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AIRTECH saw its beginning in the year 1980 in Dharwad with a vision of team
of qualified engineers who came together to serve the technical needs of the market. Thus
they established a manufacturing unit at Dharwad that began its manufacture with
CONCENTRIC COVENTRY CHUCKS as its first product. The energizing power of the
promoters saw new chucks and tools for work-holding being added regularly to the range.
This encompassed practically every work holding need. They have also helped in gain of
technical competence that provided cost effective customized solutions to some of the
most complex work holding environment. They have also developed a range of matching
cylinders.
They have specially designed their chucks, cylinders and work holding solutions for
Indian working condition to easily match some of the best known global manufacturers.
The industries who have opted for their products accepted the fact of reliability.
The stores department carry out the activity of storing the raw materials as and when it
arrives. When the raw-materials is received from suppliers the sum is tallied with the
delivery challen / invoice / cash memos / credit memos placing slips etc.
The quality assurance department checks the quality of the raw materials, semi finished
product and finished product. It verifies the quality at each and every stage right from the
purchase till the delivery of the product.
The production plant is big and clean in which workers can work out of dust and foul
without any problem. In this department all the products of different dimensions are
produced and for specific batch members specific dimension products are said to be
produced.
The marketing department regularly improvise in their designs, cut the costs to keep their
customers satisfied.
The main purpose of conducting this study is to fulfill the BBA degree apart from our
curriculum activity in the name of In-Plant training program in an Organization.
More importantly to conduct this study is to get practical knowledge at work place and
utilize our theoretical aspects in the practical problems. It is important to utilize day-to-day
knowledge for the problems that a raised in the organizations and give the decision ideas by
analyzing the problems.
3. To identify the problems in the organization and analyze the problems and
give solutions.
job in future.
works in units and prepare them to make the suggestions to develop the
unit.
Indian economy has been generating growth and outcome since many years.2008-
09 was yet another landmark year for the Indian economy and the industry, generating a
great deal of optimistic growth and promising outcome. The year was marked by 6.2%
GDP growth-earning the accolade of being one amongst the fastest growing countries in
the world.
For the Indian machine tool industry, 2008 was the year of smooth sailing, with
increased business opportunities, as a result of the demand surge from the Indian and
overseas markets. Metal working machine tool output of the Indian industry worth Rs
16,797 million, registered a growth of 34% in Jan-Dec 2008. Much of the growth in
India’s metal working machine tools came about because of enhanced requirements from
the automotive sector, the auto ancillary industry, defense, railways and small-scale
industry units.
With growth and business optimism on the swell in the Indian economy and the
industry, the year 2008 is expected to result in continuing heightened orders for the home
machine tool industry.
Metal cutting segment continue to account for 68% of the total output of the
machine tools in India. In 2008, metal cutting machine tool output worth Rs 14,780
million, led a growth of 32.8%.
Turning centre’s recorded the largest production in the industry during Jan-Dec
06, with a share of 30% in the total machine tool output. Turning centre’s together with
machining centre’s and grinding centre’s, accounted for nearly 3 quarters of the total
metal cutting produce and about 2/3rd of the total metal working output in the year 06.
Indian manufactures in the metal forming segment, on the other hand, registered a
growth of 41.7%, with an output valuing Rs 2,016 million. Press manufacturers witnessed
largest volume of business in this segment, with a 60% share in metal forming machine
tools.
In keeping with the focus of the Indian industry towards enabling manufacturing
excellence, CNC machine tools comprised bulk of the manufacture from the Indian
stable. This segment had over 69% share on the total metal working metal tool output in
2007.
CNC machine tool segment in India clocked a growth of 32% with a turnover of
Rs.11,598 million.
CNC turning centers together with machining and grinding centre’s held a share
of as high as 81% in the total CNC machine tool produce and 56% share in the metal
working output in 2007. These three segments have been leading for over half a decade.
Specially designed for Indian working conditions, our Chucks, Cylinders and Work
holding solutions easily match some of the best known global manufacturers.
EXPORT SCENARIO:
IMPORT TREND:
[Values in Rs.million]
AUTOMOTIVE SECTOR:
Indian capital goods industry was clearly the success story of the Indian
industry’s performance in 2007-2008. And a major contributory to the high
manufacturing growth.
High growth was evidenced in all the segments of the capital goods
industry. Segments such as diesel engines, earth moving and construction equipment,
industrial furnace, pumps, transformers, textile machinery and tractors had a high growth
ranging between 15% to 32% during April 2007- March 2008.
Conquering the world with their world-class capabilities, Ball and roller
bearing segment performed well to post 15.1% growth in the same corresponding year.
Electronic components’ industry had moderate demand for their products leading to a
10% growth in 2007-2008.
Mr. D Dhume.
Mr. P G K Murthy.
Late. N Sukravala.
Mr. M D Dhume.
Mr. S A Phalnikar.
Mr. P G K Murthy.
Manufacturing:
Airtech manufactures chucks and cylinders that are manufactured according to the
specification prescribed by the customers in order to meet the customer satisfaction and
requirements.
VISION:
QUALITY POLICY:
6). Treat each other with trust and respect to build a team.
LOCATION:
Airtech pvt ltd is situated in Narendra village just 5 kilometers away from
Dharwad city right beside the national highway. Hence it is very convenient for them to
transport their goods.
TRANSPORTATION:
APL offers not only standard work holding solutions but also total solutions in
work holding. That is why the APL customers are spanning various sectors like Auto
components manufacturers, ordinance factories, railways and machine tool
manufacturers.
These are competitive in cost margin. This can be manageable by APL. Through
its quality and the service it is eligible to compete with other companies.
They even face the competition from various international companies, hence
competitors can be classified as Indian and foreign competitors. Details of them are as
follows.
GMT was the first company which started its manufacturing power chucks in
India in the year 1950 with technical know how from BERG,Germany. They are still
leading the market with 44% market share. OEM prefers their chucks because of;
3). They have various sales and service staff/ office in Delhi, Mumbai, Chennai,
Bangalore and many more cities.
Their prices are 10%-15% more than APL but 20%-30% lower than imported
chucks.
Their production capacity is high hence it helps them to meet the market demand
fast.
Quality is inferior but price wise, it is making dent into end user sector. OEM’s
are not giving preference to its products. It has dealers and stockiest in almost all the
industrial towns.
It is coming up very fast and may be an eye sore of GMT and APL in very near
future.
This company is in a way of GMT. They were dealers for GMT for quite a long
time. Somewhere in 2002, some design and shop floor personnel of GMT resigned and
joined this company and started manufacturing power chucks and cylinders.
They do not have good manufacturing setup. They are in marketing especially in
Chennai and Pune. In their anxiety to come up fast and secure second place, they are
picking up design, shop floor, sales and service people from APL and GMT. Their
quality is not up to the mark but yet is able to sell and recondition good numbers of
chucks.
MNC’s COMPETITORS:
The plant is 60 acres which provides good and sufficient facilities to employees
such as:
1. Chucks.
2. Cylinders.
3. Chuck jaws.
CHUCKS:
3). Maximum diameter : APL manufactures chucks with a diameter ranging from 130mm
to 1000mm.
APL has also designed chucks operating at 6000 rpm. It produces standard as well
as specialized chucks.
Cylinders are used for operating power operated chucks. These cylinders activate
the chucks via the draw bar passing through the spindle bore and should provide the
correct operating force to match the chuck.
Some cylinders are specially designed for high speed CNC bar and chucking
lathes. They are also used in fingure chucks, clap applications and special chucks.
CHUCK JAWS:
APL manufactures standard, soft, hard and special chuck jaws. All soft jaws are
made of high carbon steel. The hard revisable jaws are made up of case hardened steel.
Special jaws are offered according to their customers satisfaction or to suit customer
requirements.
Airtech pvt ltd introduce diaphragm chucks [sd & scd] that utilise inherent
strength of spring action of steel to achieve chucking pressures on jobs. There are no
sliding parts, due to which high degree of reliability and long service life is assured and
are most used on internal grinding machines where high degree of concentricity accuracy
is required. Sd models need power sources, ie, rotating hydraulic or pneumatic cylinders
mounted on the rear side of the machine spindles. Scd model is self- contained where
cylinders are inbuilt with the chucks.
Airtech offers pull grip chuck that works on principle of master jaw collects. Its
interchangeable jaw inserts exert radial force as well as axial pull, thus drawing the job
against the face of the chuck. The jaw guides are of cylindrical shape with perfect lapping
fit in the body. Design wise, the chuck is very stable and maintains accuracy for a very
long time. Its stable design its jaw guides having perfect fit in the body its absolutely
negligible back lash - all these factors permit the chuck to operate at very high speeds
without any appreciable loss of grip due to centrifugal forces. The large jaw stroke and
easy insertion and removal of jaw inserts make the chuck versatile. This chuck is useful
only for external gripping. Short cut piece bar work on medium or small batch size is
most suited to this chuck. Gear balk turning, bearing race turning where floor to four
times is in seconds, are ideal jobs for this chuck.
Airtech manufactures retractable jaw chucks. These chucks are specially manufactured
for machining cylindrical jobs that are required to be machined over the whole length in
one operation. Centre-drilled and faced components are held in between centers. A built-
in face driver placed in the chuck drives the work. The jaws grip the component to
provide additional driving force during heavy machining. When the tool approaches near
to the end of the component, jaws open and retract for the tool to complete the machining
of the gripped portion. The driving force during the jaw-retracted position is transmitted
through face driver and hence, is less. Gripping and retraction is performed with the help
of hydraulic cylinder placed on the rear side of machine spindle.
Airtech has introduced hand indexing chucks with power clamping. It is suitable for
machining jobs at 90°c or 180°c or 120°c or any other angle in one clamping. When
the job is clamped, the operator has only to pull and push a lever to index for next
operation. The job need not be declamped for indexing. The chuck is ideal for machining
automobile transmission cross, hydraulic fittings and valve bodies. The jaw pads are
manufactured to suit the shape of the component.
Airtech pvt. Ltd supplies eccentric chucks. These chucks are used to hold work pieces in
between centers having eccentricity or irregularity. These power chucks provide
complete solution to all chucking problems where the jaw movement has to be
compensated for the above stated work piece. A centering insert with spring loaded
centre is fitted as standard equipment. It is possible to adjust the centering inserts. To run
concentric by set screws, these chucks are actuated by air cylinder model hc and hch. The
chucks are manufactured from steel and all wearing parts like taper wedges are hardened
and ground; has interchangeable centering inserts with spring loaded centre and the base
jaws are well lubricated.
Airtech manufactures high speed light weight aluminum alloy hydraulic cylinders in
compact design which reduces the weight on the machine spindle and maintains
outstanding stability during high - speed operation. These hydraulic cylinders are ideal
for high speed cnc chucking lathes while its high quality cylinder seals and accurately
controlled finish helps to avoid daily inspection adjustments. The oil supply system in the
distributor housing of these hydraulic cylinders allows little oil leak out ensuring
continuous lubrication of the bearings and avoid heat generation. These cylinders are
applicable to perform with oil pressure from 3 kgs per cm² to 40 kgs per cm². The
company also supply cylinders with non - return valves.
Airtech manufactures btt series electromechanical tool turrets. The company supplies
these tool turrets equipped with three-piece coupling facilitating the tool disc to be
indexed without lifting. These turrets are built to deliver high accuracy, fast tool change
and high rigidity and provide quality, productivity and profitability of cnc lathe. The
company also offers turrets with centre height of 63 mm, 80 mm and 100 mm.
Airtech provides 2+2+2 jaw chucks for holding large diameter thin walled components,
aluminium components of turbines and couplings, precision railway wheels and large size
gear blanks of earth moving equipment. Usually the sizes of these chucks are above 500
diameter for mounting on vertical lathes. The company provides chucks up to 250
diameter on special order. The inter-linked jaws revolve around each other.
Airtech pvt limited offers range of chucks-from manual chucks to power chucks and total
solutions. These are suitable to accommodate components of ranging in 3-80 mm
diameter. It extends to over a 1000 standard and custom designed workholding tools.
Pccdlr/pccdla dead length collet chucks are available with standard cylindrical recess
mountings and with short taper mountings, pneumatic or hydraulically operated.
Eccentric CC 160,200,250,315,400.
Compensating Power
Chuck
Area of operation is at national level covering all zones i.e, North, South, East ,
West. They purchase raw materials (rough forged steel) from Mumbai and KGF.
CUSTOMERS:
Managing
Director
Productio-
n
Manager
Planning department:
The company gets orders from various suppliers as well as from perspective
customers. After seeing to its terms, conditions and cost aspects the department issues
acceptance order. But for specialized tool where some parts cannot be manufactured the
company outsources the activities. After it comes from the outsourced agency, the
department is responsible for execution of purchase orders once accepted.
DEPARTMENT CHART:
P&P incharge
Designer
Sales Manager
Production Manager
P&P incharge:
He is a person assisting the P&P incharge head in planning and purchasing the
components or raw materials. He carries the activities of P&P incharge in his absence and
guides the employees to carry out their tasks.
Designer:
After the P&P incharge head plans the assistant of purchase and planning
incharge is responsible to assist the designer the kind of chucks and cylinders to be
designsed and the designer develops the drawing for the production manager.
Sales Manager:
Once the drawing of the design is complete the responsibility of the sales
manager begins. He is responsible to check the diagram of the respective model to be
produced so as the sales work is carried out easily.
Production Manager:
His responsibility is to give the developed design to the supervisor of the shop
floor to produce the prescribed product.
Customer Representative
Product Specification
Production Outsourcing
Once the raw materials are bought into the company the stores manager stores the
materials and provide the shop floor workers to carry out the production. If the
production is not possible from the company workers like for the specialized products
then the process is outsourced.
Here at AIRTECH pvt ltd, the raw-materials are classified into 4 categories. They are:
RAW-MATERIALS:
The raw-materials consists of basic raw materials which is raw in nature like
carbon steel and alloy steel etc
COMPONENTS:
These are the sub parts which are required as a part in the final product like
screws, nut bolts etc. They are also required in components like carbon steel and alloy
steel screws.
CONSUMABLE:
These are inputs consumed while carrying out production such as oil, lubricants etc.
PACKING MATERIALS:
The materials used for final packing of the products. Purchase department obtains
raw-materials for standard products by care a month before but for special products it
follows just in time techniques.
SUPPLIERS:
Objective:
Scope:
The procedure is applicable to both the main stores and the finished stores.
Process:
When the raw-materials is received from suppliers the sum is tallied with the
delivery challen / invoice / cash memos / credit memos placing slips etc.
In the absence of pay orders or any other document from the sub contractor, the
material is flown in only after the purchase department authorizes by issuing
interdepartmental note. The details of materials received is I entered in inward register.
Then after the completion of inward inspection the materials both accepted and rejected
comes at the stores, and with the material receipt the accepted material is stored at the
desired place.
Whenever the stock reaches the Re-order level main store raises the purchase
request to the purchase department.
1). They check the stocks and gives orders whenever required.
Objective:
To check the standards of the quality of the prescribed products and maintain the
same at every stage of process of production.
Manager
Engineer
Supervisor
Workers
Manager:
The manager is the head of the department and he takes care of the activities
performed by the employees. He keeps the activities carried in track and takes care of the
quality of the products manufactured. If the quality is assured by the manager then only
the products will go to the engineers.
He is the person who checks the accuracy of the design, that is, its length, width
etc of the product.
Supervisor:
Workers:
These are the shop floor workers who physically work with the CNC and LATHE
machines and check the quality of the product.
FUNCTIONS:
3) In case the product is outsourced, the department checks the quality and the
product is rejected if it is not satisfying the needs.
The production plant is big and clean in which workers can work out of dust and
foul without any problem. The production process is done on shift basis. There are 2
shifts of 8 hours each.
I – 8:30 am to 5:00 pm
PRODUCTION HIERARCHY:
Production Manager
Production Assistant
Supervisors
Operators
Helpers
Production Manager:
He is the HOD of the department who guides the workers in production according
to the needs of the customers.
Production Assistant:
Supervisor:
He supervises the work of the workers and check whether the work is going on
properly and takes care that raw-materials are provided as and when required.
Operators:
The persons who operates the machines manually or non-manually. These people
are given training by the department and they perform the work according to the direction
of the supervisors advice.
Helpers:
These people help the operators in putting oil or Greece to the products or
providing necessary accessories.
Different sections are made in the shop floor. There are 4 rows namely:
There are two seperate grinding operations in the shop floor because some
products which are to be grinded in large pieces are done in one grinding operation and
the products which are to be grinded finely are grinded in another grinding operations.
There is an inspection department at the back in the shop floor. Drawing is the
language for the inspection department. They have to confirm whether the shop floor
workers’ working is limited to certain constraints.
The shop floor workers are 100 – 150 in number and basically work either
manually or on CNC machines. They produce the jaws and the teeth of the jaws should
be 1/60. To measure the specific dimension of the chucks or cylinders they use an
instrument called micrometer screwgauge and so on.
Raw materials
Bar cutting-
forging-casting
Machining
Stage inspection
Assembly
Packing
TURNING PROCESS
MILLING PROCESS
DRILLING PROCESS
HEAT TREATEMENT
INSPECTION
SERRATION
CLEANING
ETCHING
ASSEMBLY
PRODUCTION PROCESS:
1). Turning:
This is the first department in which the work operation is held in a lathe machine
and rotated, while the cutting tool removes the metal from the work piece.
2). Milling:
In this process a hole is produced at the work piece before forcing a rotating cutter
known as drill bit.
It’s the process of heating and cooling of metal or alloys in order to obtain certain
desired properties such as hardness, toughness and strength.
4). Grinding:
PROCESS IN GRINDING:
Phase Grinding
Surface Grinding
Slot Grinding
Internal Grinding
5). Inspection:
The components are then sent for inspection where tolerance and size of each
component is checked. When approved these are sent to the serration process.
6). Serration:
It is the process where the teeth on the hard surface jaws form firm grip. The
serration can be used to move the jaws to hold war pieces of different sizes.
7). Cleaning:
Components are thoroughly cleaned with oil, which prevents from rusting before
it is taken to further process.
8).Etching Process:
For each and every product a number is given, the trade mark of APL is printed
on the product.
9). Assembly:
10). Testing:
The finished assembled products are tested for maximum speed and gripping
force and maximum diameter it can hold.
11). Packing:
The packing of the products is done in a wooden box and thermocol to reach the
product safe to the destination.
Marketing Manager
Representative Dealer
He assists the head of the department and takes the orders from the customers. He
also assures them the time of delivery of the goods according to their needs.
These person render the service to customers who have problems in product sent
by company
These are also known as sales engineers. These people are part of the company
who takes the responsibility of marketing the products to the customers and discuss with
them about the prices.
6). Representatives:
Representatives work on behalf of the company who go out to talk with the
customers and know their needs. They are given some quotations and given price limit to
take orders from the customers.
7). Dealers:
They are in different places who find out the needs of the customers, take orders
and give it to the company.
PROCESS OF SELLING :
The representatives all over the regions i.e North, East, West and South are
appointed. They collect the quotations and give the details to the company.
The marketing department regularly improvise in their designs, cut the costs to
keep their customers satisfied. They also have the strategy to attract the customers by
participating in the International level Exhibition, which is conducted for every 2 years in
1). Controlling information flow between head office and dealers / representatives.
2). Sales representatives should send sales report every week to main office.
4). Orders form and Sales form is issued and send to head office.
Principle :
DEPARTMENTAL CHART :
Finance Manager
Accountant
He manages the overall view of the accounts section. He checks the Final
accounts and Annual report prepaid by Assistant Finance Manager.
3). Accountant:
He maintains all the books of accounts separately in respective books i.e cash
book, journal, ledger , purchase book ,sales book etc
INVENTORY MANAGEMENT:
Inventory management also play a key role in Finance department. The Finance
manager will try investing less in the inventory because for him it is an idle investment,
where as production manager will emphasis to acquire more and more inventories as he
does not want any interruption in production due to shortage of inventory. The purpose of
inventory management is to keep the stocks such that neither there is over stocking nor
under-stocking. The over stocking will mean a reduction of liquidity and targeting of
other production process. Under-stocking on the other hand will result in stoppage of
work. The investment in inventory should be kept at reasonable limits.
The main objective of inventory management means that the materials and the
spares should be available in the adequate quantity, so that the work is not disrupted. The
investment in inventories should not remain idle and minimum working capital should be
locked in it.
3). To keep materials cost under control so that they contribute in reducing cost of
production and overall costs.
FUNCTIONS :
3). Preparing monthly operational data which includes production , sales, raw materials
and income expenditure.
Headed by : Mr Purohit.
Objective :
Procedure :
In APL there is scope for internal source of recruitment like present permanent
employees, present temporary, so as to motivate them and gain advantage of minimum
cost of selection.
For external source, the management will go for district employment exchange
where job profile of required employees will be handed over to employment exchange.
External training for the skill development is due to the change in the work
process, if a employee or group of employees have to acquiring a special skill then HOD
initiates the activity and workout on the external training schedule.
Due to internal transfer if job profile of employee is likely to change then the
HOD organizes the job training .
The HOD decides and initiates induction training to new employees after the
names of employees are prescribed by the concerned departmental heads.
1). Strategy:
2). System:
The company has the unique integrated systems in all the departments. The
execution of order is followed by all the levels of management. This includes formal and
informal procedure including the innovation system, compensation system, management
information system and capital allocation system which governs everyday’s activities.
3). Style:
4). Staff :
The organization‘s human resource refers to how people are trained, developed,
specialized, integrated, motivated and how their career is managed.
The APL has effective staff o participative in nature with positive attitude towards
organizational goals and also performing efficiently with effective results.
5). Skill:
Skills include:
4. Providing all the basic facilities including safety, PF, ESI etc.
Headed by : Mr A C Kulkarni.
Objective :
Procedure:
After receiving the purchase orders from customers, marketing department will
send the orders to planning and purchase department. They check the availability of raw
materials. Once it passes this stage it will go to design and development department
where the designers develop the drawings according to the needs of the customers.
1. AUTO CAD
2. MECHANICAL DESKTOPS
Flow chart :
Asst.D&D manager
Designers
1. D&D manager :
He assists the HOD in carrying out the activities. He guides the designers
and help them in designing.
3. Designers :
These are the key persons (Engineers) who design and give the drawings
to the production manager.
1). APL has very good image since they produce chucks as per prescribed specification
by customers.
4). They are highly concerned about Research and developmental activities which plays
vital role in new product development and design.
5). Since from its inception APL has not faced any problems regarding stick lockouts,
which indicates cordial relationship between management and workers.
Weakness:
Opportunities:
1). Company can expand its business to large extent since they are planning for capturing
market demand and reliable quality etc.
2). They enjoy benefit of labour in dharwad since there are many ITI diploma colleges
from where students are hired.
3). Since it is situated besides highway they can solve the distribution problem.
4). As company is going for ISO certification, this may help the company enter into
global market.
Threat :
1). More than 300 chuck manufacturing companies are present in industry that creates
stiff competition.
They always try their best to ensure that no products leaves the plant unless it is
thoroughly tested and certified by a team of quality specialists because they know that
these work holdings work under severe and exacting conditions.
I had a great experience in this company . I got a good priviledge and scope to do
my in plant study in AIRTECH PVT LTD where all the employees and the workers of
the company were kind enough to help me in my study.
Thus I would conclude that my in plant training was a satisfactory and successful
one.
3) Employees