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The opportunity we had with DIVGI TORQ TRANFER SYSTEM PVT. LTD
was great chance for learning and professional development. Therefore, We
consider myself as a very lucky individual as we was provided with opportunity to
be a part of it .we are also grateful for having a chance to meet so many wonderful
people professional who led me through this internship period.
And we also like to thank all workers of the company, our friends and last but not
the least, our parents for their support during the course of internship.
Sincerely,
PROJECT
ASSOCIATES
DIVGI INDUSTRIES PVT LTD, SIRSI
CHAPTER SCHEME
Chapter-1
1. Introduction
2. Statement of the problem
3. Review of literature
4. Objective of the study
5. Methodology
a) Source of primary data
b) Source of secondary data
c) Study area
d) Sampling for the study
e) Period of study
Chapter-2
Chapter-3
1. Company profile
2. Product profile
Chapter-4
Departmental study
1. Purchase department
2. Stores department
3. Manufacturing department
4. Human resource department
5. Quality department
6. Computer aided design department
7. Finance department
8. Maintenance department
Chapter-5
1. Summary
2. Findings
3. problems
4. Suggestions
5. Conclusion
6. Bibliography
Chapter-1
INTRODUCTION
1.1 ABOUT COMPANY
The history of the Group dates back to the early years of the 1960s when the
institution started life as a small scale manufacturing enterprise in the economic
world of independent India. In 1964, Remora, ‘RN’, Divgi’s relentless serial
entrepreneurship along with engineer-brother Bhaskar (BN) saw the birth of Divgi
Metal wares Pvt. Ltd. (DMPL), for the manufacture of gears and screw machined
parts.Since 1995, group company Divgi-TTS, with its workforce of 225+
employees, has been manufacturing a variety of specialized and highly engineered
solutions – Transfer Cases, Torque Couplers & Auto-Locking Hubs (ALH),
essential components for 4WD/ AWD vehicles, Synchronisers for
Transmissions (gearboxes) and components for the above products. Having
acquired the complete capability to design, develop, customize, manufacture,
supply and support, Divgi-TTS has also been providing turnkey solutions across
automotive industries; utility vehicles, agriculture, commercial, industrial and
construction equipment from its three facilities at Bhosari in Pune, Shivare in Pune
Taluka and Sirsi, Karnataka.
Divgi-TTS has an enviable customer base that included India’s and the world’s
leading OEMs; Tata Motors, Mahindra and Mahindra, Ford, Toyota and Nissan
with other customers in Japan, Korea, China, Thailand, UK, and the USA.
VISION:
To be recognized the as a world class Indian in automotive drive train components & systems.
MISSION:
To help our people and customer continuously innovate and axle in drive trains components at
world class.
CHAPTER -2
DETAILS OF DEPARTMENT
Managing director
Assistant manager
Assis
QA head
tanc
Cell supervisor e
Assistance
PURCHASE DEPARTMENT:
Functions:
1. Easy availability
2. Prompt delivery
3. Competitive price
4. Consistent quality.
STORES DEPARTMENT:
Managing director
MR
Stores in charge
Assistants
a. Billable items
b. Non- billable items
a. Billable items
Billable items are those, which are procured from outside sources.
They include machine spares, gear parts, tool – holders, cutting tools,
grinding mills and consumables.
1. Forgings
2. Consumables
FORGINGS:
Measure the forging weight as per sampling page. Enter into GRR.
Issue bin card and ensure bin cards are attached to the respective
bins.
Ensure the forgings are properly stored in bins. If any empty bins
are not available, place the forgings on card board sheets, cover
plastic and attached the bin card properly.
When incoming forgings are released for urgent production, they are
positively identified and recorded to permit recall in the event of
nonconformance to specified requirements.
CONSUMABLES:
Machinery spares are stored in steel cupboards under lock and key
with proper identification.
MANUFACTURING DEPARTMENT:
Raw materials
DISPATCH TO
DWPL SIRSI
CONSUMABLES
SUBMIT REGISTRATION
LETTER TO THE PURCHASE
RECEIVE MATERIAL TO BE DEPT
KEPT IN DENTIFIED PLACE
WITH PROPER PRESERVATION
TURNING:
ROUGH TURNING:
FINISH TURNING:
BROUCHING:
HOBBING:
SHAVING:
MILLING:
1. To take the work in progress statement for production material with in the
plant
2. To negotiate and finalize rate for scrap and to take approval from operation.
3. Prepare dispatch plan/ schedules based on scheduled requirements.
4. Organizing dispatch co ordination with individual engineer for component
for final inspection and further dispatch.
OBJECTIVES
Cleanliness of Premises:
HOD (HR) ensures that premises are neat & clean. Any material
available is neatly placed & duly identified. Any repairs to building &
infrastructure required to fulfill product & manufacturing process needs
are timely carried out. Any material is promptly removed. Every month,
any deterioration in material is brought to notice of CEO for further
actions.
Functions:
Employee training:
General training:
Further training:
1. Need based.
2. Management view regarding further requirement.
Management decisions:
While recruitment for the post of operator, cleaner, driver, and his
experience, age and physical fitness for the post is considered.
Management representative:
Customer representative:
Table 4.1
EMPLOYES
1 Staff 07 07.60
3 Operator 68 73.92
4 Helper 06 06.53
5 Total 92 100.00
Total
80 73.92
60
40
20 6.53 Total
7.6 11.95
0
helper
operator
staff
technical
staff
Interpretation:-
Table 4.2
LABOUR CLASSIFICATION
Total 68
Total
60 54.42
50
40
29.41
30
20 Total
16.17
10
0
semi-skilled Total
skilled
un skilled
Interpretation:-
Table 4.3
SALARY ALLOWNCE
Table 4.4
Permanent 35 38.04
Trainees 49 53.26
TOTAL 92 100.00
The world's top car makers turn to India for the nuts and bolts of their vehicles.
Riding this success, and capitalizing on the spiraling demand of domestic auto
companies, the Indian automobile components industry has emerged as one of
India's fastest growing manufacturing sectors, and a globally competitive one. A
number of them source critical components from India, with engine parts making
up nearly a third of all exports:
Electrical Parts
Equipments
11%
20% 10% Engine Parts
13%
13% 33%
Suspension & Braking Parts
Major Players
Toyota Kirloskar
Bosch TVS Motors
Motor Ltd
Exports: The Exports of auto components grew to USD 5.2 billion from USD 3.4
billion in 2009-10. Europe accounted for 36% of exports followed by Asia and
North America at 28% and 23% respectively. Although the proportion of exports
to Europe declined from 40% last year to 36%, however in absolute terms the
exports grew by 46%. Exports to North America and Asia grew by 65% and 48%
respectively. With exports to North America, Europe Asia and other parts of the
world are improving, a full recovery of exports are expected to gain strength in
2011-12.
Imports: With growth in the domestic market, imports of auto components also
grew by 30% to USD 8.5 billion from USD 6.5 billion in 2009-10; almost 85% of
the imports were accounted for by the OEMs, the rest 15% by the aftermarket.
Asia and Europe contributed to over 56% and over 35% of the imports
respectively. Within Asia, China, South Korea and Thailand contributed to the
maximum imports to India while from Europe the key contributors were Germany,
Italy and Czech Republic. The quantum of imports has also increased due to
several FTAs and other trade agreements signed by the Government.
PRODUCT PROFILE
The company also manufactures the spare components required by a transfer case.
The raw-materials required to manufacture these components are procured from
Bonsai, Pune.
Transfer Case:
Made up of steel.
Shafts:
Front Adaptor:
Gear:
Transfer Case:
The transfer case receives power from the transmission and sends it to both the
front and rear axles. This can be done with gears, hydraulics, or chain drive. On
some vehicles, such as four-wheel-drive trucks or vehicles intended for off-road
use, this feature is controlled by the driver. The driver can put the transfer case into
either "two-wheel-drive" or "four-wheel-drive" mode. This is sometimes
accomplished by means of a shifter, similar to that in a manual transmission. On
some vehicles this may be electronically operated by a switch instead. Some
vehicles, such as all-wheel-drive sports cars, have transfer cases that are not
selectable. Such a transfer case is permanently "locked" into all-wheel-drive mode.
Transfer cases that are designed to allow for normal road use synchronize the
difference between the rotation of the front and rear wheels,[1] in much the same
way the differential acts on a given axle. This is necessary because the front and
rear tires never turn at the same speed. Different rates of tire rotation are generally
due to different tire diameters (since front and rear tires inevitably wear at different
rates) and different gear ratios in the front and rear differentials since
manufacturers will often have a slightly lower ratio in the front vs. the rear to help
with control (such as a 3.55:1 in the rear differential and a 3.54:1 in the front
differential). If the transfer case did not make up the difference between the two
different rates of rotation, binding would occur and the transfer case could become
damaged. This is also why a transfer case that is not designed for on-road use will
cause problems with driveline windup if driven on dry pavement.
Shafts:
The input shaft brings the engine drive into the gearbox system and when a gear is
engaged it withstands the torque generated and transmitted to the output shaft.
Steel forging for input shafts allows the variety of shapes and fatigue resistance
needed to ensure reliable transmission systems.
Yokes:
Front Adaptor:
Gear:
Chapter:3
Ring Gear:
Shaping
Hobbing
Honing
Deburring
Induction Hardenning
Tempering
No of Machine used
1. Shaping Machine
2. Hobbing machine
3. Honning Machine
4. Induction Hardenning machine
5. Tempering machine
D.B.B
Roundness
Runout
Comparator
Runout Gauge
SHAFT CELL
In this cell, manufacturing shaft which is used in the transfer case. In the
shaft cell, we saw different types machines, those are CNC machines, VM
machine, deep hole drilling machine, conventional lathe, thread rolling machine
etc…..
Turning
Step turning
Spline rolling
Thread rolling
Drilling
MEASURING INSTRUMENT
Comparator
Air plug gauge
Micrometer
FLANGE CELL
In this cell, different kinds of flanges are manufacturing using CNC machines.
Here some of those are companion flange 006, companion flange 030 etc…….
The proper coolants are always used for reducing the tool wear because in the
cutting zone, high temperature is producing.
FDG CELL
In this cell, manufacturing shaft which is used in the transfer case. In the shaft
cell, we saw different types machines, those are
CNC machine
VMC machine
deep hole drilling machine
FDG Hobbing machine
Operations
Finish turning
Drilling
Chamfering
Tapping
Hobbing
MEASURING PARAMETERS
C bore diameter
Outer diameter
DOP middle,stem
MEASURING INSTRUMENT
Comparator
Air plug gauge
Micrometer
Total
8.7
INTERPRETATION:-
This chart shows that no. Of labours working in DIPL. The DIPL is
recruiting the workers on the basis of contract base. This also provides on
the job training to the trainees.
Table 4.5
LEAVE TABLE
Interpretation:-
This table indicates that the leave of the workers in DIPL. Under this table the
employees earned 15 days of leave per year. Causal leaves are 10 days per year,
sick leave are 5 days per year.
Performance Appraisal
Fringe benefits
FINANCE DEPARTMENT:
MAIN SOURCE
1. Job work
2. Sale of scrap
Functions:
Every year in 1st week of January each department has to provide their
debtors of budget to account department. Finance department put up all department
annual budgets to managing directors for review and final approval is taken.
1. Training
2. Housekeeping
3. Vehicle maintenance
4. Vehicle fuel
5. Staff welfare
6. Telecommunication
7. Other expenses
Authorized capital
MAINTAINANCE DEPARTMENT:
Assistant manager
Engineer -1 Engineer-2
Supervisor Supervisor
Filter contract
a. Breakdown Maintenance
b. Preventive Maintenance
c. Predictive Maintenance
Manager
MR
Head–quality system
Functions:
TS-16949 is a license for doing business with the customers and implementation
of TS-16949 develops a common understating of quality related expectations,
methods and practices with the customers. The common understanding and
assurance it brings leads to:
1. Defect prevention
2. Reduction in variation and waste in our supply chain.
a) ISO-9001
b) ISO-9002
c) ISO-9003
d) ISO-9004
After 1994 a new system was incorporated QS-9000. It consists of two sections.
QS- 9000 is basically formed the big 3’s viz., General Motors, Chrysler,
Ford and other manufactures.
Later in 2000 they formed TS-16949 and the latest updating is of version TS-
16949, 2002 the fund
Metals for this system is ISO- 9001, 2000 and ISO-9004, 2000 metals for this
system is ISO- 9001, 2000 and ISO-9004, 2000
In DIPL sirsi there is a separate selection for computer aided design(CAD) here the
computer is use to designing and manufacture a product where product
specification are refined by continuous improvement in successive stage based on
designer’s experience, computers, sketches and drawings.
Top Management:
The BOARD of the company is Manager for the quality management system. He
is responsible for the over all growth of the company, where as day operation are
looked upon by plant head.
DIPL has adopted Line & Staff organizational structure that offers
individual the opportunity to meaningfully learn & participate across diverse
business processes.
FUNCTIONS OF A MANAGEMENT
PLANNING
Engineering department is responsible for designing the product / part as per the
customer requirement. The customer requirements are translated into the product
realization plan through APQP (Advanced Product Quality Planning) steps.
Product leader convinces multi disciplinary actions consisting of various
business processes who act as a board of decisions for design activity planning.
This business process ensures that company confirms to all the agreed customer
requirements.
ORGANIZING
Organization Purpose:
STAFFING
DIRECTING
CO-ORDINATING
CONTROLLING
In order to ensure that the work is done as per the plans lay down.
Controlling is very much important. Controlling functions of management involves
three elements.
CHAPTER-V
SUMMARY
Industrial organization is the field of economics that builds on the theory of the
firm in examining the structure of, and boundaries between, firms and markets.
The subject has been described as concerned with markets that "cannot easily be
analyzed using the standard textbook competitive model." Industrial organization
adds to the perfectly competitive model real-world frictions such as transaction
costs, limited information, and barriers to entry of new firms that may be
associated with imperfect competition. It analyzes determinants of firm and market
organization and behavior as between competition and monopoly, including from
government actions.
Sources of Data:
1. Primary Data
2. Secondary Data
Primary Data
The primary data are those which are collected fresh for the first time and
thus happen to be original in character. The primary data collection involves the
collecting of information for the first time by observation, experimentation, and
questionnaire and through interview schedule in the original form by the
researcher himself or his nominees.
Plan of action:
The primary data was collected through discussion with the manager using
the interview schedule. This data was obtained to study the latest procedures
relating to working capital management and cash management system followed
by the company.
Secondary Data
The secondary data are those which have been collected by some other and
which have been processed. Generally speaking secondary data are information,
which have been previously collected by some organization to satisfy its own
need. But the department under reference for an entirely different reason is using
it.
It is very useful to the entrepreneur to under stand the nature and working of
organization and management and also to adopt innovative methods. By that to
reduce cost of production and to also to improve the quality of the product and to
get maximum benefit.
FINDINGS
SUGGESTION
1. DIPL has to concentrate on available market, demand for automobile
component and should not limit its operation only for DWPL.
2. DIPL has to implement more upgraded technologies in its operation to
produce new varieties of auto spares and to increase existing production.
SWOT ANALYSIS
STRENGTHS OF DIPL:
DIPL provides total transparency in dealing with its customers and are
committed to enhance their capabilities, by providing them with latest
technological advantage and utilizing maximum capacity to meet their
requirements.
They process the knowledge and the technology that is relevant to the
products being designed, manufactured and supplied.
OPPORTUNITIES AT DIPL:
1. There is a scope for making final products instead of component parts and
make it available for profit & loss.
2. There is an opportunity for making future expansion in business by going
for joint ventures & tie-ups with other company’s also.
3. The company provides various employment opportunities to new
graduates & local people of Sirsi.
4. By adopting EMS – ISO 14001, the next aim of the company is to
“Deming Award” of certified by Japanese, which is given for quality
management systems.
5. The vast area of land & space of building can be effectively used for
future expansions.
THREATS OF DIPL:
1. DIPL, Sirsi mainly depends on the parent company i.e. DWPL, Sirsi and
Pune. The parent may change its base of manufacturing for marketing its
products outside India.
2. The major raw material used in the production is steel, presently there is a
huge demand for steel & there is rise in the price of steel for last few years
in India & all over the world. The rise in the input cost will reduce the
margin of the company.
3. There is always a risk of change in Government Policies.
CONCLUSION
1. In present area of business, the organization lends to satisfy the needs of the
customer more effectively than competitors in the way to achieve high
market share and long life.
2. DIPL wants to become an excellence in manufacturing of auto plant ant at
the same time if wants to reach the stages what it is dreaming of for which
the co-ordination from employees and management is necessary.
BIBLIOGRAPHY
BOOKS:-
WEBSITE:-
www.google.com
www.wikipedia.com
www.divgi-warner.com