1111111EXECUTIVE SUMMAR1

8/6/2019 1111111EXECUTIVE SUMMAR1

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EXECUTIVE SUMMARY

BDK engineering industries ltd internationally recognized compan\ .\ bout BDK I submit

my project report. It contains lot of findings, stigcst on and conclusion also. Theoverview of the project report I summaries in this spot.

The main objective of the study is bat to know the production excellence of the

BDK.BDK uses high Quality of raw materials and also get certificate ftorn ISO9001:2000.company also offering a powerful combination of low prices and high Quality

are capturing, the heart and wealth of consumer.

These are all information collected from primary data collect 1mm inlefvieu s withBDKs managers, worker and some other knowledgeable persons ahou companies. The

secondary data collected from hooks, journals and vebsite.

My project report mainly focuses on production and Quality management. How much

production is important similarly Quality also very important. Production and qualitiesare contributory each other in development ol industry. Quality management contains

mainly three points that is Quality control, Quality assurance, and Quality important.

These are three points covers in this project report

This project report finds some weakness of the BDK. These are cost ft)r maintainingsanders is high. This is the one of the major weakness ol the 13[)K and here there is no

financial control this is also the major weakness ol the 131)1K. this project report alsoprovides some remedies. These are to adopt aggressi\ advertising with regard to their

competitors. To provides more infirmation about the valves and pumps to its employees.

It helps to company.

Finally I conclude about this project report the BDK company production and service isexcellence.


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Objectives of the study

a. To know the production excellence of BDK

b. To know the Quality control principle, of the BDK.

c. To know the production scale of Bf3K.d. To know the different aspects of Quality management in BDK.

e. To fulfill the partial fulfillment of BBA degree

f. To find out the different in theoretical aspect used in industries

g. To know the production process of the BDK.


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Scope of the study

L Project report summaries production and Quality management of the Bl)K.

2. Project report covers the theory aspect, of relates to the production Quality of the

management of the BDK.

3. Project report also summaries strength and weakness, opportunities and threats of the

BDK.

4. Project report provides production process of the Company.

Methodology

Collection of data is problematic once. We collect data main1 and other one is secondary

of data.

Primary data: primary data is collected throughout personal interviews the concerned

officers and executives in the relevant fields. The other source of the data collection was

the observation method where in observed the working of the process in the company.

Secondary data: the Secondary data was collected by referring various magazines related

to the topic and also by searching internet. The information regarding the organization

collected through company website.


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Limitation of the study

1. Time constraint

2. This project report contain only on production and Quality management.

3. It covers only production and QuTity management theory aspect.

4. Managers are so busy, therefore collection the data very dificu1t.

5.The result of the study cannot be generalized it is specific to one particular company on

one particular topic.


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ORGANIZATION STRUCTURE OF BbK:

SIC - Section In Charge

FTC - Functional In Charge

MR - Management Representative

SC - Sales Co-Ordination

QA - Quality Assurance

PPC - Production Planning


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PRObUCTION PROCESS

During the course of technical arrangement of various facilities such as machinery,

equipment etc. it is necessary to give considerable emphasis on a proper plant layout to

achieving their optimum utilization. Like industrial location, plant layout is also is of

great strategic importance. The reason is that once the plant & equipment are erected, it

would buy very difficult & costly to change layout. Therefore, one needs to keep in mind

some importance aspects while deciding the plant layout. They are,

i. Production technology & production mix.

ii. Efficiency, economic & uninterrupted flow of men & material.

iii. Adequate space for maintenance work.

iv. Scope for future expansion.

v. Scope for future diversification of the project.

vi. Adequate safety precautions as & when need.

vii. Healthy conducive layout of the plant.

viii. Proper lighting & ventilation.

ix. Proper provision for effluent disposal, if necessary.

x. Effective supervision of all sorts of activities carried at the plant layout side.

xi. Provision for proper storage, stocking etc. where needed.

A proper plant layout ensures various advantages to the enterprises,

The important one are:

Increase in productivity.

Optimum utilization of floor space and other areas of operation like loading and

unloading.

> Effective supervision and control over industrial activities.


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Improvement in working environment.

- Economy in material handling.

Optimum investment in p1nt and building.

The backbone of any small enterprise is the products or ser ices it oli.s. Therefore, what

to product and how to produce is the first step in the evolution of an operational system.

In other words, product design is the key strategic decision an entrepreneur ahs to take at

the very beginning. Therefore, one necds to keep in view various factors like changes in

environment, technology and consumer taste/requirement while finalizing products

design. This also means that product launching should be dictated by market demands.

But, product design is not easy task that anyone can do on his/her own, The fact remains

1hit a right type of products design involves certain considerations/stages to he weighted.

Generally, an entrepreneur needs to keep the lollowing considerations in view while

designing his/her products:

> Standardization

Reliability

Maintainability

Servicing

> Reproducibility

Sustainability

Product Simplification

Quality commensurating with cost

> Product Value

Consumer Quality


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Scheduling is crucial to successful production. It is importani fr hoth hatch i.e. special-

order and continuous production situation. The primary objective of scheduling is the

smooth flow of material through the production process. Simply stated, scheduling is a

system of planning and keeping track ot manpower, equipment and material used, It

ensures when to start work on a given order and by what date it should lie completed.

Production Planning & Control

Production planning involves the organization of an overall manufacturing or operating

system to produce a product.

The various activities involved in production/operation planning are designing the

product, determining the equipment and capacity requiiemeni. designing the layout of

physical facilities & materials handling slein. determining the sequence of operations and

the nature of the operations to he performed along with time requirements and specifying

certain production Quality levels.

Production planning and control function essentially consists o1 panning

production in manufacturing organization before actual production activities

starts and exercising control activities to ensures that the planned Production is

realized in terms of Quality, quantity, delivery schedule & the cost ol

production.

Objective of Production Planning & Control

To deliver Quality goods.

To ensure maximum utilization of all resources.

To ensure production of Quality products.

To maximize the product through-put time.


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To maintain optimum inventory levels.

To maintain flexibility in manufacturing operations.

> To co-ordinate between labor & machines and various supporting departments.

- To plan for plant capacities for future requirement.

Rote of PPC:

> The main role of this department is to organize materials prccurement. production

planning & periodic review with all concerned heads.

> To plan for manpower and equipment for production & control purposes.

> To plan and organize the layouts of RPD & assembly for effective operation.

To co-ordinate & arrange for the prevention, break down & maintenance of machinery &

equipment.

Conducting design review meeting, non-conformance reviews meeting, customer

complaints meeting & Quality audits for finding out solutions.

PLANNING SECTION

PROCEDURE

Production plan for the month is prepared in the previous month in consultation with

sales co-ordination department.

Following work orders are considered to prepare the production plan

Work orders which are overdue as on last day of the current month.

> Work orders which are due in the month for which the production plan to he made.

> Work orders which are due in the next months.

Left over work orders from current months plan.

The reference for processing is given considering the following points.


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Work order due date.

> Urgency from the sales co-ordination department.

Material availability of all the components.

Referring the above mentioned points & considering the monthly production capacity, the

production plan is finalized any work order received after making production plan for

which if material is available, the same is included in the production plan in the form of

additional sheet.

Shortages for the production plan is worked out for follow up

As per shortage list, the material is sent to respective supplier referring the approved

supplier list & raising material requisition to stores.

RPD requirement for the production plan is worked out & given to RPD components to

be rubber lined are loaded by issuing respective job cards.

Tentative inspection plan for clients/third party inspection is prepared & given to sales

co-ordination department reviewed & modified periodically as required.

Monthly dispatch plan is prepared in consultation with sales coordinalion department &

given to painting packing & dispatch section.

Wherever control copies of drawings are not available, requisition is given to design &

development against work orders. After completion of the order. the drawings are filed in

completed work order file.

Production plan is also prepared for processing of the stock items as required.


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PRObUCTION, PLANNING ANb CONTROL bEPARTMENT:

{A(iM J. J. I ppin

It helps to understand the influence of planning activities at every stage of production a

sound planning and control policy and its implementation shall never fail producing a

Quality product.

Objectives:

To plan and meet production requirements as customer satislaction through continuous

improvement in planning, procurement, processing and optimum resource utilization.

> To identify and control the customer supplied product. Process of the PPC Department:

> Detail study of work order is done specifications and requirements are studied.

Availability of raw-materials, semi-finished goods, finished goods are worked out.

Production plan, Inspection plan and dispatch plan are drawn and issued to concerned

department.

Requisition to stores for semi-finished goods and raw-materials to send for processing to

sub-contractors.

> PPC Department receives WO/OA amendment or inter-department memo from sales

co-ordination.


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bESIGN ANb bEVELOPMENT DEPARTMENT:

[AGN/I Prasanna Sable

It is a core section of any manufacturing company. It is a section where the design and

development of products carried out. The BDK Company has a ftill pledged Design and

Development Departmit.

The complete product range is designed and developed by this deparunent. Each product

is tested as per the testing standards and Quality norms are laid down

ensure high Quality product, employees in this department are technically quali fled.

Objectives:

> To design and develop the Quality products which are ieliable, economical,

predictable and meets the customer requirements.

To continuously improve the Quality of all products structure.

Requisition to stores for assembly material assembling o[ is material is done at this stage.

,- After assembling products are offered for inspection and testing in the Quality

assurance dept. The testing facilities include vacuum testing. helium testing and modern

test beds.

Cleared products are sent to dispatch section.


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Quality management

What is Quality?

Companies offering a powerful combination of low prices and high Quality are capturingthe hearts and wallets of consumers. Today as value drives companies are growing in

number, they are moving from computing on Irice to providing Quality, service and

convenience.befinition of Quality/

l)Quality is a state in which value entitlement is realized for the customer and provider

in every aspect of the business relationship.2)The total set of features and characteristic of a product or service that delerminc its

abilities to satisfy stated or implied needs

Quality management

Quality management can be considered to have three main components:Quality control, Quality assurance and Quality improvement. Quality management is

focused not only on product Quality, but also the means to achieve it. ()uality

management therefore uses Quality assurance and control of processes as well as

products to achieve more consistent Quality.Quality management evolution

Quality management is a recent phenomenon. Advanced civilizations that supported thearts and crafts allowed clients to choose goods meeting higher Quality standards than

normal goods. In societies where [{art]responsibilities of a master craftsman (and

similarly for artists) was to lead their studio, train and supervise the work of their

craftsmen and apprentices. The master craftsman set


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BbK maintains Quality in its production. Let us see some

ppints how they maintain Quality.

Reliability (Trustworthiness)The Quality associated with a product often increases with the dependability of the

product customer experience. BDK produc are very reliable as other unifying companies.

DurabilityThe Quality attribute that implies product performance under adverse conditions.

Safety:

This is an attribute of Quality that measures the likelihood of harm tiom goods. BDKcompanys products are well packed and its protect from Safety: Use high Quality raw

materials and also get. ISO Certificates that shows ho 1 maintains Quality and shows

safety also.

Environmental friendly or Eco friendly:This Quality attributes has both societal aspects and is individual specific. Te

requirements for being considered an environmental friendly product is becoming more

stringent (strict).The BDK also follows environment health and safety poIic. The BDK

engineering industries is every Eco friendly BDK gets Certificate There areEMS: -Environmental Management System Serviceability.

This attribute relates to the ease and cost associated with servicing a product aller thesales has been made. The service of BDK in the field of sales sector appreciated by the

market.


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Aesthetics: Relating to appreciation of the beautiful).

Aesthetics are hard to define

It is customer specific and sometimes situation specific what is aesihcticall pleasing toone individual may be considered ugly by another.

Attribute Consistency:

The attributes associated with a product should be internally consistent.Quality principles

Eight Quality management principles have been enunciated by the International standards

Institute (ISO) on which the Quality management systeni standards are based, we will usethese principles as our project report to discuss the subject.

There are

Principle I-Customer focus:

Organizations depend on their customers and therefore should understand current andfuture customer needs should meet customer requirements and stri\ e to exceed customer

expectation. We see in earlier introduction of BDK Engineering industries BDK focuses

on four elements. Customer focus is the first elements BDK listen to what his Customers

say and try to respond with innovations, often taking a long-range view whenimplementing solutions.

Principle-2 LeadershipLeaders establish unity of purpose and direction of the organization. They should create

and maintain the internal environment in which people can become [ullv involved in

achieving the organizations objectives. This worth automatically done


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Principal-6 Continual improvement

Continual improvement of the organization overall performance shruld he permanent

objective of the organization take BDK engineering industries last 3 decadescontinuously improve their Quality standards and performance. This shows principle 6 of

ISO Quality rnanageent is fulfilled in BDIK Engineering industries.

Principle-7 Factual (Reality) approach to decision making.ISO s Quality management presents another principle it seas ef1ctjve decision are based

on the analyses of date and information cook BDK take decision on base of analyzing

real problem and looks real information related to the problem. So the decisions arefactual approach.

Principles-8 Mutually beneficial supplier relationship

It means An organization and its suppliers are interdependent and a mutually

beneficial relationship enhance the ability of both to create alue.In BDK understanding between supplier and company very good and mutual beneficial.

These principle give an overview of total Quality management and show how

collectively, they can form a basis for performance improvement and organizational

excellence.Responsibilities of the Quality control dept

Quality control deep consists organizations senior executive, dept manager and seniormanagement, here discuss about some responsibilities of Quality control dept.


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Principal-6 Continual improvement

Continual improvement of the organization overall performance shruld he permanent

objective of the organization take BDK engineering industries last 3 decadescontinuously improve their Quality standards and performance. This shows principle 6 of

ISO Quality rnanageent is fulfilled in BDIK Engineering industries.

Principle-7 Factual (Reality) approach to decision making.ISO s Quality management presents another principle it seas ef1ctjve decision are based

on the analyses of date and information cook BDK take decision on base of analyzing

real problem and looks real information related to the problem. So the decisions arefactual approach.

Principles-8 Mutually beneficial supplier relationship

It means An organization and its suppliers are interdependent and a mutually

beneficial relationship enhance the ability of both to create alue.In BDK understanding between supplier and company very good and mutual beneficial.

These principle give an overview of total Quality management and show how

collectively, they can form a basis for performance improvement and organizational

excellence.Responsibilities of the Quality control dept

Quality control deep consists organizations senior executive, dept manager and seniormanagement, here discuss about some responsibilities of Quality control dept.


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1. The Quality control dept is typically charged \vith the responsibility Ir designing the

overall strategy for Quality planning control and improvement.

2. It establishes trust and eliminates fear amongst the emploveex and ensuresmiscommunication between the various levels of an organization is minimized.

3. It ensures that it provides people with the required resources, training and freedom to

cut with responsibility and accountability.4. Quality Improvement activities are seen as important as other management tasks and

leaders can integrate Quality lmpro\ emeni it into every aspect of their operations.

5. Activities are evaluated aligned and implemented in a unified way. lhe involvement ofsenior management advances the objectives of the council by inspiring encouraging and

recognizing peoples contrili it ions.

Vital Essential Important Few and the useful many

Vital few and the useful many the idea is to prioritize which Quality improvementprojects should be undertaken by the organization. In any organization, there can be a

lengthy list of possible ideas for improvement. Since the resources to actually implement

new ideas are linked leaders must choose those vital few projects that will have the

greatest impact.


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Quality and organization culture.

Quality is not program it is an outcome that evolve from an oruanizaton and culture. It is

focused an the customer and on achieving organizational exeeHenuc leaders have apowerful vital and decisive role in creating a Quality culture leaders have to we

concerned with success as mich as with failures in crating this culture. They have to focus

not only on understanding sub standard but also * super standard performance. Theeffective leader creator opportunities tr below and above overage performance to interact.

The overall Quality will not continue to improve unless leaclets continue to improve.

Quality leadership and Management are requisite to improving and sustaining systemicperformance results and improvement.

Barriers between bepartments

Barriers between organizations or between departments with in one organization are

obstacles to effective Quality Improvement. Inter department or intra-organizationfriction or lack of co-operation results in waste errors, delay and unnecessary duplication

of effort.

A Continuous and lasting Quality Improvement program requires team worth that crosses

traditional organizational lines. It requires that all worth force members, departments, andunits share a unified purpose direction and commitment to improve the organization

Intra-organizational pathways are clc\ eloped an ci cultivated as mechanism by which toimprove performance.


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Develop Quality Strategy

The Quality Strategy of the organization has to be based on the resources n the

organization The strategy should be designed to provide competitive advantage. Effectiveleaders are knowledgeable about the works being done and understand the environment

and complexities with which their workers must contend. They also know the needs offl

interested parties including customers owners. Employees, suppliers financiers localcommunities.


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QUALITY ASSURANCE bEPARTMENT:

[AGM - VI. V. Gudil

Quality refers to best sort of product that is free from defects whereas assurance refers tosecure confidence of customers or insurance.

BDK group of companies is certified with 1S0900 I-R WTOW of Germany. The

vindication of BDKs Quality lies in the acceptance of its products by leading players inthe industrial market. There has always been continuous innovation and improvement

effort to develop and refine the products uniquely to the specialized needs of various

industrial applications.Functions:

> Functional responsibility for smooth operation and administration of all the activities

for enhancing the Quality inbuilt in product.

> Establishing and maintaining Quality system and reporting Quality status to themanagement.

Participating in design review verification activities and internal audit management

review, customers complaints review

Adopting new conceptual instruments and systems as appropriate to Quality control andimprovement.

> Developing new techniques for improved inspection method and preventing non-conformance.

Ensuring the Quality of components and product at incoming stage. packing and finally

dispatching.


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Responsibility to ensure that Quality of incoming raw materials and brought out item and

sub-contracted items are in accordance v ith the establishment procedure.

MATERIALS ANb STORES bEPARTMENT:[AGM - C. Francisj

Materials department deals with purchase, sub-contractors and stare. The head of

materials department through the management representatives issues material as per workinstructions and maintain records of the same.

Objectives:

> To plan and procure materials and services confirming to specified requirements.Purchases and stare materials till they are issued far use.

The HOD has managerial responsibilities far effective tunctioning of material dept.

Material dept. has to plan for manpower, select and approve sub- contractors.

Communicate periodic performance rating to sub-contractor and issue receipt storagehandling presentation and issue of material. It has to maintain identification and easy

location of products.

The HOD of material dept. is authorized to approve sub-contractors and issue PO/PO

Amendment letter of intend work instruction and approve of sub contractors list issue ofproduct drawing and purchase corresponding is also done by HOD.


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PURCHASE bEPARTMENT:

It receives material intends from material inventory far scrutinite and initiate procurement

activities.Purchasing of order is realized an approved sub-contractor against material intend. In

case of any subsequent change that are required to any purchase order amendments are

issued indicating the changes required to the purchase order.Purchase order and order amendment shall be checked and rev iewedby FtC purchase and

approved by section in charge purchase. All materials are verified at stores according to

purchase orders.When the materials are received at all stores GRIR is prepared and hand it over to IMI for

further inspection. In case of non-conference communicate to sub-contractors all the non-

conference items are returned hack to sub-c(ntraclor and replacement are received.

Materials received in excess of ordered Qualit) may accept up to 10% subject value ofRs.5000/-.

Procedure: The control is exercised over the suppliers through the performance rating

computed from their supplier need.

The approved suppliers are assessed through their performance rating computed on thebasis of their supply need during the last quarter of every year that is January to march.

And computed once in year.In case of temporary supplier making the supply of product directly going into the final

products, performance rating is derived and communicated for every quarter.

The performance rating can be computed by the following 1&mula


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PR(x (Qi) + xl (Q2) + x2 (Q3/Q) * 100

PR Performance Rating.

Q Total Quality supplied.Qi Indicates conforming quantities.

Q2 Indicates quantities accepted with non-conference.

Q3 It indicates quantities de1iveredwithin due date.X - Merits factor for Q1=0.50.

Xl Demerit factor for Q20. 15. X2 Merit factor for Q30.50.

STORES bEPARTMENT:

Activities of stores dept. are numerous. The stores department receives materials are infollowing ways:

> Sales return from customer.

> Customer supplied products.

> Materials purchased from manufacturing ring department.Finished products.

Purchased order and order amendment shall be checked and reviewed by FIC purchaseand approved by section in change purchase and approved h\ section in change purchase.

All materials are verified at stores according to purchase orders.

When the materials are received at all stores GRIR is prepared and hand ii over to IMI for

further inspection. In case of non-conference communicate to sub-contractors all the non-conference items are returned back to suh-coniracioi and replacement are received.

Materials received in excess of ordered (hialiy may accept up to 10% subject value of

Rs.5000/-


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SWOT ANALYSIS

The overall evaluation of a companys strengths. \\eaknesscs. opportunities & threats arecalled SWOT Analysis. T h 131)K his following SWOT Analysis.

STRENGTHS:

> They are large scale manufacture & suppliers of valves & pumps.> They have good reputation in the market.

They are recognized by their Quality.

They have been awarded ISO 9001/1994 certificate by well equipped calibration roomand a chemical & metallurgy laboratory.

> They have efficient & well qualified personnel.

They have provided & healthy environment to the employee.

> They have monopoly in diaphragm valves & ball valves.They follow standard system for all activities.

They have provided many facilities to their employees.

They covers whole of North Karnataka & provides all tjies of services regarding valves

& pumps.WEAKNESS

Cost for maintaining standards is high.They dont have financial controller.

They have less computerized system.

> They have high oriented cause due to excessive labor force.

> Needs up-dating with the times in terms of plant & machinery.Labor turnover is high.


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OPPORTUNITIES

There is no more restriction for movement of products in the world due to globalization.

There is no sales tax & excise duty on employees.> There are many foreign countries still to be covered.

To diversify their business to FMCG market.

Opportunities to enter IT field.Good export market should tap foreign market vigorously.

At present it has good raw-material sources to increase production.

THREATSMore competition from Multi National Corporations (MNC),

Many foreign valve companies entering the domestic market because of globalization.

Valve & pumps industries are in the grip of recession.

> Heavily depending on foundries because of causing & other ra\\materials.There is a need for renovation of plant & machinery.

Government interference may reduce growth potential.

Documents

1111111EXECUTIVE SUMMAR1