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FLOWSERVE MICROFINISH VALVES PVT LTD
ACKNOWLEDGEMENT
The satisfaction of the successful completion of any task would be incomplete,without expression of gratitude, to the people who made it possible. Thus taking
this opportunity I would acknowledge all these who have guided andstrengthened me in pursuing my training.
I would like to express a heart felt gratitude to Mr. Rajeev Vikamshi of FlowserveMicro finish valves PVT Ltd for permitting me to do my training in their esteemedorganization.
I also thank Mr.Mayur Lodaya, Miss Sushma J, Mr. PM Vernekar, Mr. DanielEkbote and Mr. VM Nayak the external guide Mr. Nishant Lalka and the entirestaff training me at Flow serve Micro finishes Valves PVT Ltd with their kind cooperation during the training.
I take the honored privilege of expressing my sincere thanks to our esteemedDean Mr. P.N Khatawkar and internal guide Miss Rubina F. for giving thisopportunity to undergo the practical training to equip yourself with the knowledgeof organizational study.
Swapna Priya
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INDEX
Section-11. Preface 2
2. Introduction of the Company 3
3. Company Profile 6
Section- II1. Different departments and their working 9
Section-III1. Objective of the study 53
2. Data collection 53
Section- IV1. SWOT Analysis 54
2. Conclusion 56
3. Bibliography 57
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PREFACE
The dynamics of constant change in the present business environment bringsforth to us there challenges f well equipping our selves with profound theoreticalknowledge and the skill of applying the same. With this view point: In-planttraining wows thus designed to be a part of the curriculum.
In-plant training is that activity which helps us in gaining practical knowledge andcorrelates it to our theoretical study.The option of studying more about working capital was indeed an experienceworth wile for our carrier since working capital is an important part of everyorganization which determines the organizations liquidity position and its currentposition in meeting its current obligations.
Flow-Serve Micro finish valves PVT LTD, A 100% Export Oriented Unit is one ofthe renounced and successful organization. Thus, this being an esteemedorganization- I had a great opportunity for completing my training successfully.
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INTRODUCTION TO INDUSTRY
Flowserve Micro Finish is one of the 100% EOU. On the city of Hubli. The FlowServe Micro finish Group of companies consist of two units namely FlowserveMicro Finish Valves PVT LTD, and Flowserve Micro Finish Pumps PVT LTD.
Flowserve Micro finish Valves PVT LTD. Was ESTB: in 1997 to manufactureindustrial valves plug valves and valve components. The company is located in
industrial area, HUBLI which is one of the biggest industrial centers in the state ofKarnataka, INDIA.The company manufacturing unit has a 15,000sqft of built up area to house thefacility.
The companies catering the major needs of industries in the field ofpetrochemicals , refineries, fertilizers, fine chemicals, pharmaceuticals, food andbeverages and other general chemical industries.
Before knowing more about the companys success and functioning, let us knowwhat valves are.
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Valves
By definition valves are mechanical devices spherically designed to direct, stop,mix or regulate the flow, pressure or temperature of a process fluid. Valves canbe designed to handle either liquid or gas application.By nature of their design, functions and applications, valves come in a wide
variety of styles, sizes and pressure classes.
BASIC FUNCTION OF VALVES
Starting and stopping flow
Regulating flow volume(frequently called throttling) Preventing reserve flow(called anti back down)
Changing flow direction
Limiting fluid pressure
The application of valves is done in every imaginable field. There areranges of valves we encounter in our every day life; from the valves inside ourbody such as the heart valve to the valves inside the automobiles we drive, tothe water faucet we turn on /off. It is hard to realize how many there are and howwe come to depend on them.
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Brief history and background:
As mentioned earlier, Flowserve Micro finish Valves and Pumps PVT LTD wasestablished in the year 1997 to manufacture valves i.e. Ball Valves and Plug
Valves and industrial pumps i.e. ISO Pumps and ANSI Pumps. The companiesformed as a result of joint venture between Micro finish and FlowserveCorporation USA, with Flowserve as the major share holder.
Valves and pumps manufacturing units have a 15,000 sq ft. & 10,000 of built uparea to houses the facilities respectively. Both the division s has an open spaceof 10,000 & 13,000 sq ft respectively for further expansion.
In addition, the two units have excellent machining testing facilities consisting ofCNCs, Center lather, Milling, Drilling, and grinding machines SPMs etc.supported by adequate gauging measuring instruments.
Dedicated staff and workers strive to ensure thatch the company s qualityobjectives are achieved.
The company s having documented Quality system to meet the requirement ofISO 9001-2001 to ensure that its orders processed, products manufactured meetthe requirements of the customer. Father the companies also certified for CE-Marking.
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FLOWSERVE MICROFINISH VALVES PRIVATE LIMITEDORGANISATION PROFILE
1. Name of the organization : Flowserve Micro finishes Valves
Private Limited
2. Type of Organization : Private Limited.
3. Location of works andRegistered office : CTS No 568/1, Industrial Area
Gokul Road Hubli- 580-029
Phone: 0836-2333202Fax: 0836-2333205E-mail: [email protected]
4. Promoters : Flowserve Corporation, USA.Micro finish Valves Limited, Hubli
5. Year of establishment : 1997
6. Contact persons : Name:
1. Tilak. K.VikamshiDesignation: MD2. Rajeev.T.Vikamshhi
(Manuf.Manager)
7. Product details : Manufacturing and export ofIndustrial valves viz.ball valvesPlug valves and valve components
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SHAREHOLDING PATTERN:
Shareholders % of
Holding
Number of
Equity share
Equity
Capital(Rs.)
Flowserve(Mauritius)
Corporation,USA
76% 265200 26524000.00
Micro finishValves Ltd,
Hubli, INDIA
Total
24%
100%
837600
3490000
8376000.00
34900000.00
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8. Product Marketing : Flowserve Corporation USA,
Through its global subsidiaries
9. Production : Year Valves ValveGroup
2003-04 5562 125564
2004-05 13723 156215
10. Directors : Mr. Tilak . K. Vikmshi
Mr. Deepak. K VikamshiMr. S. Gopinath
Mr. Michael. DOlsen
Mr. John. M Nanos
11. Name of the Banker : Canara BankAnkush Arcade
Station Road
Hubli- 580 020
ICICI Bank Ltd
TB Road, Deshpande NagarHubli-580-0289
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Section II
PLANNING AND PURCHASE
Hierarchy of Management
Planning & Purchase
In charge
Sales & Shipping Planning Store Local
Officer I Alloy II Purchase
PLANNING:
Planning is the activity which acts as a backbone of every organization and leads them
one step further t their success. Every organization chalks out best plan which is in tunewith its resources and application of the same in order to meet their commitments.
ObjectiveFor usage of resources to meet the delivery commitments.
Responsibility
Planning and purchase in charge is responsible for drawing tentative and monthly
manufacturing plan through assistant.
Production and assembly in charge is responsible for modifying the plan to meeturgent customer requirements.
Procedure1. Plan is drawn to approximate 90% of capacity is researved to meet the urgent
amendments.
2. 2. Tentative monthly manufacturing plan for a particular month is drawn 5 weeks
earlier considering the following elements but is not limited to delivery date ofwork orders & pending orders availability of materials, feedback from P & a
Dept.
3. Tentative plan is modified / amended of required on the basis of feedbackinformation from other departments.
4. Final plan is issued 1wk earlier to the particular month.
5. Final plan is amended if required on the basis of feed back from P & A Dept6. Causes of not metering the plan are discussed with P & a Dept.
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PURCHASING
Objective:
To ensure that all purchased items and services meet the specified requirement.
Responsibility:
Planning and purchase in charge is responsible for approval of supplier and
vendor rating.
Planning and purchase in charge is responsible fro controlling procurementand utilizing qualified suppliers.
Planning assistant is co- coordinating with Quality Assurance department for
evaluation of suppliers & submits the report to planning and purchase dept for
revival and approval;
Procedure:
1. Evaluation of supplier
The potential suppliers are identified based on either introduction letter past experiencereputation of supplier in the market.
Planning assistant submits the evaluation report to P&Prge for review and if the
supplier is acceptable P&P in charge will construct the planning assistant to get thesamples.
On receipt of samples, planning assistant will arrange for inspection by QA dept.
All the approved suppliers will be re evaluated once in 3 yrs to know their presentcapability for continuing purchasing/processing of material with them.
Approved supplier with whom purchasing is not done for more than 2 yrs form his lastsupply are delegated from the list of approve suppliers.
2. Type of control excersied on approved suppliers:The requirements for raw materials / products to be purchased / possed is
based upon work order plan stock rejecting level particular supplier and the purchase
order is prepared as per the work instructions.
3. Purchasing DataThe requirements for raw materials products to be purchased possessed is based
upon work order plan stock rejection level of particular supplier and the purchaseorder is prepared as per the work instructions.
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4. Rification of purchased processed product
Customer or his authorized representative will be afforded the right to inspectthe sub contracted product at the supplier premises & also at FMVPL if contractually
agreed. Such requirements are communicated to the supplier through the purchase order
& to the sub contractor through letter.
FUNCTIONS
1) Generation and preparation of purchase Order.
Procedure
Purchase is based on lead time work order stock. Planning Assistant carriers out thefollowing activities while generating the purchase order.
Supplier name, Postal Address.
Enquiry/ Quotation / Reference / Rate contract date.
Mode of Transport
Special notes (if any)
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2. Supplier codification
Procedure:
The supplier code will consist of three parts
a) Potential Supplier or Approved supplierb) Type of raw material supplied by the supplierc) Continuous serial number of supplier for supplying the same type of
material.
In case of supplier supplying more than on type of items the code for which he is
approved initially will be applicable even though he is subsequently approved for
different type of items.
For example: A\SC 01
P\SC 01
Where A- Approved supplier
SC- Supplier supplying sand casting
1- First approve supplier supplying the sand casting
P- Potential Supplier
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RESPOSIBILITY & AUTHORITY
OBJECTIVES To manage, perform and to verify work effecting quality
SCOPE Personnel of production and assembly department who carry out activities effectingquality.
ResponsibilityManufacturing manager is responsible for appointing personnel in the department
change of responsibility assigning responsibility to personnel.
PROCEDURE
Production and assembly in charge are defined in quality management
. RESPONSBILITY OF SHIFT INCHARGE1. Loading company / product on mark
2. Providing document work.
3. Company / production identity.
4. Test status of components5. Check calibration status
6. marking finished products
7. Receiving goods from stores8. Control of tool system and fixtures
9. Proper handling of finished goods
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AUTHORITY AND SHIFT INCHARGE1. Authority to reschedule loading of machine during night shift.
2. Can decide stoppage of machine in case during night shift
RESPONSIBILITY OF MAINTAINE=ANCE INCHARGE
1. Preparations of pre maintained schedule
2. Spare parts replace recovery
3. Stock spare components
AUTHORITY OF MAINTAINANCE INUSTRY1. Has authority to deice on minor and major maintenance decision whether to shut
down or not/
PROCESS CONTROL
Objective
Is to monitor the special process continuously and to ensure that they are carried
out by qualified personnel and are in complains with document procedure to meet
special requirements.
SCOPEA special process the result of which cannot be fully verified by subsequently inspection
and testing of the product special process such as welding
PROCEDURE
The quality assurance in charge through his personnel qualified the special
process and ETB the documented procedure
The welding process are carried out as per welding procedure specification
(WPS) which are qualified as per Q.A department procedure for special
process and they respective work in instruction
Continues monitoring of the process is carried out by the productionassembly in charge through his personnel based on the data provided.
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Production and assembly Incharge
Shift 1 Shift II
Machine Operation Machine Operation
Helpers Helpers
Helpers Filters
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Production
It is one of the vital activities of every firm, it is this department which ensures the
production process is identified planned & carried out under controlled conditions inaccordance with the monthly manufacturing plan. The objective of this department is to
improve the productivity to reduce the cost of production with out any compromise on
quality and to manufacture non defective products by training their workers.
Objective1. Productivity improvement
2. TO reduce cost with out compromise on quality
3. To manufacture non defective product by training the people.
PRODUCTION PROCESSThe production process is carried out in the following three steps:
1. Control of customers supplied product
2. Process Control
3. Production Planning and process.
1. CONTROL OF CUSTOMERS SUPPLIED PRODUCT:
It is the responsibility of the cell in charge or production planning assistance to
collect the customers supplied product from the store for in corporation into the valveproduct. He collects these products from the store against every while ensuring that theproduct has been issued fro the particular work force ch it is meant.
2. PROCESS CONTROLL:
The production department ensures that the manufacturing process is carried out in
accordance with monthly manufacturing process is carried out in accordance withinmonthly manufacturing plan under controlled conditions. The production department in
charge plans the production operations.
Necessary documents are prepared by the cell in charge for the production process to becarried out. Equipments are verified as capable of production in accordance with products
specification.
The product characteristics are mentioned in conclusion with Quality Assurance
Department And non Conformity products. Are compiled against customers demand.
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PRODUCTION PLANNING AAND PROCESS
Upon the receipt of the work order copy and tentative plan monthly manufacturing plan
from the [planning and purchase dept instructs the production personnel to determine thematerial availability. In the event of material shortage the production personnel will
replace a material of shortage list to the planning and purchase dept. IF the excess
material is taken them it is returned to stores through material return note.
The production personnel will refer the production plan & collect the material for
processing from the store through material issue slip. For assembly the material are
collected through material requisition.
The shift in charge will collect the drawing from the craftsman for the processing.
The P & A in charge schedules the assembly and prepares the daily assembly schedule &
ensures that the same is carried out through the shift in charge who prepares the assembly
job card and instructions to the operators / Filter s. After assembly schedule products arehanded over to final inspection and testing section along valve assembly and testing
status format & assembly job card
After clearance from the quality dept the shift in charge will send the assembled todispatch and finished valve completion note is give to the stores.
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TWO TYPES OF MACHINES
1. Conventional Machines.
2. CNC machines
Conventional machines: All the operators in this type of machines are one manually.The costs of such machines are cheaper &n the capacity is also less and are less safe the
can machines.
CNCMachine s (CNCM)These machines aerated automatically i.e. a programmed is written for its functioningwhich is in assembly language. There are two types of CNC
A) x & y side (2 Dimensional)
B) x,y,z side (3 Dimensional)
X, y side machine can handle 2 operations at a time by the help of the programmers fed
in it.
X, y, z side machines also handle many operations at a time by the help of theprogrammed s written in it to do so.
ASSEMBLY
PROCEDURE TO ASSEMBLE THE VALVES
The plug ball valve assembly is done as per the work instruction received from m\sFlowserve Corporation USA because most of the time only components of plug ball
valve is dispatched rather than assembled valve.
After the valve is inspected by Q.A Department and if the valve is ok it will be moved to
the ok yard and then to the maintaining and then to the packaging.
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IBMR COLLEGE, HUBLI
Quality Assurance in
charge
Receiving Qualityengineer
In process qualityEngineer
Final product Component Testing
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QUALITYQuality refers to the degree of perfection by the user of a product. At Flow serve Micro
finish the objective of the Quality assurance is to maintain a consistent appraisal ofquality.
Functions of quality Dept
1. Incoming Material inspection ]
2. In-Process Inspection
3. Final Inspection
1) Incoming Material Inspection
All materials are coming from outside such as castings bought items nuts, and bolts andpickings nave subs contract items to the applicable works.
Receiving quality engineer is responsible to ensure that the quality of incoming
components is in accordance with the established methods and the qualities of all
accepted items are conforming to the specified requirements.
Receiving quality Engineer is also responsible for identification of item castings bought
out items and machine components which are received as samples and test the sample.
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In Process Inspection
Components taken for further process are also inspected. Machines that are used in the
manufacturing process are also inspected periodically.
In process quality manager is also responsible for ensuring that the special processes are
in accordance with the estb methods.
Special process carried out by in process quality Engineer is as follows
a) Welding :
In process quality engineering is reasonability for continues monitoringthe welding process parameters are listed in welding process specification and are carried
out by a welder
b) MaintainingMaintaining is carried out as per work instruction of maintaining specificationon the past experience.
4. Final Inspection
This inspection is mainly to check if any of the tapes that may have occurred in theabove stages.
Final product engineer is also a responsible for identification of terms reviewing
non- conforming products and for maintain quality records and to ensure that asseledproducts with regard to inspection and results.
Final product engineer I also responsible fro issuing test certificates material
certificated compliance and warranty certificates as against requirement of work
order.
Final product Engineer is also responsible for inspection of painted product as per
specification
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The following colors are used for maintaining.
Ball valve - Oxford blue
Hand wheel - Oxford blueAdapter pipe Silver
Plug valve P.O red
Final product Engineer is responsible to ensure that all out going components products
are subjected to dispatch inspection. He verifies the components material of construction,
size, class, special requirements and metal gas etc. with WO an ensures the sample tested
valves are packed with identified box and note down the box identification and then theinspection and testing results are noted down in the Dispatch Inspection Report.
INSPECTION COLOR USED BYQ.A DEPARTMENT
Green: ConfirmingBlack: Accepted on Deviation
Yellow ReworkRed: Reject
Dark Blue: Hold
TYPES OF TEST CONDUCTED BY THE Q.A ASSURANCE DEPARTMENT
Hydrostatic Shell Test
Pneumatic Seal sTorque Test
Pneumatic Shell test
Dimensional testRadio Grapy
Ultra Sonic
Visual Test
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TESTING Ball valves
1. Objective
To ensure pressure containing capability of the valve and as well as to ensurethrough valves.
2. Scope
2.1 Hydrostatic shell test of body and tail piece2.2 Break away to test
2.3 Pneumatic seat test of assembled valve2.4 Break away torque test.
Testing of Plug valves
1. Objective
To ensure pressure containing capability of the valve and as well as well to ensure
the torque valves
2. Scope
Hydrostatic shell test plug valve bodiesPneumatic heat test of assembled valves
Break away torque of assembled valves
3. Responsibility
Final Pd, Engineer/ testing personal are responsible to carry out the tests
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Corrective/ Preventive actions relating to defective items
Procedure:
Casting Defects
The quality assurance personal identifying the potential causing defects fills three
copies of casting defects report. A cause of defects as the one needing corrective
action by referring to previous inspecting reports or the lot of castings received as
appropriate present inspection status.
The drawing in which the defect is light face is attached to the report
Two copies of the casting defect report are submitted to the P & P charge for
further action as to talking up the matter supplied.
After receiving the casting from process dye pattern which has access corrected
after effect is re observed the same bought to the notice of P & P dept personnel
who in turn feed back the supplier
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PRODUCT PROFILE
Product Size/ Range
(mm)
Max PD
\Rating
Materials of
Constructions
Ball Valves 15-200
15-50
#800
#800
CS/SS
CS/SS
Plug Valves 15-150
15-50
#150
#300
CS/SS
CS/SS
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PLUG VAVLE
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CONTRACT REVIEW
PROCEDURE
TENDER / ENQUIRY
Any requires or tenders received for products where price are available will be reviewed
and quoted.
Manufacturing manager is responsible fro special products are tenders received fromclient are scrutinized manager is aspects of adequacy, correctness. Of techno commercial
details and then it suit to the customer.
The requirement are identified aim tender/enquiry are viewed in co ordination with the
concerned manufacturing manager and clarification are viewed further accordingly
Manufacturing manager is fully responsible and sent it to the customers.
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ORDER REVIEW
After getting approval from manufacturing manager the acceptance order will be
prepared
Techno commercial details for scrutinized the adequacy and correctness.
Department head is responsible for re- reviewed of special requirements identified
in the order.
The orders and the requirements which all the customers is ordered it will
recorded and conveyed and clarification for the ambiguities obtained from
customers I tray verbal or any documents.
When the manufacturing manager will start taking the order he should see to it
that the departments which are in his control are capable to do the customersrequirements according to that he should accept others.
The manufacturing manager will scrutinize all the clarifications needs in orderand the work order and other preparations are like amendments made according to
the manufacturing managers.
IF any approval is required for specification from the customers sales and
shipping officer will get the approval from the customers and copy will be filed in
the respective work order file.
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CANCELLATION OF ORDER:
Cancellation note will be issued concerned department and work order or amendments
undergone cancellation are taken back from all departments and a copy will be file din
the cancelled order file and the extra valves and pumps are registered fey officer in samebefore how they are specified as per the order of the particular party if there s a change in
quantity and size and totally a cancel.
These valves pumps will be relocated to other order by companying with the
complete specification of work order to which it has to be re located and a copy will besubmitted to production and assembly will make use of whole valves and pumps or
required parts by dismantling the valves/pumps.
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GENERATION OF BILL
PROCEDUER:-
To generate BM select particular work order on comp to select the respective
valve description BM serial num.
If BM is not available for any valve description then copy from similar type of
valve description and make any changes if necessary and generate the BM
In the event if any amendments to work order, BM will be amendment accordingly.
REFERENCE:
Work OPRDER
Work order amendment
Bill of material
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LIST OF CIENTS.
Flowserve Micro finish group is a joint venture of Flowserve Corporation USA and
Micro finish group of companies Hubli, .INDIA. It is a 100% ex [port oriented unit(EOU) currently products are exported to the following countries
DIVISION 1: VALVES
(BALL VALVES, PLUG VALVES, AND PLUG VALVESCOMPONENTS)
A) Flowserve: USA
B) Flowserve AUSTRALIA
C) Flowserve SINGAPORE
D) Flowserve GERMANY
E) Flowserve BRAZIL
F) Flowserve TAIWAN
G) Flowserve Korea
H) Flowserve SOUTH AFRICA
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DIVISION II: PUMPS
A) Flowserve : USA
B) Flowserve : UK
C) Flowserve : SINGAPORE
D) Flowserve : AUSTRALIA
E) Flowserve : BRAZIL
F) Flowserve : MEXICO
G) Flowserve : KOREA
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STORES DEPARTMENT
OBJECTIVE
To provide general guideline for monitoring stock levels from material receipt stagethrough finished components
RESPONSIBILITYStores officers are responsible for proper accounting. Handling and storage of raw
materials and products. Store officers of respective stores are responsible for planning the
storage space in stores section and assigning the material to identifiedLocation and maintains records of receipt and issue of material.
FUNCTIONS OF STORE DEPARTEMNT1. Verification of materials n receipt o material
2. Issue of raw material and control of raw material
3. Finished components issued for assembly\dispatch4. Handling.
1) VERIFICATION OF MATERIALS ON RECIPT OF MATERIAL.
Store officers verify the martial with respect to delivery challan of vendor weight
quantity and martial grade etc. nod compare verify the same with respect to purchaseorder.
If weight quantity and material are found ok party acknowledgement copy of delivery
challan is stamped as defined below
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Goods received subject to verification and acceptance
And the stores officers arrange to store accepted materials components and products in
respective stores to prevent damage and deterioration. The stores are identified as underSTORE 1: Sand castings, Investment Castings, Levers, End caps, adapters.
STORE II: Fasteners, Teflon, Gland, seat springs disc, accessories.
ISSUE OF RAW MATERIAL &B CONTROL OF RAW MATERIAL
Raw materials like castings issued for processing are issued to production and assembly
through material requisition note.
3.) FINISHED COMPONENTS ISSUED FOR ASSEMBLY
\DISPATCHEDFinished components bought out terms are issued to production and assembly
for assembly or shipment through material requisition.
4.) Handling
Finished components products are stored at identified area and are protected to avoiddamage by means of protective caps for bodies and tail piece, Netlon Sleeves for plugs.
Proper cushioning is to be provided while storing and travelling of finished items.
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PACKING
Objective
The main objective of packing is to carry the proper packing before dispatch
Scope
Scope of packing is packing of valves & valve spares seaworthy applicable.
Responsibility
Sales and shipping will study the packing slip through with respect to work order
Sales & shipping officer will decide the size of the box depending on quantity
Sales & shipping officer will contact the valve num from quality assurance dept against
packing slip. Valve will segregating as per packing slip and sales & shipping officer willensure that all valves have undergone final inspection before packing sales and shipping
officer will ensure that they are properly identify with respect to purchase order.
While checking the packing the following details are checked
Packing box markings
Destination box markings
Name of the transporter
Identification number
Supplier number
Number of boxes.
During the formation of packing boxes the following points are taken care
Planks are of treated anti termite treatment by spraying wooden case which
composed one part by weight.
Silica gel is used as moisture absorbent
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Boxes are lived with resin cloth with one coat of coal tar on an polythene and
embedded on jute nut
Boxes are provided with felt and felt and paper cutting as cushioning materials.
These areobhectives and scope of the packing and the precautions which taken
care while packing the valves and the spares of the valves and the chemical s
which are used on the packing box for prevention of insects.
SALES & SHIPPING DEPARTMENT
Preparations
Contac review
Preparation o fork order and Amendments
Solving customer Satisfaction
Packing
1) Contract Review
PROCEDURE:
In case of tender \Enquiry review where prices are will be reviewed and quote and in
cases where special products tender \enquires are received from the client , they will be
scrutinized for adequacy, correctness of techno commercial details and suitable tenders
are accepted and bids are prepared and sent to the consumer after approval by COO
In case of order Review , Order acceptance will be prepared and will be sent to customerafar getting approval from COO Order documents will be scrutinized for adequacy and
correctness of techno commercial details and any special requirements identified in the
concerned department.
And then COO will verify the capability to manufacture as per customer requirements in
co ordination with concerned department in charge and finally will accept the order.
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2. PREPARATION OF WORK ORDER AND AMENDMENTS
PROCEDURE
S.S.O will take care of the slowing while preparing the work ordersI) Accepted order numbers
ii) Item descriptioniii) Delivery date
iv) Special instruction, freight destination, mode of dispatch
v) Work orders
In case of amendments revised details are highlighted in the work order if possible
otherwise new work order are prepared and revised details are highlighted in theamended work order and issued as per the instruction. And earlier work orders are taken
back and a copy is preserved in Obsolete work order are taken back and a copy is
presented in Obsolete work order File
3.) SOLVING CUSTOMER COMPLAINTS
PROVEDURE
The complaints are normally received directly from customer. The complaints can bereceived in any means i.e. verbal/fax/mail etc. If any information regarding the
complaints is inadequate the same is obtained by communicating with the customer.
4 ;) CUSTOMER SATISFACTION SURVEY:
PROCEDURE
To monitor customer satisfaction or dissatisfaction a questionnaire is prepared which
includes carious points relating to quality of products prices bill delivery documentationetc which is sent to the customer fro review and comments. Based on the points obtained
customer satisfaction index is prepared by using following formulae:
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Customer Satisfaction index
If the % obtained is less than 80% then the area where customer is dissatisfied areidentified and a plan is initiated to eliminate them, Suggestions for improvement are
solicited from customer which are implemented wherever feasible and finally a record of
customer satisfaction is maintained
5. PACKING
PROCEDURE
SSO studies the packing slip thoroughly with respect to work order and will decide thesize decide the size of box depending on the quantity and will collect the valve numbers
from Q.A dept against packing slip.
Following details are taken care by SSO while packing
i. Packing box marking
ii. Designation address
iii. Name of the transporters
iv. Identification Numberv. Suppliers Name
vi. Number of boxes
The SSO will check whether the planks are of wood and are treated with ANTI
TERMITE by spraying chemicals like Hydrated Arsenic pent oxide, Blue Vitriol and
Potassium Dichromate and silica gel is used as moisture and boxes are lined with resincloth with one quote of coal tar on polythene and embedded on jute nut. And boxes are
provided with paper cutting as cushioning material,
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ACCOUNTS FINANCE
FINANCE:This department plays a vey vital role by providing and maintaining the entire details of
each financial activities of company.
OBJECTIVES OF FINANCIAL DEPARTMENT
To provide accurate and complete systematic information of financial activities
To maintain all the books of the accounts and other financial documents
To prepare periodic financial statements of company like profit and loss account
and balance sheet
FUNTIONS OF ACCOUNTS DEPARTMENT
1. Preparing of outstanding debtors and creditors on regular basis.
2. Issues of bank guarantee s indemnity bond and follow up of expired
3. bank guarantees for cancellation
4. Maintenance of accounts book inventory on tally
5. Writing of checks
6. Handling of cash payments and pretty cash
7. Issues of c forms etc.
8. Preparing export documents
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BOOKS OF ACCOUNST MAITAINED BY ACCOUNTS DEPARTMENT
It maintains its complete accounts in tally software package and takes print copiesof following registers every year.
1. General ledger register
2. Sundry debtor register
3. Sundry creditor register
4. Journal register
5. Cash book with bank column register
6. Sales register
7. Purchase register
8. Debit and credit note register
9. Bills discounting and collected register
10. Asset register
11. Stock Register
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ADMINISTRATION AND ACCOUNTS
HIERARCHY OF MANAGEMENT
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Administration andAccounts in charge
Personnel Officer
(Factory and
Personnel safety)
Accounts
Assistants
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Functions of Administration Department
Training
Recruitment
Safety
House Keeping
Other functions
1. Training
Objective: Is to provide the adequate training to the personnel of all departmentsperforming activities affecting quality.
Responsibility:Administration and accounts (A & A) in charge through personnel officer is overall
responsible to ensure that the training needs personnel of all the apartments are fulfilled.
Personnel officer is responsible for identifying the appropriate trainer inconsultation with the top management for arranging the training. In charge of
respective departments are responsible to appraise and to forward the training
requirements of their Department personnel to personnel officer.
Training is given for employees once or twice in a month depending on the
need. In training the following aspects are covered :
Product application, basic computer knowledge, instrument knowledge ,industrial safety and first aid, statistical quality control , ISO awareness
(9001:2000) , Leadership quality, man power handling , commercial acumen,
communication skills, identification and traceability, material handling
2. Recruitment Personnel officer is responsible for recruiting the right person for the right job.He takes into consideration the knowledge, skill and work experience of the person.
3. Safety
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Safety committee meeting is conducted every quarter. Safety related training for
staff and workers is conducted once in two months such as Fire Extinguisher,
Chemical Hazardous, and Personal Hygiene etc and first aid facility is also providedfor workers. Safety round up is carried out by the personnel officer accompanied by
HOD and two workmen or staff of different department.
4. House keeping
ProcedureFor effective implementation of the system, the entire premises of the company are
divided into sub zones as production and assembly division, Quality Assurance
Division, Administration and Accounts division etc. Each sub zone is headed by a
team leader and supported by co ordinates, supervisory staff and workers.
5. Other functionsThe other functions of Administration dept are as follows:
Salary Calculation
Maintenance of all relevant records
Issuing of canteen coupons
National Sample Survey
Employment Exchange
Quarterly returns of men and women
House keeping
Canteen Administration
Security Administration
Other facilities provided by the Company
o Canteens: The Company provides breakfast facility to theemployees. The canteen is maintained in a hygienic condition.
o Coupon books: Coupon books are provided to employees fortheir daily Tiffin in the company canteen at cheap rates.
o The company provides TEA to the employees twice a day free of
cost.
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o Two sets of Uniform for each employee is provided by the
company.
Salary Administration There are skilled, semi skilled and unskilled workers in the organization andthey are paid according to their ability and qualification and with consideration of
the Government regulation.
Salary Payment date.Employees Date of Payment
Staff 31st of every month
Workers 5th of every month
Labor Force
There are about 76 employees working in the organization
AttendanceThis department records the time (i.e. the time of workers in and out of thecompany) through punch card system right at the entrance.
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SECTION III
Objective of my study
1) To know the process of the organization.2) To study different departments
3) To learn about supply chain production
DATA COLLECTION
Primary source
1) Direct interaction with the Departmental heads, guide and employees.
Secondary Source
1) Collection of data from printed source and documents.
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SECTION IV
SWOT ANALYSIS
STRENGTH
1. Financial LiquidityThe firm has an overall sound liquid position as the current ratio is above
the standard ratio
Even the net working capital ratio clarifies the firm s ability to meet its currentobligations is efficient
2. High turnover
The firm s turn over on ties assets have been increasing as it is evident from allthe assets turn over ratios and the returns made on its investments are also
relatively good.
3. Working capital
Both from the financial data and the computation of ratios it is been found that
the firm has adequate working capital.
3. Quality
Both from the financial data and the computation of ratios it is been found that the
firm has adequate working capital.
4. EOU status
Being an EOU the firm gets a green card and thus making it eligible for thevarious benefits and incentives from the govt. This status helps it in reducing its
costs.
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WEAKNESS :1. Inventory :
The companys investment in inventory can be considered has high since it does
not follow the concept of Just in time2. Increase in variable expenses
From the data collected it is been found that the expense (Variable) has increased.
OPPURTUNITIES:1. Expansion & Diversification:
Various opportunities exist in the international market which the firm cancapitalize on by expansion and diversification...
2. Additional services:There is also a potential market for spare marts. The firm can also provide
additional services in terms of valve and valve components.
3. Production:
Increasing production capacity by reducing costs.
THREATS:
1. Competition :
The company can face serve competition from other potential firms in the
international marled
2. Increase in costs
The costs are bound are bound to increase when the tax holiday and otherexemptions are lifted.
3. Excessive working Capital
The firm should also not maintain excessive working capital since it may results inaccumulation of inventories, idle funds etc.
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CONCLUSION
INDIA is said to be a land small-scale industry, it is also said that is a
leading business revolution favored by political, economic, social and
demographic factors. Though it cannot by pass the poor completely it istrying it best to generate employment opportunities.
There are also developments taken up regulatory role for several small
firms are trying to achieve spectacular growth and there s the smaller firms
the smaller firms are craving out profitable niches by adopting appropriate
marketing strategies and one a days in the market consumers are considered
as the pre dominates who buys new and innovative and is in tradition
In addition even political is awakening and giving positive support to theeconomy and ultimately to business environment of India.
With the help of proper environment and public and also political and
government support can step up INDIA into global market.
I Mrs. Laxmi Thakur has profitable experience in our IN PLANT training IN
THE
Training in the most reputed firm in the group of industries that is the
flowserve microfinish valves and pumps I havecompleted my 1st in plant
training between deck -06 to Jan -07. I am proud to say that I am very lucky
to finish my training in an ISO 9001-2001 I firm which is also an 100%
export oriented unit which produces valves and pumps with CE marking
which exports its products.
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The management has also maintained a good relation with its employees
nod all the employees are quiet satisfied with the eighth the management.
Even the management is satisfied with the works of the employees. Thus
there is a sound industrial relationship maintained between the employees
and the organization.
The organization has also maintained a good relationship with the
customers. They have a regular customers from outside countries to which
they supply their products. They supply their products only to Flowserve
industries; all these have positively resulted in gaining name and fame with
the increasing refits and sales every year.
We had knowledge experiencing implant training. Be it the personnel of
Flowserve Micro finish, the workers or its environment they all have
invested their precious time in helping us to learn the practical tools of
business.
Lastly I conclude that we had a great practical experience about the industry
and helped me to learn all new technical and also practical knowledge and
also about the working of each and every department and also the flow of
process of organization.
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Bibliography
1) www.microfinishflowserve.com
2) www.karnatakauniversity.com
3) Manuals of companies
http://www.microfinishflowserve.com/http://www.karnatakauniversity.com/http://www.microfinishflowserve.com/http://www.karnatakauniversity.com/