an organizational study of

8/3/2019 An Organizational Study Of

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Sikkam Manipal University

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INDUSTRIAL TRAINING REPORT

An Organizational study of

Inder Industries

&

Analysis of the production process and the manufacturing cycle time of a product

Under the guidance of

PALLAVI MADAM

Submitted By

T PRADEEP KUMAR (Regd No: 511032560)

PRABHAKAR SINGH (Regd No: 511036106)

In partial fulfilment of the requirement for the award of the degree

Of

MBA

IN

OPERATIONS MANAGEMENT

November-2011


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ACKNOWLEDGEMENT

The satiation and euphoric that accompany the successful completion of task would be incomplete

without the mention of the people who made it possible. So with immense gratitude I acknowledge

all those whose guidance and encouragement crowned my efforts with success.

I would like to thank Pallavi Madam Sikkam Manipal Univesity, for providing the support to do this

study.

I sincerely thank Inder Industries top management for giving me the good opportunity to do thisstudy.

I express my sincere gratitude to Mr. Sanjay Kumar Chatrath, Director (Technical) of Inder Industries

for extending his valuable time and giving me all the required information for the successful

completion of this project work.

With deep sense of gratitude and indebtedness I sincerely thank Prof. Lt Col (Retd) L Shri Harsha my

project guide for giving me valuable suggestions and advice throughout the execution of the

project.

I would like to thank all the faculty members of Sikkam Manipal University and the entire Inder

Industries family.

Last but not the least I would like to thank my parents, friends without whose co-operation this

project wouldnt have possible.

Thanking Everyone.


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BONAFIDE CERTIFICATE

Certified that this project report titled An Organizational study of Inder Industries & Analysis of

the production process and the manufacturing cycle time of a product is the Bonafide work of

T.PRADEEP KUMAR, PRABHAKAR SINGH who carried out of the project work under my

supervision.

SIGNATURE SIGNATURE

HEAD OF THE DEPARTMENT FACULTY IN CHARGE

OPERATIONS MANGEMENT OPERATIONS MANAGEMENT


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EXECUTIVE SUMMARY

Analysis of the production process and the manufacturing cycle time of a

product

Manufacturing industry particularly Tools industry nature and details has been

explained in the introductory chapter and can be easily understood from it.

Hence by understanding the industry, need and importance of the good

production process can be understood. It is the production process that defines

the company and the products of the company. A company with a good

production process will always be at the forefront of the industry. So forknowing about the health of the company or for estimating about the future

condition of the company, its production process and production related

activities needs to be analysed.

In this project the production process of a product has been analysed. The

product is having a high demand in the market but the production is not up to

mark. On analysing the production process the problem has been easily

identified and removed.

In the project in addition with the analysis of the production process, a method

or way for reducing the cycle time has also been explained. By properly

utilizing the resources the cycle time can be reduced. By using the same concept

and utilizing a higher efficiency machine at the correct place the cycle time of a

product is reduced by 11%. So by making small changes the cycle time can be

easily reduced and hence the productivity of a production process will surely

improve.


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TABLE OF CONTENTS

S.No. TOPICS Page No.

EXECUTIVE SUMMARY 4

1 INDUSTRY PROFILE 10

1.1 MANUFACTURING INDUSTRY 11

1.2 INDIAS MANUFACTURING SECTOR DETAILS 13

1.3 TOOLS INDUSTRY 17

1.4 HAND TOOL INDUSTRY 25

2 COMPANY PROFILE 30

2.1 INTRODUCTION 31

2.2AWARDS AND CERTIFICATION

32

2.3 ORGANIZATIONAL CHART 34

2.4 DEPARTMENTAL DETAILS 34

2.5 PRODUCT DETAILS 36

2.6 MAJOR COMPETITORS 44

2.7SWOT ANALYSIS

45

3 RESEARCH DESIGN 51

3.1 STATEMENT OF THE PROBLEM 52

3.2 TITLE OF THE PROJECT 52

3.3OBJECTIVES

52

3.4 SCOPE 52

3.5 OPERATIONAL DEFINITIONS 53

3.6 RESEARCH METHODOLOGY 54


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4 DATA ANALYSIS 57

5 FINDINGS,CONCLUSIONS AND SUGGESTIONS 87

5.1 FINDINGS & SUGGESTIONS 88

5.2 CONCLUSIONS 89

MY LEARNINGS 90

BIBLIOGRAPHY 92


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LIST OF TABLES

Table No. PARTICULARS Page No.

1 Table Showing mean processing time for manufacturing of Chaser 59

2 Table Showing number of machines/tools used for manufacturing of Chaser. 59

3Table Showing Different Service and Arrival rates during the manufacturing of

Chaser60

4Table Showing the Utilization factors for different processes during the

manufacturing of Chaser61

5Table showing the Waiting times for different processes during the

manufacturing of Chaser63

6 Table Showing mean processing time for manufacturing of Handle 64-65

7 Table showing number of machines/tools used for manufacturing of Handle 65

8Table Showing Different Service and Arrival rates during the manufacturing of

Handle66

9Table Showing the Utilization factors for different processes during the

manufacturing of Handle66

10Table Showing the Waiting times for different processes during the

manufacturing of Handle67

11 Table Showing mean processing time for manufacturing of Body 69

12 Table showing number of machines/tools used for manufacturing of Body 70

13Table showing Different Service and Arrival rates during the manufacturing of

70-71


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Body

14Table Showing Utilization factors for different processes during the

manufacturing process of Body and showing bottleneck condition71

15Table showing number of machines/tools used for manufacturing of Body after

removing bottleneck74-75


Body after removing bottleneck75


manufacturing process of Body after removing bottleneck76


manufacturing of Body after removing bottleneck77

19Table Showing mean processing time for manufacturing of Body by alternate

method82

20Table showing number of machines/tools used for manufacturing of Body by

alternate method82


Body by alternate method83


manufacturing process of Body by alternate method84


manufacturing of Body by alternate method84-85


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LIST OF FIGURES

Chart No. PARTICULARS Page No.

1 Figure showing the different processes during the manufacturing of Chaser 58

2 Figure showing the different processes during the manufacturing of Handle 64

3 Figure showing the different processes during the manufacturing of Body originally 69

4Figure showing the order in which the different parts of the product are

manufactured78

5Figure showing the different processes during the manufacturing of Body by

alternate method81


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CHAPTER 1

INDUSTRY PROFILE


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1.1MANUFACTURING INDUSTRY

Manufacturing is the use of machines, tools and labour to make things for use or sale. Also it can

be used for selling things. The term may refer to a range of human activity, from handicraft to high

tech, but is most commonly applied to industrial production, in which raw materials are transformed

into finished goods on a large scale. Such finished goods may be used for manufacturing other, more

complex products, such as household appliances or automobiles, or sold to wholesalers, who in turn

sell them to retailers, who then sell them to end users - the "consumers".

Manufacturing takes turns under all types of economic systems. In a free market economy,

manufacturing is usually directed toward the mass production of products for sale to consumers at a

profit. In a collectivist economy, manufacturing is more frequently directed by the state to supply a

centrally planned economy. In free market economies, manufacturing occurs under some degree of

government regulation.

Modern manufacturing includes all intermediate processes required for the production and

integration of a product's components. Some industries, such as semiconductor and steel

manufacturers use the term fabrication instead.

Manufacturing industry refers to those industries which involve in the manufacturing and

processing of items and indulge in either creation of new commodities or in value addition. The

manufacturing industry accounts for a significant share of the industrial sector in developed

countries. The final products can either serve as a finished good for sale to customers or as

intermediate goods used in the production process.


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1.1.1 EVOLUTION OF THE MANUFACTURING INDUSTRY

Manufacturing industries came into being with the occurrence of technological and socio-economic

transformations in the Western countries in the 18th-19th century. This was widely known as

industrial revolution. It began in Britain and replaced the labour intensive textile production with

mechanization and use of fuels.

1.1.2 WORKING OF MANUFACTURING INDUSTRY

Manufacturing industries are the chief wealth producing sectors of an economy . These

industries use various technologies and methods widely known as manufacturing process

management. Manufacturing industries are broadly categorized into engineering industries,

construction industries, electronics industries, chemical industries, energy industries, textile

industries, food and beverage industries, metalworking industries, plastic industries, transport and

telecommunicationindustries.

Manufacturing industries are important for an economy as they employ a huge share of the labour

force and produce materials required by sectors of strategic importance such as national

infrastructure and defence. However, not all manufacturing industries are beneficial to the nation as

some of them generate negative externalities with huge social costs. The cost of letting such

industries flourish may even exceed the benefits generated by them.

1.1.3 ECONOMICS OF MANUFACTURING

According to some economists, manufacturing is a wealth-producing sector of an economy, whereas

a service sector tends to be wealth-consuming. Emerging technologies have provided some new

growth in advanced manufacturing employment opportunities in the Manufacturing Belt in the

United States. Manufacturing provides important material support for national infrastructure and

for national defence.

On the other hand, most manufacturing may involve significant social and environmental costs. The

clean-up costs of hazardous waste, for example, may outweigh the benefits of a product that creates

it. Hazardous materials may expose workers to health risks. Developed countries regulate


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manufacturing activity with labour laws and environmental laws. In the U.S, manufacturers are

subject to regulations by the Occupational Safety and Health Administration and the United States

Environmental Protection Agency. In Europe, pollution taxes to offset environmental costs are

another form of regulation on manufacturing activity. Labour Unions and craft guilds have played a

historic role negotiation of worker rights and wages. Environment laws and labour protections that are

available in developed nations may not be available in the third world. Tort law and product liability

impose additional costs on manufacturing.

1.2 INDIAS MANUFACTURING SECTOR DETAILS

1.2.1 MANUFACTURING INDUSTRY IN INDIA

The manufacturing industry in India has all the qualities which enhance economic development,

increase the productivity of the manufacturing industry and face competition from

the global markets. The Manufacturing industry in India is believed to have the potential of

improving the economic condition of India.

Studies conducted on the manufacturing industry have concluded that India has a working

population of 75%. Out of this, only 600 million have acquired education till middle school. Due to

this reason, the manufacturing industry in India, which is labour intensive, can provide the requisite

number of employment units in the country. Studies have indicated that the productivity of the

manufacturing industry in India is approximately 1/5th of the productivity in the manufacturing

industry of United States of America. It is about as compared to the productivity levels in South

Korea as well as Taiwan. Labour productivity has escalated only to a small extent in case of India in

comparison to United States of America, on the contrary, labour productivity has increased manifold

in countries like Taiwan and Korea.

1.2.2 SECTOR/MARKET SIZE

India is fast emerging as a global manufacturing hub. India has all the requisite skills in product,

process and capital engineering, thanks to its long manufacturing history and higher education

system. India's cheap, skilled manpower is attracting a number of companies, spanning diverse

industries, making India a global manufacturing powerhouse.


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According to a United Nations Industrial Development Organisations (UNIDO) International

Yearbook of Industrial Statistics 2010, India ranks among the top 10 producers of manufacturing

output in 2009. While the US and China occupies the first two places, India is in the ninth place

followed by Brazil. India surpassed Canada, Brazil and Mexico in 2009 to reach the 9th position from

the 12th position it held in 2008.

According to the report, India is among the global top ten in the following sectors: basic metals;

electrical machinery and apparatus; transport equipment, other than motor vehicles, trailers and

semi-trailers; textiles; leather, leather products and footwear; coke, refined petroleum products,

nuclear fuel; chemicals and chemical products. According to the UNIDO estimates, India's

manufacturing value added (MVA) per capita is US$ 283.

The Index of Industrial Production (IIP) data for February 2010 shows a robust growth of 16 per cent

in the manufacturing sector as compared to February 2009. The cumulative growth during April-

February 2009-10 over the corresponding period of 2008-09 was 10.5 per cent.

1.2.3 GROWTH TRENDS

The HSBC Market Purchasing Managers' Index (PMI), the most reliable indicator of manufacturing

activity in the country based on a survey of 500 companies, stood at 57.2 in April 2010. A figure

above 50 means activity is expanding and it has been above that level for 13 months.

Exports from Special Economic Zones (SEZs) grew by over 122 per cent to US$ 49.5 billion in 2009-10

compared to US$ 22.4 billion in 2008-09. IT, IT hardware, petroleum, engineering, leather and

garments are the leading exports from SEZs.

y Borg Warner Inc, a US based US$ 4 billion (2009) auto component and systems

manufacturing company with presence in 18 countries, has established its Indian

manufacturing facility at Sip cot industrial park at Sriperambadur near Chennai at a cost of

US$ 6.6 million.y US-based electronic manufacturing services company Sanmina-SCI opened a new

manufacturing facility in March 2010, at Oragadam, Tamil Nadu at an investment of US$

55.6 million.


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y Ingersoll Rand plc has earmarked about US$ 100 million investment in its Indian operations

during the next three years and expects to source products and services of an equal amount.

y Panasonic India plans to invest US$ 100 million in its new plasma TV production facility in

2011.

1.2.4 GLOBAL MANUFACTURING HUB

India is fast emerging as a global manufacturing hub with a large number of companies shifting their

manufacturing base to the country. Moreover, India has the largest number of companies, outside of

Japan, that have been recognised for excellence in quality. As many as 21 companies have received

the Deming Excellence awards; 153 companies have achieved Total Productive Maintenance (TPM)

Excellence Award for their total productivity management practices by the Japan Institute of Plant

Maintenance (JIPM) committee.

y GE Healthcare is drawing up plans to grow its India business and develop the country as a

global hub for manufacturing low-cost medical devices.

y Volkswagen AG will make India a low-cost manufacturing hub catering to select export

markets. Volkswagen will export fully-built models and completely knocked-down kits of its

hatchback, Polo, to South East Asia, Middle East and Africa from its Pune plant.

y Japanese automobile major, Yamaha, is planning to make India a hub for manufacturing its

premium and deluxe bikes for overseas markets. The companys Indian unit supplied 66,904

bikes in fiscal 2010 to Yamahas global operation compared with 38,639 units in 2008-2009,

a jump of 73 per cent.

y According to a report by RNCOS, Global Vaccine Market Forecast to 2012 published in

February 2010, India has emerged as a new hub for vaccine manufacturers from across the

world.

1.2.5 GOVERNMENT INITIATIVES

The government has issued the new consolidated FDI policy, which has come into effect from April 1,

2010. The government is also looking at publishing a new manufacturing policy document to make

India a world class manufacturing hub. The policy is likely to be published by June 2010.


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1.2.6 TOP 50 MANUFACTURING COMPANIES OF INDIA

S. No COMPANY

1. Aditya Birla Group

2. Hindustan Lever Network

3. Bombay Dyeing

4. Reynolds India

5. Hindustan Paper Corporation Ltd

6. Haldia Petrochemicals

7. Emani Group

8. Birla Yamaha

9. Mittal Dhatu Rashayan Udyog

10. Surya Salt

21. Lark Engineering Company(India)

22. Commodities Intertrade

23. Homocol

24. Atlas Cycles

25. V K Exports

26. Haridarshan Sevashram Pvt Ltd

27. Stanlay

28. Surya Electronics

29. Deccan Gold Mines Ltd India

30. ASGI(India) Industries

31. Tea Machinery from Amrfeo

32. Ratan Engineering Company

33. Baba Digital


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34. Sutlej Industries limited

35. Raja Sulpher Industries

36. S U Pumps

37. Kantilal Sanghvi & company

38. Ajanta Steel

39. Mahavira Cycle Industries

40. Yogesh Pharma Machinery Pvt Ltd

41. Kwality Electronic Industries

42. Ansuiya International

43. Zenax chains

44. Tytan Organics Pvt Ltd

45. Salil Enterprises

46. SJ fabricators

47. Caliber Valves

48. Arihant Industries

49. Aerosa Exports Pvt Ltd

50. Lohiya Groups of Industries

1.3 TOOLS INDUSTRY

1.3.1 INTRODUCTION

Tools industry a strategic industry, forms the backbone of many if not most of the major sectors of

industrial activity in a country in the traditional manufacturing context. Therefore, a country such as

India which is on the threshold of becoming a major global industrial and economic power must

have a strong, well-developed, robust and modern tool industry to support and assist its

manufacturing sector.


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The tools industry in India has played and will continue to play a key role in enhancing

competitiveness and enabling development of quality and excellence in the output of the

manufacturing industry and of the Indian economy as a whole. Tools also contribute to the vibrancy

of small and medium scale manufacturing industries, in particular, the millions of job shops in the

country.

In India, the Rs. 20 billion tool industry supports more than Rs. 2,000 billion manufacturing sector in

the country. The Indian tools industry predominantly comprises manufacturers from the small and

medium-sized enterprises. About three-quarters of total tools production in the country comes out

of ISO certified companies that are involved in manufacturing of metalworking machine tools,

manufacturing solutions, accessories, and cutting tools & tooling systems. India-wide, the sector

employs some 75,000 skilled and unskilled persons.

Based on current trends and emerging demands, the computer numerically controlled (CNC)

segment is emerging as a key driver of growth for the tools industry in India. Indian-made machine

tools are currently exported to over 55 countries major ones being United States, Italy, Brazil,

Germany, and the Middle East. Lathes and automats, presses, electro-discharge machines, and

machining centres form the bulk of export orders for Indian manufacturers.

1.3.2 HISTORICAL BACKDROP

This sector has had a long history of growth in India, beginning in the 1940s. From early 1950s to mid

1970s, the tools industry evolved under an umbrella of protection in which the growth was based on

import substitution.

During the 1950s to mid-1960s, this sector bolstered in confidence and began to absorb imported

technology and manufacture tools to specifications given by foreign collaborators. It also initiated

developmental work directed to modifying tools and developing variants of machines for which

design had been acquired by the purchase of licenses.


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The next phase of liberalisation of policies of the government allowed selective imports that made it

imperative for the domestic industry to catch up with quality specifications of imported machines, at

reduced costs and to adopt best practices for reducing technology gaps.

In the 1980s, the industry developed further and was able to acquire know-how in machine tool

technology in order to reproduce and even develop new machine tools. The national expertise

developed over the years provided the needed human resources to initiate creative modified

versions of existing machine tools manufactured under licence, thereby further paving the way

towards self-reliance through aggressive R&D in India.

1.3.3 CURRENT STATUS IN INDIA

The Indian tools industry manufactures almost the complete range of metal-cutting and metal-

forming tools. Customised in nature, the products from the Indian basket comprise conventional

tools as well as computer numerically controlled (CNC) machines produced tools.

Efforts within the industry are now underway to improve the features of CNC machines, and provide

further value additions at lower costs, to meet specific requirements of users. The slowdown in the

Indian economy since mid 1999 had its impact on the prospects of Indian tools manufacturers.

While the decrease in domestic production was lower in the case of conventional metal-working

machine tools, computer numerically controlled (CNC) machine tools manufacturers too suffered,

although marginally. Lathes, machining centres, special purpose machines, and grinding machines

were categories of machine tools that sustained much of the order inflow even during 2001

although these segments registered a decline, in comparison with the previous year.

An industry, which has undergone a radical paradigm shift in its thinking, the Indian machine tools

industry is now recognized as a provider of low-cost high quality lean manufacturing solutions. The

industry resiliently supports all its users to enhance productivity as well as improve competitiveness

for the betterment of the final customer. It is a well known and often repeated fact that the machine

tools industry forms the pillar for the competitiveness of the entire manufacturing sector since

machine tools produce capital goods which in turn produce the manufactured goods.


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Hence being an integral sector, growth of the machine tools industry has an immense bearing on the

entire manufacturing industry which is crucial for the country's strategic requirement such as

defence, railways, space, and atomic energy. World over too, industrially developed countries have

created market niches on the back of a well-developed and supportive machine tools sector.

The hub of manufacturing activities is concentrated in Mumbai and Pune in Maharashtra, Jalandhar

and Ludhiana in Punjab, Ahmedabad, Baroda, Jamnagar, and Rajkot in Gujarat, Coimbatore and

Chennai in Tamil Nadu, Bangalore and Mysore in Karnakata, and some parts of eastern India.

There are a number of issues of critical importance to the industry. These are:

y The competitiveness and quality of tools manufacturers depend on the competitiveness and

quality of its subcontractors

y Attracting and retaining talented manpower is an issue since the industry can grow only with

knowledge accumulation

y High fragmentation is leading to low economies of scale

y Indian educational curriculum in the ITIs or engineering colleges is not geared to impart the

all round technical knowledge required by the engineers and operators in this sector. For

example, a service engineer in the sector needs knowledge in hydraulics, mechanical,

electronics and electrical.

1.3.4 CORE COMPETENCY

The Indian tools industry manufactures almost the complete range of metal-cutting and metal-

forming machine tools. Customised in nature, the products from India comprise conventional

machine tools as well as computer numerically controlled (CNC) machines. One of the significant

developments in machine tool industry in recent times have been the Computer Numerically

Controlled (CNC) machines. Emergence of CNC machine tools and its dominance over the last few

years in the overall product segment stemmed from its value-added features, such as enhanced

productivity, higher precision, increased reliability, better finishing, and improved aesthetics and

design. Achievement of higher growth and increased share of CNC machines in the overall output


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surmises the commitment of Indian machine tool manufacturers to providing competitive

manufacturing solutions, now at cost effective prices. In terms of key product segments, high growth

areas for the Indian machine tool industry include turning centres, machining centres, grinding

machines, and cell manufacturing, amongst others. The other emerging demand is for total

manufacturing solutions, whereby users seek to economise on manufacturing cost and time.

1.3.5 INDUSTRY STRENGTHS

The tools industry in India is recognised for:

y Capability to manufacture low-cost, highly productive manufacturing solutions,

especially customised products, for Indian and overseas users in the range of turning

centres, machining centres, and grinding machines.

y Consistent attempt to transform the industry to become more productive, more efficient,

and, above all, much more cost competitive. Products offered by the Indian tool industry

today are priced much lower than earlier.

y Strong emphasise towards improvement of quality. Over 75 per cent of the total production

of the industry comes from ISO certified and CE accredited manufacturers.

y Engineering expertise on design, CAD, documentation, testing and evaluation. Most tools

manufactured in India are indigenously designed.

y Pool of skilled workforce specialising in assembly, design, and software development, as well

as in efforts to further strengthen their design and innovative skills.

y Forging backward integration with sub-suppliers and vendors for greater standardisation of

components and assemblies.

y Initiatives to form clusters and enter into consortia, with even competing manufacturers, for

developing world-class manufacturing solutions.

y Proactive efforts to reach out to customers through process of interactive dialogues at the

industry and at the individual company levels.

y Special focus on increasing reach of the industry to other potential overseas markets. The

tool industry is making special forays to establish presence in key machine tool markets

through joint participation in overseas fairs, as well as establishment of exclusive tool show


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centres. As a result, Indian tools are today well accepted in China, Germany, Italy, France

and in North America.

1.3.6 MANAGEMENT EFFICIENCIES

The tools industry is a very fragmented sector and the marketing abilities of the industry are far from

what it is in the other sectors of the capital goods industry. Larger companies are also handicapped

either due to bureaucratic norms or due to lack of capability. This is probably the reason why in this

sector, a few manufacturers have formed a consortium which outsources the marketing and

aftersales services. This may be a feasible model for the general purpose machines or low

technology products. However, with the entry into the high-end solutions, the industry needs to

catch up with global marketing strategies and practices.

An aggressive marketing strategy is followed only by 10 percent of the companies. 65 percent do not

even collect competitors information. Only 19 percent of the companies consider strategic alliances

with global players for technology as an option. In fact a handful of 10-15 companies are already into

strategic alliances with global players and are reaping the benefits. It is quite evident that the sector

lacks the managerial efficiencies and capabilities with mostly the market leaders having a strategic

planning process in place. Most of the players in the SSI category are not willing to come out of the

category even though there are opportunities because of the financial constraints faced by them toinvest in further capacity building.

The ones who are beyond the SSI limit are not in an investment mode because they are

apprehensive about the growth prospects and some are already bearing the brunt of the reduction

in customs duties and import of second hand machines. Except for the top 15 percent companies,

the rest are driven by demand led growth. No efforts are forthcoming from their end to explore

export markets, or diversify to other products because of lack of technological edge, or cost

competitiveness.

Quality consciousnesses of the sector is average with only 56 percent of the companies having

reported to be ISO certified or are in the process of certification. There are a handful of companies


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who also manufacture CE certified machines. The problems of quality are higher in this sector

probably because the industry depends more on outsourced products where quality standards may

be difficult to enforce. Many a times due to cost considerations, the companies cannot afford to

procure the high quality reputed imported/indigenous components due to which the performance

and accuracy of the machines suffer. However, the tools industry is believed to have improved its

quality in the recent past as compared to what it was 3-5 years back. The industry needs to improve

its quality further since the user segment has also rated the quality aspects lower than the imported

machines

.

The ISO certified companies have a market share of 85 percent. However, it is important that all the

companies are quality conscious since specifically the smaller companies are supplying tools to the

component manufacturers whose quality in turn determines the quality of the equipment.

1.3.7 PROBLEMS OF INDIAN TOOLS MANUFACTURING INDUSTRY

The various problems which are being faced by the Indian tools manufacturing industry are:

y There are not enough large firms and there is little cooperation among small and medium

players though a few of the medium sized companies have made efforts to come under a

unified umbrella to build their own niche market and share the marketing and after-salesservice.

y However, since they each of them operate in a niche market, there is less competition.

y Indian companies also lack adequate capabilities in terms of export marketing.

y Industry is very weak in its marketing abilities and depended on separate marketing

organizations for sales.

y The Indian tools industry needs to be more innovative, bold and aggressive in marketing

itself.

y Indian tools manufacturers are also facing difficulties in obtaining capital to finance export

sales. They need distributors to hold inventory of standard products abroad to make inroads

into the export market and this requires huge capital.


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y Indian firms also lack the ability to translate technological research into market advantage.

Though India has the competitive advantage of engineering skills and low man-hour cost of

research assistants, yet this advantage cannot be capitalized due to partly lack of finance

and partly lack of coordination between the user sector, the tools industry and the Institutes

of research.

y The Indian domestic demand arising from the small component manufacturers who are the

sub-suppliers to the engineering, automobile and defence sector is not very demanding with

respect to the latest technologies due to cost considerations. However, this segment will

create the highest demand for machine tools considering the fact that India is today

becoming a manufacturing outsourcing hub for all the major industries worldwide. These

component manufacturers would need to invest in most sophisticated and flexible machines

for better productivity and quality of products to meet stringent international standards.

y The Indian tools industry on an average exports 6% of its sales. This low export performance

by the industry is due to, reasons as mentioned below:

1. Lack of export marketing capabilities2. Lack of financial resources to sustain inventory levels necessary to be kept.3. Lack of subsidized participation in trade fairs and trade missions

y It is evident that for the Indian machine tools industry to be prosperous in the long run it

needs to:

1. Build large capacities of cost competitive standard products2. Build a marketing network in the domestic and international market to make its

presence felt

3. To look at its operational efficiencies and build companies with financial power to spendon marketing


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1.4 HAND TOOL INDUSTRY

1.4.1 INTRODUCTION TO HAND TOOLS

The most popular product category is hand tools. The tools, which are operated by hands, are known

as hand tools. Hand tool products include a broad category of hand tools. Hand tool products are

broadly used in all type of industries. Today technology has become highly advanced but still the

importance of hand tools products cannot be ignored. In fact hand tool products are the backbone

of all the industries; no matter how advanced are the machines and technology used there. No

industrial process can be executed without using hand tools.

As machine can never replace importance of mankind the same way automatic tools can never take

place of hand tools. The use of hand tools is must in every kind of industrial job but sometimes it is

not promptly noticeable. Even if the entire process is executed by automatic tolls and machine, then

too hand tools are required for additional jobs like packing, finishing etc. Furthermore the efficient

working of machine is also dependant on hand tools. Hand tools are essentially required for repair

and lubrications of machines.

Apart from this they are widely used for home repairs, garages, electrical appliances etc. A kit full of

primary hand tools products may be easily found at any home. Hand tools are used to execute verycomplex as well as simple tasks. Screwdriver is such a common hand tool product, which is the part

of every engineers tool kit as well as in every household. Spanners, screwdrivers, pliers, clamps,

riveters, wrenches etc., are used for tightening and riveting the various screws etc.

Hand tool products are designed to carry easily. Thats why every vehicle has its own set of hand tool

products. It can be used in time of any breaking of machine where one does not find any help. Hand

tool is a saviour in time of need. A kit of hand tools products is like a first-aid box for machinery.

1.4.2 TYPES OF HAND TOOLS

In general tools can be classified as: driving and chopping tools ; cutting and smoothing

tools ; drilling, boring and countersinking tools; measuring, levelling and layout tools (rules, tapes,

marking tools, levels and plumb bobs, squares); gripping, prying and twisting


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tools ; holding, raising and grinding tools; digging tools (shovels, posthole diggers, picks and

mattocks); portable power tools and trailer-mounted tools (electric tool trailer and generator,

portable power tools);miscellaneous tools.

The single bit axe chopping tool is used to fell, trim tress, split and cut wood. It may also be used for

notching and chopping logs and timber. The double-bit axe is limited to the splitting, cutting,

trimming and shaping wood.

Mauls are used in conjunction with a wood-splitting wedge to split wood. Hammers come in various

sizes and shapes, and based on that they must be used for different jobs.

The screwdriver and bit also come in a variety of sizes and designs and it may be used to tighten and

loosen screws, for precision work, to punch holes in leather, or to remove small nails or tacks.

Saws come with various types of blades, which are used to cut almost any type of material,

conduit, metals, glass, galvanized pipe, and PVC pipe.

Chisels are used for cutting wood, by being forced into the material. Drilling tools are commonly

used in woodworking, metal working or "does it yourself" projects, and some especially designed

drills are used in medicine. Boring tools are used to cut or finish the inner diameter of

hole. Dividers are instruments used for measuring distances between two points, transferring or

comparing measurements directly from a rule, or for scribing an arc, radius, or circle.

Micrometers are instruments used to measure distances to the nearest one-thousandth of an inch.

Levels are tools designed to prove whether a plane or surface is in the true vertical or true

horizontal. Adjustable parallels are used as gages for levelling and setup work. The rule or tape is

used for measuring. A plumb bob is used to establish a true vertical transfer and line-up reference

point, and to take readings or soundings in tanks and voids. Pliers can be used for gripping or cutting

an object.

Wrenches may be used to reach behind or below blind surfaces or in the building trades and on

heavy objects which require alignment before fastening. Vises are used for holding or clamping

large, heavy objects, for holding light materials or for holding pipe, and for forming and shaping

metal.[ Work which cannot be held in a vise, or which has to be held for extended periods of time

are usually held with the help of clamps. Jacks are used to raise or lower work and heavy loads short

distances. Timber handling tools are used for lifting or moving heavy objects such as logs or

timbers. The mattock is designed for digging and cutting operations.


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Digging tools are designed for the breaking and digging of soil. There are different types of digging

tools intended for heavy digging, to bore holes in the ground for posts, poles and explosive charges

or for light work or for digging in cramped, tight places. Portable electric power tools are designed

for a wide variety of uses including construction, tree cutting, bridging, or tree clearing. The cement

trowel is used in concrete work for levelling, smoothing, or pushing wet cement into place. The brick

trowel is used to scoop and spread mortar. The grapnel is used to trip wires designed to go off on

contact, to find

1.4.3 INDIAN HAND TOOLS MARKET

India has a competitive advantage in the hand tool industry compared to other countries because of

easy availability of raw materials, entrepreneurship skills and skilled labour at competitive wages.

The hand tool industry as a whole is witnessing a shift of manufacturing base from traditional

manufacturing countries in Europe and Taiwan to the developing world and this is a good sign for

India to benefit. There has been an average growth of 17% per annum of the hand tool market in

India for the last 7 years.

Estimated No. of Units in India - 2500

SSI Units - 95%

Large Units - 7

Estimated number of workers - 25000

Major Manufacturing regions - Jalandhar/ Nagpur

1.4.4 CHARACTERISTICS OF THE INDUSTRY

A labour Intensive Industry: A source of employment to many, hand tools industry is basically labor

intensive in nature, whose development is of great importance for a competitive as well as a self-

reliant industrial structure. The manufacturers of hand tools produce a comprehensive range of of

hand tools, right from carpentry and plumbing tools to striking and cutting tools.

Energy intensive industry: Apart from being a labour intensive industry, this industry is also an

energy intensive one. It is estimated in a recent study that in most economies adoption of energy

efficient processes and technologies can yield in energy savings of up to 30 to 50%.


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Effective contributor to the economy: Adding positively to the income of a country, hand tools

industry has contributed to economy in terms of development and technology up- gradation.

1.4.5 CONSUMPTION PATTERNS OF HAND TOOLS

This depends on the following factors:

y Price

y Supply chain dynamics

y Product quality, design and safety

y Service

y Environmental factors

1.4.6 DRIVING FORCES FOR HAND TOOL DEVELOPMENT

Hand tools were in use since a long time and there has been a great change in the designs of hand

tools from time to time. There were many factors that led to hand tool development.

y Workers safety & health

This is a very important consideration in today's designing of hand tools. Hand tools should be

designed in such a way so that they reduce wear and tear on the operator. Ergonomics hand tools

have become very popular, driven by an increased emphasis on worker safety and health. Workers

nowadays prefer tools, which reduce stress on the body and at the same time reduce employee time

loss due to job-related disabilities. Today, designers are coming up with more comfortable grips,

reducing the weight of the object, and making hand tools adjustable to different body types.

y Chemicals

When tools are designed, manufacturers consider ergonomics, performance and the environment.Besides considering health and cleaning factors, hand tools are also produced nowadays using less

chemicals, using less environmentally damaging products which are not harmful to the the human

body and which becomes an environment friendly product.


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y Cleaning

One of the driving forces for change in hand tool has always been to make cleaning easier. For

proper functioning and durability of hand tools, it is necessary keep them clean after usage. In most

cases, the latest designs go for flexible handles which can be removed and cleaned separately as

both the handle and the tool blade are of different materials.

y Hand Tools Standards

With the rapid advancement and expansion in the global trade, standardization of various products

is very necessary. The standards given to various products help in expanding international trade

which in turn bridges the quality gap between the manufacturers, suppliers and buyers of different

nations. In hand tools as well, standards play a vital role.

Standards are required in hand tools for the following reasons:

1. They provide performance requirements.

2. They provide safety requirements.

3. Standards are available for all types of hand tools like pliers, screwdrivers, wrenches, striking

tools, torque instruments etc. \

4. These standards also include the various tests that are required to determine conformance

with the safety and performance requirement


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CHAPTER 2

COMPANY PROFILE


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2.1 INTRODUCTION OF THE COMPANY

Inder Group of Industries is a pioneering manufacturing company specialised in Plumbing Tools, Pipe

Threaders, Cutters, Vices, Pliers, Striking Tools, Spanners, Drain Cleaners, Pipe Benders, Pipe

Wrenches, Under Pressure Drilling and Tapping Machines and other Diy Tools.

Since 1958 INDER brand tools have become the trusted name in the tools manufacturing industry.

The company has won many awards for its quality and workmanship. It has been awarded Golden

International Award for THE BESTTRADE NAME 1995, at Bilbao, Spain. The company won a trophy in

International Trade Fair held in New Delhi in the year 1990, from National Small Industries

Corporation for maintaining highest standards of Quality and Workmanship and company also got

bulk orders in IMTEX, UNITECH and AMTEX exhibition in India.

The company supply the goods all over India besides various Government and semi government

departments. The companys turnover from sales in India is about 20 - 22 crores. The company also

exports goods to USA, UK, Europe, Poland, Denmark, Australia, UAE, Kuwait, Jordan, Qatar, Saudi

Arabia, Egypt, Kenya, Russia, Estonia, Germany etc. The turnover of the company from exports is

about 8 -10 crores. The total turnover of the company is about 30 crores.

The company has been able to keep abreast of developments in mechanical trade and constantly

adding to the manufacturing trade and constantly adding to the manufacturing programme of new

tools and appliances. Each product is subject to vigorous quality inspection at each stage of

production and tested for performance under extreme working conditions. The company is also

coming in the field of Hotel business, Education & Immigration services and Real Estate & Land

Development activities.

2.1.1 VISION

To be a market leader in the tools manufacturing industry.

2.1.2 MISSION

Our primary focus is to provide our customers the products of high quality according to their need

and requirement.


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2.1.3 OBJECTIVES

y Analysing the industry trends.

y Development of strategies to provide the best quality products to the customers.

y Execution of all plans and programs related to the production.

y Design of overall strategy for customer retention and quality management

2.2 AWARDS AND CERTIFICATIONS

Inder Industries has been certified from various organizations like it is an ISO 9001:2000 certified

company, and its product are ISI marked. Inder Industries also exports its products and it products

are also in conformity with European standards. Inder Industries has won many awards like Golden

International Award for The Best Trade Name at Bilbao, Spain in the year 1995 and an award in

International Trade Fair held in New Delhi in the year 1990. The various awards and certifications

won by Inder Industries are shown below:


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2.3 ORGANIZATION CHART

CHART 1

2.4 DEPARTMENTAL DETAILS

1. PRODUCTION / TECHNICAL DEPARTMENT

The major department for the industry is the production or the technical department. This

department is headed by the director of the department. The director of the production department

is Mr. Sanjay Chatrath. All the workings of the production department take place under the guidance

of the director of the department. Director of the department are followed by the production

managers and they are further followed by the production executives. Production executives are the

person under which the actual production takes place and they are followed by the actual workers

CHAIRMAN

MANAGING

DIRECTOR

SALES & MARKETING

MANAGERS

ACCOUNTS

MANAGERS

DIRECTOR SALES

AND MARKETING

DIRECTOR

ACCOUNTS

PRODUCTION

EXECUTIVES

DIRECTOR

EXPORTS

ASST. ACCOUNTS

EXECUTIVE

WORKERS

DIRECTOR

TECHNICAL

SALES

REPRESENTATIVES

PRODUCTION

MANAGERS

ACCOUNTS

EXECUTIVES


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who makes the production possible. All the people in the department have specific duties and the

people have to perform those duties and then report to the higher authorities. This department is

responsible for the production part of the industry and it is the most important department for a

manufacturing industry. The director of the department i.e. Mr. Sanjay Chatrath has a huge

influence on the people of the department because of his hard working nature and he keeps

everybody in the department active and on their toes.

2. SALES AND MARKETING DEPARTMENT

Sales and marketing department is headed by Mr. Sunil Chatrath. He is the director of sales and

marketing department and keeps track of all the sales in Indian market. Sales and marketing

manager works under him following by sales representatives. A total sale of the company in Indian

market is 20-22 crores annually. This high sale is achieved by sales and marketing departments

dedication to meet the high sales and continuous growth of the company. This company has

pioneered in Indian market by its name and has achieved high sales by its hard work to become the

landmark in the market.

3. ACCOUNTS DEPARTMENT

Accounts Department is headed by Mr. Ajay Chatrath. He is director of accounts department in

Inder Industries. This department have all the details of purchasing raw materials and incoming cash

in terms of sales. Mr. Ajay Chatrath is heading this department very efficiently and accounts

manager is the person working under him who keeps track of all the money related details that

company is undergoing. Accounts manager have accounts executive and assistant accounts

executive under him who are giving their best to the department and playing major role in

companys success. Accounts department controls unnecessary expenses and allows expenses

wherever its required.

4. EXPORT DEPARTMENT

Export department is headed by Mr. Vijay Chatrath. He is the director of the export department.

Sales and marketing managers for foreign markets works under him following by sales

representatives. The company exports goods to USA, UK , Europe, Poland, Denmark, Australia, UAE,


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Kuwait, Jordan, Qatar, Saudi Arabia, Egypt, Kenya, Russia, Estonia, Germany etc. The annual turnover

for foreign market for the company is around 8-10 crores. Pioneering in foreign market is not a easy

task and it has been achieved by Mr. Vijay Chatraths hard work and other peoples support which

has lead the company to get so vast market outside India.

Marketing associates for Indian market and foreign market are Mr. Raj Kamal, Mr. Vicky Bhagat, Mr.

Sanjeev Anand, Mr. Brij Bhushan, Mr. Rajesh Sharma, Mr. Ravi Bhagat, Mr. Sukhdev Sharma, Mr.

Sunil Bhagat, Mr. Harjit Singh, Mr. Paramjit Sehdev, Mr. Raj Sharma, Mr. Mohit Sharma, Mr. Satpal

Bhagat, Mr. Ashwani Kumar, Mr. Kamal Bali, Mr. Trilok Nath, Mr. Basant Sharma, Mr. Mansoor

Khan(Sri Nagar), Mr. Hanspal Singh(Denmark), Mr. Mujahed Hussain(Dubai), Mr. Abidally(Egypt), Mr.

Kapil Sethi(Delhi), Mr. Jas Hothi(Australia).

2.5 PRODUCT DETAILS

Inder Industries provides a wide variety of tools to the customers. It is the leading manufacturer of

different types of tools in the country. The different type of tools manufactured by Inder Industries

falls into these categories:

I. PIPE AND BOLT THREADING MACHINESThere are different and many types of pipe and bolt threading machines which are produced by

Inder Industries. The different products under this category are shown below:

1. Electric pipe threading machine

It has a compact structure made of cast aluminum alloy light weight body, easy to operate, has good

safety and low noise level, referring to the international advanced technology suitable for threading

requirement of pipe thread for BSPT & NPT on request. It has a profiled die head for standard taper

pipe thread and it has a dependable clamping, free from slip and deformation.

2. Universal electric pipe and bolt threading machine

It performs all the functions performed by the above machine but it has some extra features like it

can be used for bolt threading. It has self lubricating die head and two more additional functions are

pipe cutting and de-burring of pipe.


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3. Oil gun with bucket

It is a portable hand operated device which is easy pumping to just push trigger. Its large pan collect

chips and re-circulates oil through reservoir to avoid wastage of oil.

4. Thread nipple holder

The Thread Nipple Holder makes short nipple easily in any length and can be used with any pipe

threading machine. Pipe clamping from the inside enables the manufacture of nipple from outer

plastic coated pipes.

5. Adapter for close threading nipple

Adapter is used to hold short or close nipples or studs for threading BSPT or NPT and it includes one

insert and 5 adapters size 1/2, 3/4, 1, 1.1/4, 1.1/2 and main body itself 2 adapter.

6. Universal pipe stands

It is heavy duty, light weight, adjustable and is used to balance pipe while pipe threading , grooving or

cutting and it is available in fix and folding types and rollers can be fitted on any types of stand.

There are various other machines and products manufactured by Inder Industries which falls under

this category like Ring thread gauge, Pipe balancing stands, Carriage stand for electric pipe threading

machine, Electric pipe grooving and threading machine, Hydraulic thread rolling machine etc.

II. PIPE THREADERSThe various types of machines and products which fall under this category are given below:

1. Ratchet Pipe Threaders

It is a compact tool for threading small pipes, suitable for use in difficult corners and close to walls.

The die heads have large clearances holes to prevent chips out. It is packed in a compact and light

weight metal and plastic carrying box.


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2. Ratchet Pipe Reamer

Self-designed Ratchet Pipe Reamer is for extra fast and easy hand reaming of the pipes edge. This

reamer is self feeding and easy to start and operate.

3. Ratchet Conduit Threaders

It is a compact tool for threading small electric conduit pipes up to 2, suitable for use in difficult

corner and close to walls. Dies are designed with large holes for standard conduit (BSC) threading in

one cut.

4.Adjustable Pipe Die Stock

The Adjustable Pipe Die Stock is an economical, most convenient and most versatile Threaders set.

Its adjustment can be set on different type of pipes. The parallel threads always have clearance for

pipe fittings.

The other products that fall under this category are Spare Die Head, Spare Chaser, Spare Ratchet

Handle, Spare Conduit Die Head, and Super Ratchet Pipe Threaders etc.

III. PIPE VICES AND BENCH VICES1. Self-Locking Pipe Vice

Self Locking Pipe Vice is also popular by the name of Hinged Pipe Vice. In this the frame and base are

hinged together. The replaceable steel jaws are accurately machined, hardened and tempered. The

handle and main screw are also of steel while the frames and bases are of strong SG (Spheroidal

Graphite) which is guaranteed unbreakable.

2.Pipe vice Pillar Type

It is entirely different from the existing vices. The frame and base are combination of mild steel and

SG iron graded casting to ensure strength and durability. The handle and main screw are also of steel

while the frame is joint with two high tensile L-key bolts.


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3. Pipe Vice Fitted Stand Light

The tripod stand is a fabricated steel frame fitted with a self locking pipe vice capacity 60mm made

of SG iron casting. The stand features a hinged tray, for odds and ends, and a fold down platform so

that the plumber has a firm foothold and can add his own weight to the stand, creating a very stable

work station for heavy on site jobs.

Some other machines and products that come under this category are Pipe vice Open Type, Bench

Chain Vice, Chain Pipe Vice, Multipurpose Vice Stand Heavy, Portable Chain Tristand, Steel Vice,

Ratchet Load Binder etc.

IV. PIPE WRENCHES AND CUTTERS1. Pipe Wrench

This heavy duty pipe wrench is specially used in the oil, gas and civil engineering industries. Its parts

are interchangeable. High tensile strong SG iron casted handle and hardened tool steel parts are

designed to work on heavy job.

2. Rapid Grip Pipe Wrench

It has a unique design to provide speed along with the best performance. It operates with one hand

and hold job quickly with spring loaded jaw and ratcheting action.

3. Mini Bolt Cutter

Mini Bolt Cutter is designed for cutting small bolt, wire, mesh and cables. Quick and easy adjustment

with bolt mechanism with slim head permits cutting close to job.

4. Sheet Hole Cutter

Sheet Hole Cutter is the unique tool which is used in Electric field when desired hole need in

available junction box on any soft sheet M.S, copper, brass, aluminum, PVC and fiber etc. is required

without electricity and drill.


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5. HDPE Pipe Welding Machine with Clamping

HDPE Pipe Welding set is a electric and mechanical device which is used to weld HDPE, PVDF and PB

pipes. Machine includes Heat element, Digital temperature controller, Safety Box, holding vice with

different sizes of jaws, facing machine and long leverage handle for pushing while welding.

The other machines in this category are Aluminum alloy pipe wrench, Chain pipe wrench forged,

Heavy duty offset pipe wrench, Hacksaw frame, Pipe reamer for internal and external, Tube cutter,

Dragon quick release tube cutter, Jumbo plastic pipe cutter, Digital PPR pipe welding set, Rotary pipe

cutter, Hinged pipe cutter, Hydraulic power driven pipe cutting machine etc.

V. DRILLING AND TAPPING MACHINES1. Online Under Pressure Drilling and Tapping Machine

Under Pressure Drilling and Tapping machine is used to Drill and Tap in running water line while

under pressure. It makes the hole and tap up to 2 in single operation without electricity. Machine is

recommended for connection ferrules to drinking water mains for connection to consumer without

stopping water line. It has unique design and involves engineering challenges so that it is capable of

Drilling and tapping on cast iron, ductile iron, steel and asbestos cement pipes of various diameters.

It is hand operated, easily maintained and highly durable to ensure simple installation of service

valve to the main pipe and provide a quick, permanent and leak free service connection via

conventional swivel ferrule service valve with or without service saddle and best feature is for whole

taping operation to be carried out without interrupting the supply through the main being tapped

and it is also capable for dry tapping of the aforesaid mains. All models are packed in robust lock up

case with a necessary range of tools and accessories with operations operational manual.

2. Magnetic Drill Machine

Magnetic Drill Machines are electric operated with special designed, developed and manufactured

to the very highest standards to provide users with a powerful portable and cost effective solution to

hole cutting problems.


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3. Hydraulic Under Pressure Drilling Machine Auto Feeding with Power Pack

Hydraulic operated auto feeding Under Pressure Drilling Machine is used for drilling to take branch

connections from Large Diameter Cast Iron, Ductile Iron and Mild Steel Pipes, trepanning vessels and

blank flanges while under pressure.

Operation:

The first operation is to mount a welded steel flange or cast iron tee on the main to drilled and

pressure it carries. Place the valve for stopping off operation or permanent for a branch operation. A

combination of cup drill and center drill is used to cut the piece or coupon from the pipe. Spring

loaded balls on the center drill expand beneath the coupon after drilling and cutting. The drill shaft is

retracted and the coupon brought back the cutting portion with the drill head, tight the valve and

machine can be removed.

The other machines under this category are Ratchet Drill Machine Multipurpose, Combined Tap Drill,

Tapping Machine, Engineering Reversible Ratchet, and Annular Cutter H.S.S for Magnetic Drill

Machine etc.

VI. PIPE BENDERS1. Hydraulic Motorized Pipe Bender with Hinged Frame

Motorized operated for long radius heavy gauge ERW pipe bending ideally suitable for C class size

3/8 to 6 gas, water, steam DIN 2440/2441 up to 90 bending.

2. Hydraulic Pipe Bender with Double Frame open Bending with Power Pack

Motorized with power pack specially self designed for short radius heavy and thin wall thickness

bending size 3/8 to 2 gas, water, steam, stainless steel and conduit up to 180 in two steps.


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3. Portable Conduit Pipe Bender with Vice

Fabricated portable conduit pipe bender with vice is designed for conduit pipe bending with lever

system up to 180 and SG iron makes it strong. Self locking pipe vice 35mm for holding pipe while

plumbing job required for threading and cutting etc.

Other machines which comes under this category are Hydraulic Pipe Bender with Separate Pump,

Spare Bending Formers of Hinged Frame, Hydraulic Pipe Bender with Double Frame open Bending,

Hydraulic Pipe Bender with open Frame, Hydraulic Bar and Strip Bender, Hand Pipe Bender, Special

purpose Hydraulic Pipe Bender with Mandrel system, Manual 3 axis pipe bending machine etc.

VII. CRIMPING TOOLS AND MACHINES1. Hydraulic Press

Unique design integrates all the hydraulic elements within chassis, provides a saving in the workshop

space and ensures protection in transport. It is easy to assemble and ready to use. Set of two V

blocks included and legs with bolt holes for fixing to the floor.

2. Hydraulic Hose Crimping Machine

Hydraulic Hose Crimping Machine is used to crimping hydraulic and auto hose pipes. It is hydraulic

operated and give the accurate crimping to avoid any loose connection which may cause for leaking.

3. Hydraulic Crimping Plier

Hand operated Hydraulic Crimping Pliers are used in field of electric to crimp Copper/ Aluminum

terminals and connectors etc. It can be used at sight accordingly to sizes of connectors and its

hydraulic force fix up very tightly with available dies.

4. Hydraulic Gear Puller

Hydraulic bearing puller tool is convenient for operating. Puller can be touched working center

quickly after rotary according to the distance between puller and piston center. It can choose pump

freely, the jaws with three legs can be adjusted from high to low point.


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The other machines which fall under this category are Hand Pipe Crimping Tool, Hydraulic Punch

Driver, Hydraulic Cable Cutter, Ratchet Cable Cutter, Hydraulic jack, Digital Control Auto Hydraulic

Hose Crimping Machine, Hydraulic Punch Press etc.

There are various other types of tools which are manufactured by Inder Industries. The types of

other types of Machines which are manufactured by Inder Industries are:

VIII. ASADA THREADING MACHINES which includes Beaver Pipe Threading Machine, Diechaser for Beaver Electric Pipe Threading Machine, Beaver Pipe Grooving Attachment, Die

Head without dies for beaver electric pipe threading machine, Asada speedy bolt threading

machine, Hand held pipe circular saw, Asada band saw beaver etc.

IX. CONCRETE AND GAS CUTTERSwhich includes Gasoline pipe, pillars & road cutter, Electricconcrete cutter, Diamond core drillers for concrete, Pipe hole cutting machine, Manual gas

pipe cutting machine, Electro gas pipe cutting machine, H-Beam cutting machine, Electric

metal saw etc.

X. PLIERS AND LUBRICATION TOOLSwhich includes Water pump plier, Adjustable wrench,Combination plier, Long nose plier, Side cutting plier, Vice grip plier, Bearing puller three

legs, Bearing puller two legs, Pincer,T

ower pincer, Grease gun, Block plane, Iron jack planeetc.

XI. CARPENTRY TOOLS which includes G-Clamp, T-Bar clamp, Wrecking bar, Tyre lever, Flatchisel, Pipe puller tap, Pinch-off vice grip plier, Hex Allen keys, Flaring and swaging tool set,

Flaring tool 45 etc.

XII. SPANNERSwhich include Open ended slugging spanner, Ring slugging spanner, Deep offsetring slugging spanner, Ring spanner bent type, double open ended spanners, Combination

spanners, Reversible ratchet socket wrench, Bi-Hexagon ring spanner etc.


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XIII. HYDRAULIC PALLET TRUCKSwhich includes Hydraulic Hand Pallet Truck, Hydraulic PalletTruck with Scale, Hydraulic High-Lift Pallet Trunk, Hydraulic Rough Terrain Hand Pallet Truck,

Hydraulic Hand Stacker, Hydraulic Power Press etc.

XIV. ELECTRIC HOISTS which includes Electric Hoist, Electric Trolley, Battery Winch, HandWinch, Electric Winch, Rotary Hoist Frame, Triple Spur Gear Chain Pulley Blocks etc.

XV. MEASURING TOOLS which includes Iron Level, Aluminum Level, Laser Level, Try Square,Engineering Square, Tailor Square, Mason Square with base, Micrometer, Wooden folded

scale, Hobby Brass Plane, Plumbobs with Brass Nipple, Tyre depth gauge, Vernier Caliper,

Dial Vernier etc.

2.6 MAJOR COMPETITORS

1. AMBIKA FORGINGS

It is one of the biggest companies in the tools industry. However it is not the leading manufacturer of

tools but it has one of the biggest market shares as it outsources most of its products. It is a

manufacturer of forging tools, hand power tools, hand tool kit, ring spanners, cone spanners,

spanner tools, wrenches tools, pipe wrenches, bench vice, steel bench vice, hand drill machine,

industrial hand tools, industrial power tools, portable electric drills, rotary hammer, industrial angle

grinder, metal jig saw, cut machine, saw machine, hand tool kit etc.

2. HINDUSTAN EVEREST TOOLS LIMITED

Another major competitor of Inder Industries is Hindustan Everest Tools Limited. They are the

manufacturer of world class hand tools in the brand name "Everest" since 1963 and their plant is

situated in district Sonepat (Haryana). They provide major competition in Indian market only in

products like pipe wrenches, spanners etc.

3. TAPARIA TOOLS

It is another competitor for Inder Industries. It has the largest market share among all tools

manufacturing industries. It provides major competition to Inder Industries in terms of exports. It


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has got its marketing representatives all over the world and is a stiff competition in all types of tools

for Inder Industries.

There are various other players in the tool manufacturing industry which provide competition to the

Inder Industries. Some of them are Jalani, Eastman Industries, Jagdambay forgings, Mekaster tools

limited etc.

2.7 SWOT ANALYSIS

SWOT analysis is a strategic planning method used to evaluate the Strengths,

Weaknesses, Opportunities, and Threats involved in a project or in a business venture. It involves

specifying the objective of the business venture or project and identifying the internal and

external factors that are favourable and unfavourable to achieve that objective.

A SWOT analysis must first start with defining a desired end state or objective. A SWOT analysis may

be incorporated into the strategic planning model.

Strengths: Attributes of the company are helpful to achieving the objectives.

Weaknesses: Attributes of the company that is harmful to achieving the objectives.

Opportunities: External conditions that is helpful to achieving the objectives.

Threats: External conditions which could do damage to the objectives.

2.7.1 AREAS TO CONSIDER

Some of the key areas to consider when identifying and evaluating Strengths, Weaknesses,

Opportunities and Threats are listed down below:

Strengths

1.Technological skills

2. Leading Products

3. Distribution channels


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4. Customer Loyalty

5. Production quality

6. Scale

7. Management

8. Innovative product or service.

Weaknesses

1. Absence of important skills

2. Weak Products

3. Poor access to customers

4. Low customer retention

5. Unreliable products or services

6. Management

Opportunities

1. Changing customer requirements

2.Technological advances

3. Changes in government Policies (Favour to the firm)

4. Change in population

5. New distribution channels

Threats

1. Changing Environment


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2. Emergence of new companies

3.Technology used may get out-dated

There are some questions which are needed to be answered for the SWOT analysis. Questions for

the Strengths, Weaknesses, Opportunities and Threats are given below:

Strength is something that a firm truly do well, something that truly differentiates the business, a

key metric that is improving, etc. Most companies do surprisingly bad job of identifying what they

are really good at doing. Every company has strengths

Strengths Questions

y What makes firm stand out from the competitors?

y What advantages does the firm has over other business?

y What are the major sources of a company's revenue and profit?

y What is the market share of the company in its various product lines?

y Does the company have strong brands?

y Is the advertisement effective?

y What is the major focus are of the company?

y Does the company have a pool of skilled employees?

y Is the company able to innovate?

Weakness is a real gap, or a problem, or a key metric that is going bad in the company; something

firm is not doing very well; something important that firm really dont know or arent sure about. In

fact, one good outcome of a SWOT is to discover what firm really dont know and then do something

about it.


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Weakness Questions

y What do firm customers complain about?

y What are the least profitable product lines for the company?

y In what areas is the company not able to recover costs?

y Is the advertising effective?

y Is the company not focused?

y What are the biggest expenditures of the company?

y Will the company able to stand price competition from competitors?

y

Do the employees have faith in management?

An Opportunity is a favourable external condition; something (that firm hasnt acted on or taken

advantage yet) that could impact it positively. Opportunities are new ways that firm can

exploit the STRENGTHS, WEAKNESSES & THREATS, new things that the firm can do to

potentially improve the business that turn into recommendations and actions. This list

becomes the most important part of the SWOT for prioritizing and determining what next steps

to take.

Opportunity Questions

y Are there emerging trends that fit with the company's strengths?

y What are the interesting trends? Company positioned to take on those trends?

y What favourable circumstances for the firm?

y Is the company entering new markets?

y Is the company advanced in technology?


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A Threat is something external to the business that can potentially impact the firm negatively:

competitors (actually doing specific things vs. just being there), changing conditions in the particular

marketplace, the overall economy, government regulations, etc. Threats are part of the playing field

that firm cant ignore. They are part of the context of the business.

Threat Questions

y Are the competitors becoming stronger?

y Does the company see other external threats to the company's success?

y Internally, does the firm have financial, development, or other problems?

y What is the competition doing?

y Are the required specifications for your products or services changing?

y Is changing technology threatening firms position?

2.7.2 SWOT ANALYSIS OF INDER INDUSTRIES

STRENGTHS

1. Inder Industries is a leader in tools manufacturing.

2. It has quite good market share.

3. Inder Industry is a reputable name in the market.

4. It has motivated employees with motivated employers.

5. It has demand of its products even outside India.

WEAKNESSES

1. It has quite low employee base.

2.They do not use the latest technology.


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3. Cycle time for products is quite large.

4. Employees are not highly skilled.

5. Not enough advertising is done of products.

OPPORTUNITIES

1. Inder Industries can increase their market share by better advertising.

2. More joint ventures in foreign countries will help Inder Industries to increase their sales.

3. By employing newer technology they can improve their productivity.

4. By providing training to their employees they can increase their efficiency.

5.The company can use its trusted name in entering the new businesses.

THREATS

1.The competitors may use new technology and take their market share.

2.They have high quality advantage over its competitors, once the competitors find out the

High quality production methodologies then there will no advantage.

3. Competitors may advertise their products better than them and as a result their sale may

Decrease.


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CHAPTER 3

RESEARCH DESIGN


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3.1 STATEMENT OF THE PROBLEM

Inappropriate use of machines in terms of number and type leads to rise in the manufacturing cycle

time of a product during manufacturing process. As a result of higher manufacturing cycle time of aproduct, the productivity or production capacity of a production process decreases.

3.2 TITLE OF THE PROJECT

Analysis of the production process and the manufacturing cycle time of a product.

3.3 OBJECTIVES

The main objective of this project is to analyse the different steps in the production process of a

particular product and to look out for the faults in the production process which are affecting theproductivity. By analysing and understanding the production process the areas of improvement can

be identified which will ultimately result in the increased production i.e. reduced manufacturing

cycle time of a product.

The other objectives of this project are:

y To identify the bottleneck, if any in the production process.

y To identify or find ways for eliminating the bottleneck.

y To analyse the manufacturing cycle time of a product.

y To find ways to decrease or reduce the manufacturing cycle time which will result in

increased production.

3.4 SCOPE

The scope of this project has implications for all the manufacturing industries. It provides them with

a way to analyse their production process and then seek ways to improve their production processand reduce cycle time. This project tells the implications of improper use of the machines in terms of

number and type at particular steps of production process which may even lead to a situation of

bottleneck.


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3.5 OPERATIONAL DEFINITIONS

y Jobs

Jobs are the units of work that move through a process or the units of work that wait and that are

worked upon.

y Cycle Time

The elapsed time from when a job enters a process until it is completed and leaves the process is

known as the cycle time. It is calculated by adding the processing time and the waiting time.

y Workstation

Workstation is the place where work is performed; where jobs arrive, wait if necessary, are worked

on and then leave.

y Bottleneck

The workstations state of having more jobs to do than can be done and jobs are forced to wait

because the needed servers are already busy or when the service rate of a workstation is less than

the arrival rate of the workstation then the workstation is said to be bottlenecked.

y

Input

Inputs are the newly arriving jobs to be worked on.

y Service

It is the mechanism where units are served, or processed. Service is characterized by the number of

servers and by the service time. The number of servers is the number of units that may be worked

on at once. In a single server system, one unit is processed, then the next, then the next, etc. When

more than one server is present, a unit is processed by any available server and all servers may be

busy at once.


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y Waiting Time

Waiting time is the amount of time jobs wait in queue because the needed servers

(people/machines/systems) are busy.

y Service Time

Service time is the time required at an workstation to complete the work on one job; the time

required by one server at one activity to perform one job, once work begins.

y Processing Time

Processing time is the sum of the average process times for each workstation in a production line.

y Arrival Rate

Arrival rate is the rate at which the jobs arrive at a workstation.

y Service Rate

Service rate is the rate at which jobs are serviced at a workstation.

y Utilization Factor

It gives the percentage of the time the machine or tools remains busy during the production process.

It is the ratio of the arrival rate to the service rate.

3.6 RESEARCH METHODOLOGY

3.6.1 Sources of Data

1. Primary Data - It refers to those data which are collected for the first time and thus are original in

character. For this study the primary data is collected by observing the production process, like

processing time at each workstation and the number of machines used at each workstation.


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2. Secondary Data - It refers to those data which have already been collected by someone else. For

this study the secondary data is collected from the company database.

3.6.2 Research Method or Type of Study

The type of study adopted for this project is Descriptive and Analytical Research.

Descriptive Research includes fact-finding enquires of different kinds. The main

characteristic of this research is that the researcher had no control over the variables i.e. the

researcher can only report what has happened or what is happening. In this case for understanding

and describing the production process the process was analyzed as to how it is carried out. It

describes the different stages or steps of production process and the number of machines used at

each workstation.

For Analytical Research, the researcher uses facts or information available and collected,

and analyses them to make a critical evaluation of the process. It includes using all the facts

collected regarding the production process, analyzing them and then using those data to access the

efficiency of the production process and finding the ways to improve the production process

3.6.3 Sampling Plan

1. Sampling unit Processing time for each process of the production process are taken to analyse

the total time taken during the manufacturing of a product.

2. Sample Size - 50 samples of processing time of each process of the production process are taken

for the analysis of the manufacturing cycle time.

3. Sampling technique - As this project is related to quantitative analysis therefore the best sampling

technique for it would be simple random sampling i.e. a probability sampling method. This method is

used because we are taking the processing time of the different process randomly and there is no

bias involved.


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3.6.4 Tools or Techniques used for Data Analysis

The major tool or technique that is used in this project is the queuing theory. It is the most widely

used technique for the study of waiting lines that are formed during the processing of a product.

Waiting lines are an inevitable characteristic of the operations and the time that a product has to

wait in a queue for processing is known as waiting time and it is included in the manufacturing cycle

time of a product.

3.6.5 Limitation of the Study

y The different processes like drilling, milling are done by the workers on the machine so

processing time depends on the human element as well.

y My own limited knowledge in this highl

an organizational study of

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