issued in 1916 to inventor Nikola Tesla.
At that time, however, speedometers had already been in production for several years. The
development of the first speedometer for cars is often credited to A. P. Warner, founder of the
Warner Electric Company. At the turn of the century, he invented a mechanism called a cut-
meter, used to measure the speed of industrial cutting tools. Realizing that the cut-meter could be
adapted to the automobile, he modified the device and set about on a large promotional campaign
to bring his speedometer to the general public. Several speed indicator concepts were introduced
by competing sources at the time, but Warner's design enjoyed considerable success. By the end
of World War I, the Warner Instrument Company manufactured nine out of every 10
speedometers used in automobiles.
The Oldsmobile Curved Dash Runabout, released in 1901, was the first automobile line equipped
with a mechanical speedometer. Cadillac and Overland soon followed, and speedometers began
to regularly appear as a factory-installed option in new automobiles. Speedometers in this era
were difficult to read in daylight and, with no lamp in the housing, virtually illegible at night.
The drive cable in early models was attached to either the front wheels or the back of the
transmission, but the integration of the drive cable into the transmission housing wouldn't happen
for another 20 years. After that improvement was made, the basic technical design of a
speedometer would remain untouched until the advent of the electronic speedometer in the early
1980s.

Raw Materials

Materials used in the production of speedometers vary with the type of gauge and intended
application. Older mechanical models were entirely comprised of steel and other metal alloys,
but in later years about 40% of the parts for a mechanical speedometer were molded from
various plastic polymers. Newer electronic models are almost entirely made of plastics, and
design engineers continually upgrade the polymers used. For example, the case of a
speedometer's main assembly is usually made of nylon, but some manufacturers now employ the
more water-resistant polybutylene terephthalate (PBT) polyester. The worm drive and magnet
shaft are also nylon, as is the speedometer's gear train and spindles. The glass display lens of the
recent past is now made of transparent polycarbonate, a strong, flexible plastic that is resistant to
heat, moisture, and impact.

Design

In a mechanical speedometer, a rotating cable is attached to a set of gears in the automobile's

transmission. This cable is directly attached to a permanent magnet in the speedometer assembly,
which spins at a rate proportional to the speed of the vehicle. As the magnet rotates, it
manipulates an aluminum ring, pulling it in the same direction as the revolving magnetic field;
the ring's movement, however, is counteracted by a spiral spring. Attached to the aluminum ring
is the pointer, which indicates the speed of the vehicle by marking the balance between these two
forces. As the vehicle slows, the magnetic force on the aluminum ring lessens, and the spring
pulls the speedometer's pointer back to zero.

Electronic speedometers are almost universally present in late-model cars. In this type of gauge,
a pulse generator (or tach generator) installed in the transmission measures the vehicle's speed. It
communicates this via electric or magnetic pulse signals, which are either translated into an
electronic read-out or used to manipulate a traditional magnetic gauge assembly.

The Manufacturing Process

Steel components

 1 To form molten steel, iron ore is melted with coke, a carbon-rich substance that results
when coal is heated in a vacuum. Depending on the alloy, other metals such as aluminum,
manganese, titanium, and zirconium may also be introduced. After the steel cools, it is
formed into sheets between high-pressure rollers and distributed to the manufacturing
plant. There, the individual parts may be cast into molds or pressed and shaped from bar
stock by large rolling machines.

Plastic components

 2 The various plastics that arrive in an instrument manufacturing station were first
created from organic chemical compounds derived from petroleum. These polymers are
distributed in pellet form for use in the injection-molding process. To make the small
parts for a speedometer assembly, these pellets are loaded into the hopper of a molding
machine and melted. A hydraulic screw forces the plastic through a nozzle and into a pre-
cast mold, where the plastic is allowed to cool and solidify. The parts are then gathered
and transported to assembly stations.

Assembly

 3 The manner of assembly and degree of human interaction depends on the quality of
speedometer. Some inexpensive speedometer systems are made to be "disposable,"
meaning that the instruments are not built for easy disassembly or repair. In this case, the
 hardware is fastened using a process called riveting, in which a headed pin is inserted and
blunted on the other end, forming a permanent attachment. Higher-end speedometer
systems consist of two major assemblies attached by screws; the advantage is that the
inner hardware of the gauge is accessible for repair and recalibration.
 4 The inner shaft and speedometer assembly are then fused into place with rivets or
screws. The permanent magnets used in mechanical speedometers are compressed and
molded before arrival at the plant, and therefore only require mounting onto the worm
drive. In the case of electronic speedometers, fiberglass-and-copper circuitry is also
manufactured by vendors, and does require programming before it is screwed into the
larger system. These larger components are transported to a separate assembly station,
where they are mounted into the housing with stud-terminal or blade-terminal plastic
connectors. Beyond its primary

The inner mechanisms of a speedometer.

Duty as a protective case, the housing also serves as a platform for attaching exterior
features such as the dial face, needle, and display window. Again, these processes require
automation due to large output, but human effort is needed at every step to inspect and
ensure product consistency.

Calibration

 5 Calibration is the process of determining the true value of spaces in any graduated
instrument. It is an especially vital process in the manufacture of speedometers because
 driver safety is reliant on an accurate readout. In a mechanical gauge, magnetic forces
produce the torque that deflects the indicator needle. When calibrating this type of gauge,
an electromagnet is used to adjust the strength of the permanent magnet mounted in the
speedometer until the needle matches the input from the rotating cable. When calibrating
an electronic gauge, adjustments are made when calibration factors are written into the
memory of the meter. The system can then refigure the balance between input from the
transmission and output of the needle. New automated systems for calibrating both
mechanical and electronic speedometers are now available, saving an immense number of
the man-hours usually required for this process.

Quality Control

Probably the most direct method of quality control is the calibration process. Auto parts
manufacturers work under the measurement standards developed by International Organization
for Standardization (ISO), which ensures that universal guidelines between gauge manufacturers
are used. In-house quality assurance teams develop specifications for each new product before it
moves to the assembly line, and the same teams later report whether those guidelines are adhered
to on the factory floor. Gradual levels of assembly also involve inspection by factory personnel
to make sure that the automation is working smoothly.

Byproducts/Waste

No byproducts result from the manufacture of gauges. Waste materials include scrap metals and
plastics, some of which can be reused in later production runs. Because the raw materials
involved are prepared outside of the factory, no significant amount of hazardous industrial waste
results from manufacture. Emissions from factory automation are government-regulated and
surveyed by environmental protection groups.

The Future

Design firms are currently experimenting with improvements in speedometer readout, an effort
to eliminate the moment of distraction needed for a driver to look down and gauge his or her
speed. Digital readouts projected onto the windshield appear to be the next developmental step.
Some proto-types for these speedometers actually make the readout appear as though it is
floating over the engine hood. Because this type of display looks as though it is several feet
beyond the steering wheel, drivers will be able to continually monitor speed without having to
take their eyes off the road. The mirrors and projection devices used in this system could also be
adjusted to suit the driver's position, much in the same way that a rear-view mirror does. In
addition, speedometer projection systems will eventually be integrated with navigation tools,
allowing directional information to appear with gauge readouts.

Two Wheeler Dust Tube

We are manufacturing, supplying, and exporting wide collection of Two Wheeler Dust Tube
and allied parts to our esteemed clients. These are made by using high end technologies in our
modern manufacturing facilities. We maintain stringent norms of quality by complying with
international standards. These are extensively used and highly acclaimed for optimum
performance and durability. Our valued patrons can avail these at leadingindustry prices.

Features:

 Dimensional accuracy
 Reliable and long lasting

Plug Cap
We are considered as one of the most prominent organizations engaged in manufacturing and
supplying optimum grade Plug Cap. We manufacture these holders using high quality material
sourced from our highly authentic market dealers. Professionals working with us also make sure
to follow all laid quality guidelines while manufacturing these center holders. We have also
ensured that these holders are made available to our customers within predefined time frame.
Plug Cap offered by us is reckoned for the following quality features:

 Easy fitting
 Rust resistant
 Accurate dimensions
 Fine finish

Cush Rubber
Backed by rich industry expertise, we are engaged in manufacturing and supplying a superlative
assortment of quality approved Cush Rubber. These rubbers are manufactured in our state-of-
the-art unit using high grade material and innovative technology. We have been following all
stated set regulations of this domain so as to ensure that our offered rubbers are in line with
international product range. Cush Rubber offered by us are appreciated for their following
quality features:

 Longer service life

 Easy maintenance
 Perfect shape
 Accurate dimensions

Clutch Lever
Established in the year 1997, we are one of the most trusted organization engaged in
manufacturing and supplying supreme quality Clutch Lever. This lever is made using optimum
quality material in our state-of-the-art manufacturing plant. After manufacturing, these levers are
passed through a series of testing so as to ensure that only high grade and defect free range is
delivered at our clients. Clutch Lever manufactured by us are made available to the clients
within predefined time period.

Special Key Features:

 Durability
 Ruggedness
 High stability
 Rust resistance
 Excellent finish
 Sturdy construction
 Dimensional accuracy
 Longer service life
 Corrosion resistance
  Application specific design

Side Stand

To suit the variegated requirements of our valued patrons, we have been able to manufacture and
supply superior grade Side Stand Foot. These stands are manufactured in our highly
sophisticated manufacturing plant using optimum grade material and hi-tech machines. With the
assistance of our highly prompt and diligent transportation department, we have been able to
deliver these stands at clients' ends within predefined time frame. Side Stand Foot offered by us
is made available to the clients at best market price.

Features:

 Robust construction
 Optimum service life
 Durable
 Accurate design
 HUMAN RESOURCE DEPARTMENT
Department structure

HR DEPARTMENT

MANAGER

Asst. MANAGER

Asst. PERSONNEL OFFICER Jr. PERSONNEL OFFICER

OBJECTIVE
 Reduce the absentisieem from 10% to 5% in the course of one year.
 Improve employee satisfaction by 10% using a survey of current situation at the end of
one year.
 To enable individual employee to improve their efficiency by 5% in the course of 1 year.

Manpower planning
The number of employees in an organization is decided by the number of products
delivering. The Government decides the number of employees to be worked for the company to
achieve the targeted production it is called Employee Sanction Strength.
The capacity of the plant is 7200 units/year.i.e, 600 per month.
Number of workers needed to make 1 vehicle is 20 workers per day.
Employee sanction strength= 20*(600/25) =480 workers.
The current sanction strength of employees of FIBO is 495(shop floor workers + managerial
category)
But since the current production rate is set as 300 units per month, the employee strength is
maintained as 250-260.
A problem that FIBO facing: The 1/3rd of employees in the company are unskilled workers,
who were inducted at the beginning of the company.
Recruitment is a very carefully process to be done. Otherwise it will make unnecessary losses in
future.
CURRENT MANPOWER PLANNING:
The number of contract employees is checked based up on the production. The work is being
outsourced to the outside parties, if there arises an immediate shortage. After getting the
proffered output of production, the machinery is used for the manufacturing of other products
like coir spinning machines etc.
Its current plan is to maintain the level of production with minimum input.

RECRUITMENT AND SELECTION

There are three methods of recruitment
1) Direct Recruitment
2) Employment exchange
3) Public Service Commission

1) Direct Recruitment: Direct recruitment is done through advertisement in newspaper.

2) Public Service Commission: The post of helpers, typist, office assistants, stenos, clerical staff,
drivers etc are done through PSC. Whenever there arise a need for employees on such posts, it
will be reported to PSC. But there is no such recruitment in recent times since there is no need
for such posts.
3) Employment exchange: This is done through the employment exchanges. This is because of
the Compulsory Notification act. The required number of candidates and their qualifications are
informed at the employment exchanges. The eligible candidates are recruited and selected.
4) For higher posts, there will be interview only. In the interview board, there will be members
from board of directors, HR manager and the domain/subject expert sometimes as per the
direction from the government. Then the merit list is published .Then fixed list is published for
selected candidates.
Selection procedure
The first step to selection is written test, applicable to all category of workmen. An
interview is conducted for those who succeed in it. Applicants to technical post undergo a trade
test also.
Apprentices: Apprentices are selected from three sources.
 Related Instruction Centre(RIC) - To recruit ITI candidates
 VHSE board
 Central Apprentice - For graduation & B.Tech (office is at Chennai)
 Diploma holders are selected through supervisory development centre FIBOamassery.
Induction
An induction program will be given to all the candidates who join the FIBO as a fresher.
They will be provided on the job training. Most of the time, their probation period will be from
six months to one year. After that, if the candidate’s performance is satisfactory, he will be
appointed as permanent.

Training and Development

After the intake of a permanent employee, he will be given training for 1 year.
Permanent appointment is given after that. The training can be inside or outside the organization.
During the period of training, the basic pay alone is given. After appointing the employee as
permanent, he will be paid salary with all the kind of benefits.
Apprentices and management trainees are appointed based on contract basis to get trained in
their domain areas. They will be given stipend only.
EMPLOYEE PROFILE
Workmen re classified in to permanent workers, probationary, temporary and casual workers. At
present there are 255 permanent employees.

Employees can be classified based up on two norms, they are:

1) Based up on Standing order
2) Based up on wages of employees/wage settlement.
In FIBO the employees are classified up on wage segment. They are
 Officer category/managerial
 Technical category/workmen
In FIBO, the employees are classified in to two categories based on wage settlement. They are :
1) Officer/managerial
2) Technical/Workmen
The detailed categorization is given in the pay scale structure below
Number of employees in various departments

Department Permanent Employees Trainees Apprentice

Sub-contract department 2 - -

Marketing 8 - 2

Maintenance 11 - 3

Store 15 - 3

Quality Assurance 18 - 4

Heat Treatment 2 - -

Tool Room - - -

Painting 9 - 3

Assembly 26 - 9

Fabrication 30 - 8

Machine Shop 55 3 19

Planning 5 - 1

Design & Drawing 7 2 4

 Service & Spares 8 -

Administration 14 - -

HRD 15 3 2

Purchase 12 1 3

Accounts 15 2 2

General 4 - -

TOTAL 254 11 63

WORKING TIME
The working time in FIBO is 8 hours per day. There are maximum 5 shifts in the company.
(1) Executives : 9 am – 5 pm
(2) Ministerial staff: 9.30 am – 5 pm
(3) Workmen : 9 am-5pm (general shift)
6 am – 2 pm (1st shift)
2 pm – 10 pm (2nd shift)
ATTENDANCE
The attendance of FIBO is calculated through the punching system. The employees
punch their attendance card and the attendance will be registered in the server. The salary is
calculated based on this. For every minute late, the belated time will be calculated and respective
salary will deduct and causes ‘loss of pay’. Such exception is only for the entry time of first 30
minutes. If the employee is late more than 30 minutes, he has to take half day leave.
Wages and salary administration
There are two scale of pay. They are:
1) For officer segment( every 4 year revision)
2) For workmen segment( every 5 year revision)

Stipend
The trainees & apprentices are given stipend every month. It’s as follows.
 ITI - Rs 1440
 Diploma - Rs 1850
 Degree - Rs 2600
 Management trainee - Rs 3000

SALARY RELATED TERMS

Dearness allowance (DA)

There are two type of DA.
1) Fixed DA /Government DA:
This is for the people of the managerial category. Fixed DA varies every quarter. The
current government DA is 123% of the basic scale of pay. This DA is fixed by the
government and is based on the salary point scale. It is as follows:
Fixed DA = (basic ×123) /100

2) Variable DA:
This DA is for workmen category. This is fixed by the government based on Cost of
Living Index/ Consumer Price Index (CLI/CPI). ‘Economic and Statistics Department’
prepares Consumer Price Index. This DA percentage varies according to the inflation
every month.
Calculating Variable DA (VDA)

To calculate Variable DA the following are necessary.

1 Base Point: It is determined at pay revision and it varies at every pay revision. The
current base point of FIBO is 950.
2 Indices : It is the cost of living index of the month as in CLI
3 Points for each scale of pay. It is as follows:

Basic pay scale Points

Up to Rs 2950 3.95
Rs 2950-3500 4.20
 Rs 3500-4001 4.75
Above Rs 4001 4.90
Steps to calculate VDA
Index of month (CLI) – Base point = Result
Point × Result = VDA of the month

House Rent Allowance (HRA)

This is decided by the management with the understanding of labor unions. This is revised
every 5 years and further change in HRA is made. The current DA rate is
Work men: Rs 350
Officer category: Rs 260

Adhoc pay
This is give to those employees who are eligible for promotion and not promoted yet even after
the time bound within which they have to be promoted. When adhoc pay is added to the salary,
the respective DA of adhoc pay is also given to the employee. That is adhoc pay is added to the
basic salary and its DA is calculated. When he got promoted, the adhoc pay is removed and the
new scale of pay to the promoted position will be given.
Attendance bonus
If the employee takes only one leave in the month of 26/27 working days, he will be
eligible for Rs 25 attendance bonus. But if there are two leaves or ‘loss of pay’, he won’t be
eligible for the attendance bonus.
Gratuity
The employee will get 15 days’ salary as gratuity for one year’s work. The employee will
eligible to receive gratuity, when he completes minimum 5 years service. As per gratuity act, in
FIBO while in service if any employee passes away, he will get full gratuity amount up to his
retirement age.

The base for calculating PF is 26 (working days a month).The amount used to calculate gratuity
is the ‘basic pay +DA (if exists)’.
Gratuity=15 day’s salary= [(basic+DA)/26] × 15
(This is equal to the 4.8% of annual salary [basic + DA(if exists)])

Gratuity amount at a particular year of service =

[(basic+DA)/26] ×15×Number of years of service*

*- Number of years of service: More than 6 months service will be counted as full year of
service.
i.e; 1 year 7 months will be counted as 2 years.

Incentives
Incentive is given to all the employees from top to bottom of the organization, when
extra production takes place. But since the current production is limited, there is no incentive the
employees.
Production (vehicles) Amount
300-325 Rs 2.00
326-350 Rs 2.50
351-510 Rs 3.00
Above 511 Rs 4.00

Washing allowance: Rs 30 per month is given to work men as washing allowance.

Stitching allowance: Rs 250 per year is given to workmen those who have uniform and Rs 35 for
women.
Risk allowance: Rs 50 per month is given to work assistants and helpers who undertake
operations like painting, heat treatment, ammonia pointing welding etc.
Special allowance: Rs 25 per month to senior tradesman.
Shift allowance: First shift – Rs.2.50
Second shift – Rs 3
Shoe allowance: Administrative department provides Rs 300 as shoe allowance in every 8
months to every employee.

Provident Fund (as per PF act 1952)

12% of the salary (Basic + DA) is paid to Provident Fund account from the salary of the
employee. The same amount will be provided by the employer to the PF account. The 12 % of
both employee and employer is statutory. But the employee can voluntarily pay additional
amount more than 12% to the PF account. But the employer doesn’t have to pay accordingly as
the employee pays, other than employer’s 12% share.
Around 8.33% of the 12% of PF share of the employer will go to the Pension fund of the
employee.
The interest of the Provident Fund is 8%.
An employee can take money (as loan having no interest) from PF account(employee
share) twice in an year. He can also take money for education, marriage (up to 60%), home
construction (up to 90%) etc. The proof of such things should be provided such as building
plan, approval from authorities, engineer etc for construction, marriage certificate copy,
invitation etc for marriage after the function and statement from bank etc for education. The
employee may or may not repay the amount taken from the PF account (as loan).Generally
there is no need to pay back the money. This loan amount is permitted from the employee’s
share of 12% of basic salary that he pays every month. The employee cannot take money
from the 12% of the employer’s share to PF.
The account section pays the PF in the bank with the ‘common PF account number’ of the
company and gives the Chelan to HR section. The company has its own single PF account
number as whole for all the employees. Each and every individual employee has their own
personal PF account numbers. The HR department prepares the list of employees with their
individual PF account numbers and sends it to the PF office along with the Chelan.
If the monthly PF of an employee is not paid by the company, the MD of the company
may get imprisonment.
Leave
Casual leaves - 20
 Medical leave - 10 full day leave/20 half day leave
Earned leave/annual leave: The employees have the right to take 1 earned leave for every 20
working days (20:1) (based on factories act). But the management has the right to put
forward attractive plans in front of the employees to motivate them. Earned leave can be
encased. The maximum numbers of earned leaves that can be enchased are 300 days.
In FIBO the earned leave ratio is as:
Managerial category - 11:1
Workmen category -13:1

Holidays
FIBO follows a systematic method for deciding holidays in a year. There can be up to 13
holidays in a year. Out of these 4 days is national holidays-jan26, may1, aug15, oct2.The
remaining festival holidays are decided by the management and workers committee.

Total number of leaves in an year

Annual - 30
Casual - 20
Medical - 10
Holidays - 13
Week Sundays - 52
________________________
TOTAL LEAVES- 125 /year.
Promotion opportunities and appraisal
Promotional policy
50% recruitment is through direct method and the rest id through promotion. The
promotional levels are:
Technical
Engineer, senior engineer, Ass.manager, manager, Deputy General Manager, general manager.
Nontechnical
(1) Accountant, junior personnel officer, junior law officer, superintendant, sales executive.
(2) Ass.accountant officer, Assistant administrative officer, Ass.personnel officer,
Ass.welfare officer.
(3) Account officer, Personnel officer, administrative officer etc

In FIBO promotion is based on

 Seniority
 Qualification
 Performance

If a person won’t get promotion till 10 years due to lack of qualification, poor performance etc he
will be given a grade. It is called up gradation.
Difference between up gradation and promotion:
The upgraded person will get salary hike only. He won’t be given authority according to the
salary increment. But in the case of promotion, the employees have both salary hike and
authority.
PERFORMANCE APPRAISAL POLICY
 It should be in prescribed form.
 The entries in the performance appraisal form shall be clear and precise and shall be
based on the officer’s personal observation of the work and conduct of workmen.
 The entries shall be made by the officer in his own hand or type written by him and shall
be kept confidential ad the report shall be under the safe custody of the personnel
department.
 If there are any adverse of such nature that the workmen need an advice or admonition
only, the concerned Head of Department shall render such advice of admonition. In more
serious cases, the head of department shall give opportunity to the concerned to submit
explanation. The intimation to the workman together with his reply, if any, shall be kept
in the personal file.
 The confidential record shall be prepared by the officer under whom an employee is
working and shall be submitted to the head of the department who shall countersign it,
adding his own remarks, if any.

PERFORMANCE APPRAISAL PROCESS

It includes the appraisal from the immediate head of each employee. Performance
appraisal is done on the basis of certain factors such as job knowledge, job responsibility, quality
of work, cost consciousness, organizing ability, punctuality, problem solving ability etc.
Performance appraisal goes through the steps as follows:
(First appraisal by employee, then appraisal by the rater (immediate next head) and reviewed by
the head of the department. Calculation of appraisal score of employee done based on five point
rating system. The final rating is done by the rater. Counseling is also given for low level
performers).
Steps
 Issue performance appraisal form to employees.
 Self appraisal by the employee.
 Appraisal by the rater.
 Review by the rater.
 Review by Department head. Calculation and appraisal score of each employee in
personal interviews.
 Counsel employees for improving performance.
The five point rating method is used for performance appraisal. Grading are given below
in two tables. Five point rating method is used:

Grade A B C D E

Performance Excellent Very good good average Poor

Point 90-100 70-89 50-69 30-49 10-29

DISCIPLINARY PROCEDURE
Discipline is a watch word maintained in FIBO. Disciplinary actions are strictly
followed. There has not any instances of dismissed at FIBO till date. As usual, the worker is
given a show cause notice and a time limit is given to produce his explanation. If the explanation
is satisfactory, no further action will be taken. But if it is not satisfactory, he will be given a
charge sheet and thereafter enquiry. A workman can be suspended for enquiry. He will be paid a
subsistence allowance according to the TRICHY payment subsistence act 1972. If the
explanation is convincing, then the suspension is withdrawn and wages for the period of
suspension will be paid in full. If no explanation is received, the management may proceed with
action.
Enquiry may be held by enquiry officers appointed by the higher authorities. Enquiry
officers will make recordings and forward it to the concerned authority. Then charge sheet and
the recordings of the enquiry will be given to the concerned authority and the decision is
communicated to the workman. If the charges are proved by the enquiry action will be taken, if
not the worker will be called on duty and his wages for the suspended period will be paid in full.
GRIEVANCE PROCEDURE
The company has an open door policy as far as grievance handling is concerned.
Workmen are true to take their grievance to their superior authority and seek a redressed. The
usual procedure for handling of grievances is given below:
 Grievance report to immediate supervisor.
 If workman is not satisfied/ not receive reply within 7 days he can go to next immediate
supervisor.
 If that decision is not satisfactory/ doesn’t receive reply with in 7 days, he can send the
grievance to the head of department in written with signature.
 If the decision of head department is unsatisfactory/ doesn’t receive reply with in 7 days
he can present a copy of grievance not to the Head of HRD department who will make
necessary entries to grievance register. He will then conduct investigation of all relevant
facts and endeavor to settle the grievance satisfactorily shall be final.
 The head of HRD department will implement the final decision if any and will inform the
response in writing.
INDUSTRIAL RELATIONS
According to the referendum, the union having 15% membership will only be recognized. Now
in FIBO there are 3 unions.

Name of union Reg. No. Affiliation

TRICHY Automobiles 126/82 INTUC

Limited Employees Union

TRICHY Automobiles 102/84 STU(Swathanthra Thozhilali

Employees Organization Union)

TRICHY Automobiles 325/84 CITU

Employees Association

From the discussion with HR manager

 Now there are 257 permanent employees in FIBO
 Company was in loss before some years and is slowly coming to profit.
 Employees are given training in different areas for the expansion program.
 As a part of product diversification, coir spinning machine is made and handed over as per
demand. By providing training, the management is trying to impart a change in the work
culture. The work culture that FIBO follows is a traditional one. It needs to accept the change
according to market and time as the other public sector companies are also changing.
 In Department Performance Appraisal (DPC), HRD department has the plan to implement a
written test for the officer category. But due to the opposition from the side of employees, it
became unsuccessful.
 Absenteeism: For lateness, the proportional amount of salary will be reduced. A regular
attendance is kept. There is a time keeper to make sure that employees are on time. He is
responsible and checks the duties on time.
 Situation analysis is a must for a HR manager. One has to stay calm and listen to the
problem/issue first. HR has to stand independent in taking the decisions, without any biases
 Exit interview: Usually there is no exit interview done in FIBO at the time of retirement.
ADMINISTRATION DEPARTMENT
DEPARTMENT STRUCTURE

MANAGING DIRECTOR

ADMINISTRATION MANAGER

JUNIOR EXECUTIVE

WORKER

The main functions of administration department are as follows:

 Committees
The committees in FIBO are formed by the unions elected each year. Each union
nominates one person to each committee. Equal number of persons from the side of labor unions
will be nominated from the management side. The committees in FIBO are canteen committee,
safety committee, magazine committee, estate committee, scrap committee.
Committees are under administration department. Election is also carried out by
administration department. The union which wins election undertakes club and society. Usually
the election is carried out in 3 years.
Labour welfare committee: It provides Rs 62,000 to family on death of personnel. It is by
aggregating the salary of 1% of employee plus 1% by the management. It gives awards to the
children who tops in exams like SSLC, B.Tech, +2 etc. The price money varies as Rs 1000, Rs
750, Rs 500.
 Punching card and ID card are issued by the administration department. In turn, an employee
has two cards.
 Security: Managing the security people is done by the administration department. Fresh
quotation is invited every year for the security people. ‘Ex- service league’, an association of
ex-service men carries out security job nowadays.
Total number of security = 18
Supervisor salary - Rs 200(improved from Rs 160)
Security Guard - Rs 160 (improved from Rs125)
 Uniform for the workmen are issued by the administration department- Pista green shirt and
black trousers for men and Pista green saree and black blouse for women. Stitching
allowance of Rs 250 is given for men and Rs. 100 for women.
 Canteen: every year new quotation invited in dailies like malayala manorama,
mathrubbhumui, TRICHY kaumudi etc to undertake canteen. Canteen committee votes and
selects the best quotation. Management given Rs 300 subsidy for each employee every
month. Coupon is given to employees for food. Water, building, utensils etc are free for
canteen undertakers. There is a ration permit of 3500 Kg rise and 2000kg sugar for FIBO
canteen.
 Stationery: administration department buys and stores he stationery items like calculator,
files, glue, paper, pen etc. In every 2-3 months it is bough wholesale from Triveni shop, for
an amount up to Rs 40,000. It is supplied to each respective department as per the need and it
makes sure that the items are not manipulated.
 Letter dispatch: Every outgoing letter is sent via administrative department. There is a
machine called ‘Franking Machine’ to seal the letters, which is issued from the postal
department. The parcel weight is measured and the respective stamp rates are printed.
 Advertisement: Some organizations demands for advertisement as promotion for programs,
in magazines, diaries etc. The photos that are advertised is brought to the organization, and
then only the money is paid. To print the FIBO diary, administration department approaches
different firms for advertisement to reduce cost. It has a long time regular advertisement
providers.
 Furniture: It is bought and supplied by the administrative department. The repair work is
also done by this department.
 Retirement: Administration department arranges a send off function in the portico on the
day of retirement of an employee. The company car is arranged to take him home. He will be
given a gift and a party will be arranged.
 Supplying the government calendar from collecting it from the government press is the duty
of administrative department.
 Funeral arrangement: In the case of demise of an employee, Rs 5000 will be given to the
family to carry out funeral function. Rs 3000 will be given to the close relative of the died
person.
 Garden: the garden is maintained by the administration department.
 Head load workers: The wage of head load workers is paid by the administration
department.
 License Renewal: It’s the job of the administration department to renew the license of
company every year. If the license is not renewed, the company cannot work. The industrial
license application is given in the form-2. It is according to the rules – 4 , 12.
The application for renewal is sent along with the duly filled in ‘form-2’ and the Chelan
of Rs. 75,000 and the names and details of Board of Directors. Original factories license will
also be sent along with this and it is renewed and a new license is issued back to the
company. The license is renewed from :
“The inspector of Factories and boilers
 PURCHASE & SUB-CONTRACT DEPARTMENT

DEPARTMENT STRUCTURE

Manager (materials)

Assistant manager Supplier development

Senior engineer

Junior engineer

Clerical staff

At tender

PURCHASE DEPARTMENT
Objectives:-
 Satisfy the supplier by giving regular order
 Reduction in rate of rejection in materials
 Vendor rating up graduation
The main function of the purchase department is to purchase the raw materials which are
necessary for the production process.
The products purchased are divided in to 5 divisions – A, B, C, D, and E.
Product type A: includes – tyre, engine, tube, sheet etc
 Product type B: includes – upper cone, horn, speedometer, cable for gear control, heel
cylinder assy, brake lever assy, mango lever, spring etc.
Product type C : includes – shaft with support, clip cables, shim adjusters, petrol tank neck,
rear break adjuster, spacer for head lamp, cable for clutch, support bracket, rivet, wiper
fitting, screw etc.
Product type D: includes – div. bleeding, overflow pipe, speedometer cable, ignition switch,
decompression cable, main electrical loom, DC horn, battery cable assy, BULB – B 53, tail
lamp assy, reflex reflector, indicator (green), silencer mountings, stop bush spring.
Product type E : includes – sheet (MICA/PVC), tape (cotton), paint(INC golden, yellow) ,
primer, putty, thinner, rubbing compound, polish wax, seal 101 chemi, react chemi, additives,
welding glass, button mop, emergency powder.

Purchase cycle
 Calls quotation
 Negotiation
 Checks quality
 Purchase development
Purchase department ensures the availability of right material at right tie at right place at the right
quantity. The department is under the control of purchase manager. All the activities regarding
purchase are under gone in this department. This department is responsible the procurement of
raw, materials. Its supply and service the raw materials and purchase parts in the finished goods
must be the information from the marketing department, planning department prepare the sales
plan and send the production plan & material plan to the purchase department Based that
requirement. The department purchases both raw materials and semi finished goods. Prepare the
purchase order and then it scheduled to making purpose. Then give the order the company
purchase mainly from Haryana, Uttar Pradesh and almost 25% is form Mumbai. The purchase of
materials from vendors and they rate vendors and evaluate them on the basis of parameters like
quality, price, time. The department is following ABC analysis for purchasing of products. They
do have a PDCA cycle of doing things.
ABCDE analysis is used to follow for the purchase. The order that is placed for ‘A’ category is
before the week, for ‘B’ before one month and for ‘C’ items. The order is placed before six
months. The responsibility for ‘A’ quality is with materials manager, ‘B’ quality with Asst.
Manager and ‘C’ is with Asst. Engineer (purchase). There is a purchase committee formed for
the purpose of bulk purchase of products. This department also uses vendor rating and vendor
evaluation techniques. If the rating of the vendor ‘C’ grade they will encourage the vendor to
promote to ‘B’ grade. If they are not living up to their expectation. The company will delete the
vendor names from the vendor list.
The company purchasing more than 2200 components for a single product. The categories into
A, B, C, D, E and subcontract.
Most of the suppliers are from outside of the state. Mode of transmission is by truck or railway
or airways, based on the time and need. Some of the main transportation agencies in the
company are TRICHY Transport Corporation. Sourashtra Roadways, ABT purchase etc. If the
mode of transportation is through truck then thee consigner (vendor) give the consigner copy
(CC) of the lorry receipt (LR) to the consignee forwards the CC of Ir to the agency and collects
the goods. If the transportation is through railway then the documents in Rail receipt and for
airways it is always bill.

The Procedure for a purchase

 Enquiry for question
 Receive the quotation
 Negotiation of the quotation
 Revise the quotation
 Compare the statement
 Proposal for the purchase
 Place purchase order
 Follow up the material
 Collect the material
 Quality inspection
 Raising GNR or GRJ (Good receipt note/Goods rejection note
 Payment to vendors
 Payment for vendors is in 3 ways
 Direct Credit – forwarding original FIBO & invoice to the accounts department
for the payment, usually within 30days.
 Direct advance - against Performa invoice
 Through bank – the vendor will sent the original invoice and CC to Lr to
purchaser’s short bank. The bank sent BLSC (Bank Letter for Short Credit) After
the payment, the bank will forward the Lr documents & invoice to the purchaser.
There is a purchase committee. It includes DGM, manager- production, manager- purchase and
one member from accounts section.
Local purchase: Small and the products of urgent shortage are brought locally by paying money
instantly. This is to avoid production held-up.
 The purchase up to 15000 is controlled by the manager
 Between 15000-100000, by the purchase committee
 Above 100000 controlled by MD with recommendation of purchase committee through
GM
List of the purchase schedule:-
 Register for the copy of invoice
 LR forwarding register
 Comparative study
 Procurement data analysis
 Purchase order
 Enquiry notice
 Annual purchase plan
 List of approval suppliers
 Bank document
 FIBO receipt
 Supplier rating document
Supplier satisfaction is one of the main aims of the department. The department keeps good
relation with the suppliers and pays money on time. It also makes sure that the products
purchased are of good quality and keep motivating the suppliers to provide good quality stuff.
SUPPLIER DEVELOPEMENY SECTION
The section finds out the goods and fair source of supply.
Procedure for supplier development:-
This section looks for the potential source of suppliers by referring the journals, attending
exhibitions, seminar and trade fair. After making contract with suppliers, the section will prepare
a supplier list form. Applications are received from the supplier and the committee evaluates and
selects the good one. After the section a written letter will be sent to the approval supplier for the
issue of required raw materials. The department is responsible to keep the supplier list and
approval records. Performance of every supplier in the approval list will be reversal once in
every six months.
Functions:-
 They act for the development of existing suppliers and identify their problem, then come
out with good solution.
 Develop fresh parties for their requisition by R&D department
 Identify quality supplier from
 Provide alternatives solution for quality products.

SUB- CONTRACT DEPARTMENT

DEPARTMENT STRUCTURE

MATERIALS MANAGER

SENIOR ENGINEER

ENGINEER

JUNIOR ENGINEER

CLERICAL STAFF
 In FIBO many of the terms such as differential cage, axel, shaft etc are sub contracted from
outside.
This department has the same function as the purchase department. In this department the
details regarding outsourcing products or materials are stored and updated. This department
is functioning under the purchase manager. Sub Contracting materials are given inside and
outside TRICHY for work. Materials manager is in contract of sub contract department.
Objectives:-
 Supplier Satisfaction
 To reduce rejection in sub contract items of differential cage from 10% to 20%
 To reduce rejection of axel, shaft from 20% to 2%. The sub contract department
follows PDCA cycle in this activity.
Main Sub Contract areas are:
Cluster gear, main gear with bush, hand chassis etc.
Activities:
 Receive production plan from planning department
 Make purchase enquiry
 Invite quotations
 Prepare comparative statements
 Send negotiation letter
 Receive negotiation letter from vendors
 Prepare work order proposals.
 Proposal approval
 Issue work order
 Place loan note for approval
 Deliver materials
 Follow up note for approval
 Receiving inspection of sub contract items
 Receive FIBO
 Check FIBO to account department
 Forwarding of FIBO to account department
 Sending payment with copy of FIBO to work contracts
 Request to store for returning of rejected materials

MARKETING DEPARTMENT
DEPARTMENT STRUCTURE

GENERAL MANAGER

ASSISTANT MANAGER

ACCOUNT OFFICER

SENIOR ENGINEER

ASSISTANT SALES EXECUTIVE

CLERICAL STAFF

North India is the main market of FIBO. In 3 wheeler industry FIBO has only 1 % market
share. IBO mainly produce 3 wheeler chassis and send it to the god own I north India. Then it
is supplied to the dealers as per their demand. The dealer makes the body for the vehicle as
the customer demands and sells the product. The dealers will get a significant amount in
body building. It can be up to 1.4 lakh. This is because different people have different
 interest and they use this vehicle for different purposes. In TRICHY FIBO cannot compete
because there are a lot of manufacturers who gives super-finished goods to the customers.
FIBO is sharpening the edge to get in to the market. Another reason that the north Indian
customers buy the product is that its performance. It has a good mileage and high power that
it can run in any conditions of road. IBO is producing fully built vehicles as per demand.
Marketing means making available products suitable for sales. The efficient making
department is the corner stone for success for every organization. In FIBO marketing
department is under the control of GM (marketing). The activities of this department are
directly reported to the MD. This department identifies the customers, interact with them and
find out their needs and thus figure out the market potential of various products.
Marketing management is a pre-requisite for the successful Operation of any business
enterprise. Marketing management shall be responsible for the after service activities of the
company. The marketing department shall maintain a register showing details of the warranty
claims against each vehicle. Marketing determines the needs of the customer and sets out the
pattern of production of goods and service necessary to satisfy their needs.

QUALITY OBJECTIVE:-
 Extend awareness about MX400 vehicle among all dealers.
 Locate more dealer outlets in Karnataka and Tamil nude.
 Appoint dealers in the unrepresented areas in the northern states.
 Making available vehicle according to demand of the customers.
FUNCTION:-
 The marketing department ensures that the company’s products are marketing to various
outlets, taking in to consideration the demand for various types of vehicles at the various
outlets.
 Appointment of dealers
 Dispatch of vehicles
 Preparation of sales and dispatch plan
 Collecting feedback information of the product.
 Termination of dealers
 Advertisement and sales promotion
  Transportation management
 Contract review
 Procurement and sales of spare parts
 Warranty settlement
 Free service coupon settlement
 Customer complaints
 Pre-delivery inspection and provide free service at dealer point
 Acceptance of order for special purpose products
 Procedure for contract amendment
 To co-ordinate the function of material production and sales department.
4 P’S OF MARKETING:-
PRODUCT:-
FIBO produces mainly 3 wheeler auto rickshaws of diesel as well as petrol versions. At present it
is mainly concentrating on the diesel version under the brand name “FIBO”.
Products
1) TRICHY GL 400 V2 electric start chassis- Rs 76,000
2) TRICHY GL 400 V2 rope start chassis – Rs 74,000
3) TRICHY GL 400 V2 MX 400 electric start chassis- Rs 83,000
4) TRICHY GL 400 V2 rope start - Rs 77,000
New products

1) Self start (340cc) petrol engine [CNG]

2) Self start (340cc) gas engine
Other products: FIBO manufactures rocket components for ISRO from 1990. It worth’s up to Rs
50, 00000. It has started manufacturing coir spinning machine and it has become successful.
More and more machines are supposed to be manufactured in FIBO.

PRICE:-
FIBO follows cost plus pricing strategy in which the margin is included for its products. It also
considers the price of competitor’s vehicles while fixing price.
Market price of its products is kept comparatively lower than the competitor’s model. Before
making the crucial pricing policy FIBO conducts forecasting for its products mainly by
 Feedback from dealers
 Conducts market survey
 Compare the sales of competitor’s similar products.
 Company also conducts market research with the help of some external agencies

The various products of FIBO having different price in various locations and the detailed market
price list of the various products are given below
PLACE:-
The marketing of vehicles is done through dealers and agents. The main market of the products
of FIBO is north India. The main markets include Haryana, Uttaranjal, Punjab, Rajasthan, Uttar
Pradesh, and Gujarat. Here are also small markets in TRICHY and tamilnadu.
Exports:- a major portion of annual production is exported. FIBO earning through foreign
exports in last financial year were. Its major destinations include Bangladesh, Srilanka, Nepal,
Sudan, Nigeria, Guatemala, South Africa, and Botswana etc. recently FIBO has signed a
memorandum for the export of 1500 diesel 3 wheeler vehicles with meders Liberty Techo
Company and it was one of the biggest orders received by the company. The last time export
worths $ 1600.
Dealers are selected on the basis of show room facilities, service and man power etc. Company
gets in to contract with dealers for a minimum of 2 years. Company has liaison officers at Delhi
to co-ordinate the north Indian operations. The main dealers in TRICHY are marikar and
TRICHY state agro industries.

PROMOTION:-
FIBO Mainly uses customer promotion and trade promotion techniques to enhance sales. Main
sales promotion techniques are:
 Company participates in auto shows
 Advertisement in local channels
 Gifts in all seasons
  Incentives to dealers making maximum sales
 6 free services are given at crossing 500,1000,2000,3500,4500 and 5250 kms
 Warranty of spare parts. The warranty is for a period of 6 month from the date of
purchase or crossing 5000 km whichever is earlier
 Sales incentives to the dealers as sales promotion

Sales In Last 9 years

No Year Sales

1 2001-2002 6858

2 2002-2003 6185

3 2003-2004 6756

4 2004-2005 5091

5 2005-2006 5900

6 2006-2007 4900

7 2007-2008 2917

8 2008-2009 1605

9 2009-till 2605

Total number of 3 wheelers sold out till now is : 1,20,000 vehicles.

Competitors:-
 Bajaj auto ltd
 Piaggio auto
 Atul auto industry
 Sitarn auto industry
Dealers:-

STATE NUMBERS

Haryana 12

Punjab 10

Rajasthan 15
Uttar Pradesh 8

Dealers are given special incentives on achieving the more target and on selling more product.
Dealers are given special offers to keep a good relationship with them. FIBO provides all the
support both technically and in management level. But nowadays there are no high sales.
Special orders: sometimes FIBO receives special order from Travancore dewaswom board. FIBO
manufacture special purpose tippers for them.
Other activities:.

FINANCE DEPARTMENT
DEPARTMENTAL STRUCTURE

GENERAL MANAGER

ACCOUNT OFFICER ASSISTANT MANAGER (FINANCE)

ASSISTANT ACCOUNT
(FINANCE
OFFICER
CASHIER COMPUTEROPERATOR
ACCOUNTANT

INTERNAL
ASSISTANT ACCOUNTANT
AUDITOR

CLERICAL STAFF

Seven persons are enough to start a public limited company. a company is started by contributing
money. The capital of FIBO is contributed by Government of TRICHY when it started. The
initial investment was 4 cores when the company started. It was in loss till 1992.then a revival
package was allowed by BIFR.It was approached to banks to get money and to government for
grand. In 1994-95, it started making profit. It continued up to 2004-05. Its accumulated loss was
wiped out and it sent worth became positive. There was a surplus in the balance sheet. From
2005-06, it again came to loss and continues till now. This is because the production and sales is
not enough to meet the target.
Current status:
Companies accumulated loss – 15 core.
Companies net worth is negative.(net worth = asset – liability)
Production less than 300 vehicles a month will make liability. So, R&D is to be developed to get
it manage. They have to give quality product. Nowadays company suffers the lack of sufficient
amount of fund for the day to day operations. The government should provide more money to
meet working capital. There are scores of rupees as current liability.
Money is the life blood of any organization as it is required to purchase raw materials and
machines, to pay wages and salary etc. the financial statement of the company is prepared under
the convention accrual basis as a going concern. Complying with the accounting standards
prescribed under the company’s act 1986. Documents for original entry are prepared directly in
the computer and a copy is sent to the appropriate authority for further verification and approval.
If any entry is to be certified, it can only be done through an adjustment document. This ensures
security of documentation against any accidental errors or manifestation. The ultimate
responsibility of carrying out the finance functions lies with the top management. Thus a
department to organize the financial function should be under the direct control of the Board Of
Directors.

MAIN FUNCTIONS:
Cashier collects cash receipt. If any payment is taken place, a bank payment voucher is
prepared. Every voucher is prepared by the debit and credit system through the computer. When
transaction takes place, a sales invoice is prepared by the marketing department for the dealer.
When invoice is prepared, the computer database is used to create debit and credit and which is
sent to dealers. From sales list, a trial balance is prepared. When payment is taken place,
payment voucher is prepared. Every transaction is prepared by clerk. It is send to the finance
manager. Then the payment is given by the cahier.
  Cash receipt/payment
 Bank receipt
 Finalization.
 Capital structure
 Purchase.
 Sales
 Managing computer.
 Preparation of VSR
 Withdraw/receive/payment of cash.
 Position and filling of VRS.
 Settlement of tax, temporary salary, interest advance.
 Payment of retainer fee.
 Physical verification of cash.
 Verification/approval of all cash /bank receipt and payment vouchers.
BANK RECEIPTS/PAYMENTS
 Preparation of RT vouchers.
 Amount transfer vouchers.
 Writing of cherub.
 Generation bank books.
 Preparation of bank reconciliation statement.
 Verification of checklist of sales bills, stipend etc.
 Remittance of all recoveries made from salary.
 Settlement of canteen account etc.
Finalizations
 Analysis of ledger.
 Ratification of errors.
 Adjusting and clearing entries.
 Preparation of trial balance, P&L accountant & balance sheet.
 Assisting internal audit.
 Assisting statutory audit.
 Preparation of annual reports.
Capital structure
Capital structure is a major aspect of financial planning. The capital or funds come in the
form of long term and short term departments, preferences and equiy shares. The company has
no share holders other than loan from TRICHY government. The company’s other financial
support is only from the financial institution SBI. Debt-equity ratio of the company was 6.7:1 I
n2001-02, .44:1 in 2002-03, .38:1 in 2003-04.

Purchase
 Opening tenders
 Posting and filling FIBO
 Preparation of payment vouchers
 Analysis of supplier vouchers
 Analysis of supplier account.
Sales
 Arrange follow-up invoice.
 Preparation of sales tax return.
 Payment of incentives.
 Warranty claim statement.
 Attending sales tax hearing.
 Verification of account.
Managing computer
 Salary bill processing.
 Arrears calculations.
 Keeping the accounts database.
 Calculating the employee benefits, credits, debts etc.
 Preparing the documents of transactions.
 Maintenance of computer system is done by finance department.
PLANNING DEPARTMENT
DEPARTMENT STRUCTURE

ASSISTANT MANAGER

JUNIOR ENGINEER

OFFICER

Planning department is under the control of GM(production). This is the base of all production,
marketing, storing and all other managerial functions of the management. All the major functions
are performed within the framework of plans done by the planning department.
This department mainly concentrating on production, marketing, storing and all other
managerial functions of the management. It is mainly concentrating on scales planning. But also
maintenance the material planning and production planning. They are taking the decision on
market targeting, market mix, priority of raw materials (A, B, C, D, E ) etc. Based on the
information from the marketing department, they produce monthly target. Then the target will
send to the concerned department. If any faults happen, then make correction after discussing
with the GM.
Functions
In FIBO planning takes in 3 phases.
 Planning phase
 Executing phase
 Control phase.
This department gives the information about the allocation and utilization of machines and
materials required for production. Incoming raw materials are delivered to the quality assurance
department after that collect in store and then distribution. It also does the controlling function.
The day to day works are sent to this department to check whether the production is in
accordance with the planned level or not.
RESEARCH & DEVELOPMENT DEPARTMENT

MANAGER

Sr. Engineer

Jr. Engineer

This department designs the model of products and provides information about various
items, which the company can produce. This department is under the control of the marketing
manager.
In FIBO, R&D department provides information about the various products which can be
provided by the company.
Design section:
Based on the market study done by the marketing department and competitors, the marketing
section decides the design for the product.
Italian design is the basic design adopted for the Indian 3 wheeler industry. In FIBO, they
designed the petrol model in 1984. In 1985 they designed the diesel engines vehicles. FIBO
designed the tipper, bottle carrier, jumbo, 4 stroke petrol engine vehicles etc.
FIBO product engineering section has the computerized design system and testing
equipment to ensure the international standards. Experienced engineers have transformed the
basic Italian model.
The latest trends in production are to provide fuel efficient and eco-friendly vehicles. Company
is introducing engines of bharat stage-3.
Major achievements
 Introduced diesel engine 3 wheeler in the market for the first time.
 Introduced 6 seater diesel engine 3 wheelers.
 Development of aerodynamic design.
 Introduced TRIMO which is a 3 wheeler micro car with round steering. It had good
market potential. But the production became unsuccessful due to financial, legal and red
tape constraints.
 Design, development and introduction of TRICHY 360 pick-up van with hydraulic
system.
 Introduction of TRICHY MX400 chassis.

R&D IN WHEELER FUNCTIONAL AREA

 Improving riding control
 Aerodynamic body design.
 Re-design seating capacity.
 Development of AF series of gearbox, resulting in the increase of maximum speed from 4
kmph to 50 kmph.
 Fixation of quality grade for present gear components.
 Analysis of low clutch life period and introducing necessary modifications.
 Research and analysis to reduce rolling friction of existing models.
 Research for the modification of present engine to upgrade to next bharat stage level.

FUTURE PLANS:
 Improve the quality and reliability of products.
 Design and development of high-tech 4S petrol engine.
 Improve the quality of the components used for production.
 Improve the quality of sophisticated precision components for space application of
VSSC.
 Plan to develop hybrid electric vehicle as a combined project with KELTRON.
 PRODUCTION DEPARTMENT

PLANT PROCESS

Supplies raw materials

( through suppliers

Stores raw materials

Fabrication Machine shop

Paint department

Quality inspection Quality inspection

Sub assembly

Final assembly

Quality inspection

Stores department

PROCESS:
In the first step, the materials are purchased from the supplier and sent to the manufacturing
process. The manufacturing is done according to the specifications given by the product design
section. The marketing department will be involved in the work of collecting the design
specifications from the market. Once these specifications are collected from the market, the
design department will design the product and send it to the approval of the purchase department.
Once the purchase department approves the design, then the planning department prepares the
production plan. Using this plan, the materials are taken from the stores department and products
are made by the production department. Each and every step of production process will undergo
a quality check. The finished product is also undergone a quality check and is sent to the stores
to hand over to the dealers.
The entire work flow is divided into 3 major processes
1) MOP(management oriented process)
2) COP(customer oriented process)
3) SOP(support oriented process)
(1)MOP deals with the market representative (MR) and IQA. In order to achieve the targeted
profit, (2) required steps are taken by them. It is concerned with providing good of good quality
at a competitive price. For this purpose the quality assurance department is established.
(3)COP deals with making the customer satisfied by providing all the services they require.
Various departments are covered under COP. They are marketing, designing, planning etc.
SOP is concerned with providing necessary services that supports the MOP and COP. SOP do
also play an important role in the organization. Unless SOP is not working at 100% efficiency, it
is not possible to provide quality goods on time. SOP covers various departments like – stores,
HRD, QA etc.
ABOUT THE DEPARTMENT:
Production department is the main department in which certain ideas and technologies are
adopted for purchasing the quality products. The employee’s crew includes industries at
engineers, machine operators, plant maintenance etc. The production department is mainly
classified into 5 sub Units. Each sub units have separate manager
FIBO has the capacity of producing 600 units per month. The production department is mainly
concerned with manufacturing of various parts of the vehicle monthly production is fixed on the
basis of target demanded in the market available of raw materials and the financial capacity of
the company.
In earlier days, production of FIBO in some month was 750-800, now. It is around 300. This is
because of some financial crisis and some sales promotion techniques. There is no separate using
for promoting in advertisement and the authorities do not take any such promotional activities.
Non- advertisement is one of the failures of the competition among others such as piaggio, Ape,
Bajaj Auto etc.
The sub units under the production department are
 Machine shop
 Heat treatment
 Tool Room
 Fabrication
 Assembly
 Paint
FIBO receiving the projects from the organization in sub contract base such as VSSC,
KELTRON etc.
Objectives:-
o Minimize the rejection rate
o Reduce the network of material
o Improving the utilization of material
o Rejection of material if nay to the store.
o Undergoing machining operations of accepts material
o Ensure the quality of the products.
Machine Shop:-
DEPARTMENT STRUCTURE

GENERAL MANAGER

ASSISTANTGENERAL
MANAGER

SENIOR ENGINEER

ENGINEER

WORKMAN
Machine shop producers the sub pairs which are required for the production of the finished
goods. Tool room is a part of this. The maintenance of the tool room is done at tool room for
production. As per the planned schedule. The store issue the material required for the production
in a weekly manner, Gear selector, steering road etc are produced in the plant. The shop is under
the control of the Sr. Engineer .
Machines in the machine shop
o Capston lathe CD1
o Capston lathe CD 2
o High speed lathe H22
o Turrent lathe
o Enterprise centre lathe
o Copying lathe hidustan.
o Facing & catering machine.
o CVC turning lathe (weiler)
o CVC turning lathe
o 2D capston lathe New 2D2
o Redial drilling RD 50.
o Radial drilling RD6
o Radial drilling – Balitiboi RD 25
o Drilling machine – baltiboi RD-32
o Drilling machine new Baltiboi RD322
o Column drilling machine New CD 402
o Accumax pillar drill
o Bench drill.
o Automatic tapping machine.
o HMT Horizontal milling machine (FN1 EH1)
o HMT Horizontal milling machine (FN2 EH2)
o Horizontal milling.(BFW)
 o Universal milling
o HMT Vertical milling (FN2V1)
o HMT Vertical milling new (FN2V2)
o Milling machine(MTR)
o HMT Horizontal cylindrical grinder(K1300)
o HMT cylindrical grinder(K1300-300p)
o Cylindrical grinder(K1300)
o AWH grinder(GT)
o New Spin Surface GH (GVS30)
o Surface grinder pranga
o Internal grinder(GIF -80)
o Gear Shaper Old
o Gear shaper HMT New
o Gear Hobbing Cutter
o HMT Broaching Machine
o HMT Vertical Milling VTC
o Fine Boaring Machine 734
o Fine Boaring Machine 375
o Honing Machine
o VMB-8
o Rolling Machine
HEAT TREATMENT:-
Here the components are heat treatment this station includes.
 Muffler furnace
 Gas car building furnace
 Induction hardening etc.
These are under high temperature. Pallet trucks are used to transport the material since the
temperature is very high. The tempered and hardened units are tested by the quality control unit
DEPARTMENT STRUCTURE

JUNIOR ENGINEER
 WORKMAN

Tool Room:-
The maintenance of tool is done in the tool room department. The consumable tools requires
frequent maintenance. FIBO also receive products from organization such as VSSC, KELTRON
etc. These projects include of certain components and are carried out here
DEPARTMENT STRUCTURE

SENIOR ENGINEER

WORKMAN

Fabrication:-

ENGINEER

JUNIOR ENGINEER

WORKMAN
It comes under the asst. manager engineer is the head. The main functions are welding cutting
etc. Some machines are used;-
 Bending machine
 Pressing machine
 Welding machine
 Shearing machine
 Lythe enterprises
 Nimbling machine
160 ton is the capacity pressure
The initial worries like bending , pressing, welding etc are doing here after that they will forward
to the other sections like machine shop, assembly etc. The fabricated body parts are then
thoroughly checked by the QA department.

Welding Process
There are 4 type of welding.
 Mig welding (using Metal + CO2)
 Arc welding( using rads)
 Spot welding (carbide point)
 Gas welding- this method is used to weld the diesel tank or petrol tank.
Assembly:-

SENIOR ENGINEER

JUNIOR ENGINEER

WORKMAN

Production manager is the head of this department. Gear assembly, engine assembly vehicle
assembly, handle assembly etc are the main fictions. It holds sub assembly, Doom Assembly etc.
Some types of assembles are-
 Rear break plate assembly
 Tire assembly
 Rear axle assembly
 Differential assembly
 Hub assembly
 Chassis assembly
 Handle bar assembly
 Propeller shaft assembly
  Fork assembly
 Front hub assembly
 Gear box assembly
 Electrical assembly
 Diesel assembly

Line Assembly:-
Line assembly is one of the main assembly sections. There are main two stages in line assembly.
Stage A: Join chassis & differential (rear axle assembly). It includes the assembling of foor
break, hand break, propeller shaft. The front fork is also fixed.
Stage B: differential oil is filled. Back and front tires are fitted in this section. The handle bar is
also fixed.
From this department, it goes to the doom section to assemble doom shield, glass, diesel tank and
from there, it goes to Engine assembly.
Engine Assembly:-
Greeves GL 400 engine is used to manufacture 3 wheeler. It is a single cylinder diesel engine.
It’s a 4 stroke engine (low pollution, more mileage)
Specifications of engine – 400cc, 3600rpm at maximum and 1000 rpm at minimum, HP-7.5, air
cooling system.multi plate clutch,
Engine price – around Rs. 24,000
Engine oils: - 20-40 grade (1.25)
SAE 90 grade(1.45 litres)
140 grade filer oil , this is for filler plug at the rear part
When the grade of the oil increases, its viscosity decreases.
Filering devices: there are 3 filtering processes. They are -Air filter, diesel filter, and Oil filter.
Gear Box section
Gear box section manufactures the gear. Torque and speed of the engine is determined by
the gearbox. Engine’s uncontrolled power is controlled by gearbox. The teeth of gear box needs
very sharp attention in its manufacturing process. Small teeth have high regulation and large
teeth have low regulation.

Paint shop-

JUNIOR ENGINEER

WORKMAN

Junior engineer is the head of this department. The painting works of the finished goods are
done here, before the painting the products are sending to the pre-treatment section. It is
called as tank process.
It is done to avoid the resting. A crane is used for cleaning. A pre-treatment is done before
painting. Small components are spray painted using conveyer belt. After that the components
are sending to the locator for drying.
Two Types
 Spray Painting
 Dip Painting
QUALITY ASSURANCE DEPARTMENT
The main aspect of these departments to check and maintain the quality of finished as well as
incoming materials. The finished goods go through three stages of inspection. They are:-
 Vehicles inspection
 Test running
 Final inspection

ASSISTANT MANAGER

SUPERINTENDENT

WORKMEN

OBJECTIVES:-
 Cost reduction
 Quality- checking
 Providing all suggestions
 Wastage control
 Higher productivity
 Reduce defects of implant items by10%
 Create a cultural among the employees of the company towards” total quality” concepts
and higher productivity through planned training for all employees
 Direct and prevent non conformance defects as early as possible and climate them
through appropriate change to the quality management system.
 To reduce the percentage of vehicle with brake pedal problem. 30% to 5%
 To reduce the defects of following components in the production department to less them
10%
Differential Cage
Tramission Staff
Differential Bush
Crown wheel pinior
FIBO is an ISO 9001-2000 affiliated company.
QUALITY POLICY:-
The management and employees of FIBO are committed to development, manufacture,
marketing & service three wheelers, meeting customer needs through a proves of continual
improvement of its quality management system.
FUNCTIONS:-
In order to maintain the quality policy and objectives the incoming materials and in plant
materials and finished goods undergo several inspections in different stages. Chemical lab is also
plays a major are in Quality Assurance Department.
The critical activities:-
 Incoming inspection
 In process inspection
 Fabrication
 Finished vehicle calibration
 Calibration.
Incoming inspection
 Receive provisional FIBO from stores department.
 Conduct inspection as per QAD plan.
 Rejected items with GRM given to stores
 Accepted items with FIBO are given to stores department and provide tags in process
inspection
 Conduct spot inspection
 Conduct stage inspection
 After machine operation are inspected
 Defective items are given to final inspector after doing work
 Accepted items are given to sub-store
 Defective items are given to sub store after rework.
Fabrication
 Spot inspection: done at each step of production. It is done by setting an approved model
each material and compared the original with it
 Stage inspection: Done to check whether any operation is missed or is there any errors in
operation
 Final inspection: there final products are inspected for quality. The compatibility of that
products is also checked
Finished vehicle calibration
 Vehicle testing of the accepted vehicles
 Vehicles testing after rework
 Transferring accepted vehicles to the finished goods store
Calibration
 In house calibration in their standard room
 Invite quotations from external agencies to calibrate
 Prepare comparative study and take decision
 Give work to external agency
 Calibrated
 Place stickers on the calibrated items
The finished goods are passes through four another stages to ensure quality
 Vehicles inspection
 Testing running
 Final inspection
 Inspection before dispatch
STORES DEPARTMENT
The success of the business largely depends up on efficient and effective stores. Stores are the
place where the raw materials. Semi finished goods and finished goods are kept after the
production. Stores department comes under GM (production). FIBO follows ABC analysis for
inventory storage.
According to the nature of items stores are kept:-

Store I: hardware items, painting items, rubber parts, gear items etc.
Store II: Bearing components, location assembly battery
Store III: Casting, forging, sheet metal items.
Store IV: Raw materials, pipe wool.

ASSISTANT MANAGER

JUNIOR TRADESMAN JUNIOR TRADESMAN

WORKMAN

It follows ABC analysis for the inventory

 Inventory Control:
A. Items will store only before one week
B. Items will store only before one month
C. Items will store before 6 month
A- Required 70% of the total price, B- items required the 20% and C- items required to 10%
The main items is store are , hardware items, rubber parts, gear items, sheet metal items, raw
materials, pipe wood etc
Classification & codifications:-
Materials stored are classified according to their nature& usage. All the items are given part no.
as cod and having tag.
In addition to then\ main store there is a sub unit also. The store keepers record the data of
materials on the bin card and adjust the store balance. The entire information is entered in to the
computerized store ledger system called card-x, which give systematic and accurate record.
Verification is done at every end of the final year. Actual stock is compare with the stock shown
the ledger. Store keeper is the concerned authority is responsible for any difference in stock
level.
Functions:-
 Receive the raw material and store it
 Dispatch of rejected raw materials
 Rejected material will be returned to party within 45 days after clearing provision
FIBO.
 Reduce the stock o non-moving item
 Control the inventory as the level fixed for maximum and minimum stock
 Improve the storage facility for bearing battering rear back plate assembly tool items
 Preparing documents for central excise department.
Critical Activities:-
 Receiving of raw materials and storage of item
 Issuing of materials
 Dispatch of rejected materials
 Receiving, dispatch and storage of finished goods
 Disposal of scraps
 Periodic stock verifications
 Preparing of documents for central department
 MAINTENANCE DEPARTMENT
Department structure

ENGINEER

JUNIOR ENGINEER

WORKER

Maintenance department functions under the control of manager (production). This department
undertakes the work of electrical, mechanical, and civil maintenance. The maintenance
procedure is done as team work of supervisors and technicians. Maintenance work, which can’t
be settled by the department, is done by licensed contractors and outside exports.
Functions:-
There are mainly two types of maintenance are conducted at FIBO
 Preventive Maintenance
 Breakdown Maintenance
Preventive maintenance:-
It is carries out to increase the lifespan of the machine. It is classified as daily, weekly, quarterly
and yearly maintenance.
Initial activities in preventive maintenance includes
 Prepare schedule for preventive maintence
 Check availability of machines for planned data
 If the machine is not available for planned data reschedule it.
 Check availability of spares
 Place indent with purchase department
 Stores spares in sub store
 Allocate technicians
 Do the preventive maintenance
 Check the completeness of preventive Maintenance
  Prepare the monthly report
Break down maintenance:-
It is carried out at the time of breakdown of machines, when the breakdown of machines is
informed by the concerned trade man. If a number of machines are breakdown at a same time
then the machines are prioritized on the basis of loss of breakdown per hour
Activities in breakdown maintenance
 Check the nature of complaints whether the complaints is mechanical. Civil or electrical
 Check minimum stock level spares
 Check spare parts procurement through purchase department
 Allocate the technicians for repair work
 If the maintenance department can’t rectify it obtain the service of engineers from others
 Complete maintains and repair work handover the machine

SERVICE & SPARES DEPARTMENT

Its function is to provide quality services to the customer. It I under the control of marketing
department.
Functions:
 Collect feedback report from marketing department about the products.
 Collecting the field complaints.
 Pre-delivery inspection.
 Framing customer satisfaction.
The company providing free service campaigns along with dealers once in 6 months or annually.
Coupon service: It is done as an after sales service this service is based on particular period or
kilometers whichever is earlier. The coupons are received from the customer and send the
accounts department and credit note is prepared.
The service based on service period is as follows:

Distance Period(within days) Amount(Rs.)

500 30 75

1000 60 75
 2000 90 100

3500 120 100

4500 150 100

5250 180 100

WARRANTY SETTLEMENT
A warranty settlement is given to the vehicle for 6 month from the date of purchase or till
6000km, whichever is earlier. Warranty is not valid for the rubber parts. In case of damages,
dealer will fill up warranty service claims. Maintaining chassis number, engine number and the
date of sale will send to the company. FIBO identifies the batch number and accept it if the case
is genuine.
Spare parts maintenance
The department has a spare parts store. The sale of spare is through the dealers. The dealers will
be having a store of fast moving spares.