WS INDUSTRIES

8/7/2019 WS INDUSTRIES

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INTRODUCTION ABOUT THE NATURE OF THE

ORGANIZATION

HISTORY

WS INDUSTRIES, incorporated in the year 1981 is a landmark in the pump

city of Coimbatore. The factory is situated on the highways at Ganapathy just 3 kms

away form the main Bus Station and around 6kms from t he Railway Station.

The company projects its supremacy through extensive quality control and

wide range of products. Products quality is achieved with the use of modern

technology like CAD/CAM, CNC machines, special purpose machines and active

involvement of employees. Various departments of the firm are linked through

computer networks, which speeds up processes with accuracy and facilitate

immediate response to satisfy customers needs. The components and the final

product go through rigorous inspection at the testing rig, which is fully equipped with

latest measuring equipments.

OBJECTIVES

The companys vision is Service to Mankind by way of providing energy

efficient products with in-house technology and designs to serve agricultural and

domestic consumer community. The company also has sister concerns namely,

Marks Industries WS INDUSTRIES that are involved in manufacturing and

trading activities.


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Each product manufactured by the firm has established itself successfully in the

competitive market scenario because the companys core competence is Product

Differentiation.

Products

The company is engaged in manufacturing the following products:

1. Openwell submersible pumps with capacity range from 3 to 120 HP in the

three phase category is a product with immense popularity for its ease of

handling, high discharge and trouble free operation especially in the

agricultural sector.

2. Mini submersible pump crowned as SUB-SEVAK is a new launch and is a

first of its kind. These pumps have a capacity range from 0.5 to 2.0 HP both in

single phase as well as in three-phase. Its efficiency and capacity to pump

more water to high rise buildings has earned it a very high reputation and has

helped it create a strong foothold in the domestic market sector.

3. Double stage jet pumps speak of product differentiation from the conventional

jet pumps in the market because of its operation at higher depths and absence

of control valves.

SALIENT PRODUCT FEATURES

Special product features create a strong competence and have established their

brands through the length and breadth of the country.

The features are

1. All the motors manufactured operate at very low voltage and are specifically

designed to withstand the wide voltage fluctuations prevailing in rural areas.

2. Submersible pumpsets for agricultural use are specially designed to save

energy for operations under 240/460 Volts single phase power system.

3. Absence of control valves in jet pumps.

4. Mini submersible pumps fitted with as many as 10 impellers help develop

higher heads to use in flats etc. contrary to monoblocs which has only one

impeller.

5. Absence of threaded joints in both pump and motor to facilitate for easy

dismantling and assembling during services.


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AFTER SALES SEVICE

The pumpsets coming out of the factory pass through highly rigid quality

control. Due to this, it normally does not require any immediate service after sales.

However, in case of any specific requirement, they are well equipped with trained

service staffs who are always at their disposal to render satisfactory service to the

customers.

All the distributors and dealers are also well trained to attend the repairs and

services. Most dealers have service stations and are well equipped with spares.

Priority is given at the factory for repair works and the pumpsets are dispatched after

due service on the same day itself. The company is operating with three branches at

various places namely Bangalore, Secunderabad and Chennai ford sales and prompt

service to its customers.

DEALER NETWORK AND ESTEEMED CLIENTS

The company have a wide dealer network spread all over the country. They

are trained to provide technical assistance to select suitable pumps to meet the

requirements of customers.

Apart from the umpteen private customers all overt the country, they have

regular patronage from various Governments. Notable among are Tamilnadu Water

Supply and Drairage Board, Kerala Water Authority, Andhra Pradesh State Irrigation

Department, Public Health Engineering Department of Rajasthan, Central PWD,

Southern Railways and various Collectrates all over Tamilnadu.

Their esteemed clients also include many patrons in the countries of Gulf Co-

operation council for whom the pumpsets are exported regularly.


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STORES AND PURCHASES DEPARTMENT

Totally three stores are operating in the Head office. One for electrical items,

one for pumps and an another for motors. The items for stores are obtained from

different vendors. For each item, a standard vendor is maintained by the organization.

The most popular vendors of the Deccan industries includes Kundan-Bangalore,

Pumps and Spares-Ahmedabad, Unnati-Ahmedabad, Technoprints-Delhi,

Commercial Cargo movers (p) Ltd-Kolkata, Finolex-Pune, Pee-Products-Mumbai,

and Foundries-Coimbatore.

Various items found in the stores includes impeller, circlip, sleeve, LB Bush,Coupling, Keys, Studs, sandguard, end wings, name plate, nuts, bolts washers, neck

rings, rubber items, emery sheet, drill bits, soap, paste, etc.

PROCUREMENT PROCESS

With reference to the current stock statements, indents, requirements and

previous POs status, the purchase orders are raised by the purchase manager. The

same is sent to Joint Managing Director for approval. Unplanned items are also

procured in the vendor, date (mostly falls between 25 th and 31st of each month), the

scheduled days etc, and the same is sent to the Vendors. Vendors are inltimated

through phone, mail or in person about the PO sent and the supply requirements.

Sometimes along with the PO, the drawings are also sent to the vendors to mention

the change in specifications of the items required.

Stores incharge is also informed about the status of the order. Vendors have to

supply the items within the specified date. Beyond the specified date ad tolerance

limit is maintained. If the supplies of items are delayed beyond the tolerance limit, the

purchase order itself is closed. Pending details, remainder letter are made are made

use of for convenience. The reorder level is maintained for each item.

Stores-in-charge takes follow-up actions of the issued POs. this includes

contacting vendor for confirmation of the details, delivery schedule and other terms. If


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variations are found during monitoring, the same is informed to the purchase manager

for corrective action.

Once the items are ready with the vendors, the same are supplied a through

various transports. At the same time, the vendors send the LR note along with the

original bill to the organization. The LR bill have the details such as LR no, date, the

transport, the vendor, to whom it has to be reached, no of articles, actual weight,

freight charge, the actual value of the goods sent, st-charges, hamali,risk charge,

CST,etc. After receiving the LR bill, the organization makes sure of the items are

arrived at the godown and obtain the same to the industry.

VENDOR IDENTIFICATION AND APPROVAL

The organization is maintaining the approved vendors list with the details such

as the vendor name, the items that each vendor supply, rate of the items, TNGST,

CST, etc. The process, new vendor identification and approval is initiated due to any

or all of the following: New product Bill of material, Cost reduction, continual

improvement, vendor rating, refer by department head, commercial terms, Non

planned requirements.

The requirements are analyzed by the purchase manager. Based on the

findings the purchase manager decides to select new vendors for particular

components. The quantity required per annum and the current rates of purchase with

commercial terms are provided in a form to the JMD for review.

On JMDs approval, Vendors are identified through established means and

vendors are contacted for initial quotes and offers. Vendors are short listed on the

basis of quality, cost and other commercial terms. Sample drawings are sent to the

short listed vendors for samples. Sample PO are raised and filed.

The incoming materials are verified against the PO. The Samples are sent for

approval of the respective departments. Tests may be carried out and results obtained.

The tests and reports are complied along with terms and sent for JMDs approval. On

JMDs approval, Vendor is added to the approved vendor list and is sent to respective

department for reference.


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Address of various persons, vendors, industries, dealers, etc.are maintained for

quick reference.

STORES INWARDS

The materials received vide PO/verbal order, are verified for quantity

correctness, proper maintenance at the godown (heat, rain, pressure, etc), defects due

to transportation by the stores personnel. Depending on the nature of the materials

received, the material inward and receiving inspection form is computer printed and

issued to QC personnel for the correctness of quality and dimensions.

The material inward and receiving inspection holds the name of the material

received, vendor details, the purchase order placed, purchase document details. The

quality inspection is carried out by the QC Engineers, and assures the quality of the

material received. The items found to be defective are sent back.

On the tested ok by the QC engineers, the materials are accepted into stores

and suitable stored for issue. The MIRI report is duly filed and retained by the stores

personnel as a document for future reference.

On QC inspection, if the materials are found to be defective, the received

materials are sent back to the vendor. Rejection goods report is generated by the

stores-in-charge and the same is forwarded to purchase department.


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PRODUCTION DEPARTMENT

The production is the most important department in the organization and is

paid utmost attention. The Employees involved in production adhere to theorganization on contract basis and are paid based on the number of pumpsets they

manufacture.

The production of the components are carried out using both CNC and lather

machines. The CNC machines are imported from Korea and are used in case of mass

production and the Lathe machines are obtained from Kirloskar. Two CNC machines

are operating in the main unit, one with single spindle and the other double spindled.

In case of double spindled CNC machine, two separate processes are carried out and

two separate monitors are there to control them. Auto door function is also there in

double spindled CNC machine. The CNC machines are provided with the conveyor or

collecting the chips and these chips are reprocessed into components whereas the

ordinary lathe machines are not provided with the conveyor and the chips collections

is performed manually.

PRODUCTION IN-PROCESS

The production of in-house machined components are planned based on

forecasting taking into account the previous week productions pending order and

stocks. Materials needed to produce as per production plan are acquired from the

stores and issued to the operator and the same is recorded in in-process inspect note

book.

The inspected finished components are stocked in stock yard/stores as

suitable.

FORWARDING NOTE PREPARATION

The forwarding note is prepared if necessary, for those sets dispatched through

private and public transporters.


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OUTPASS GENERATION

The Outpass is generated as a final document to dispatch the products with

reference to the invoice or other supporting documents. The outpass prepared through

the system encompasses the following

Customer details

The product details

Quantity details

OTF details

Production No.details

Packing details

Transporters details

The outpass also serves as a checklist for dispatch

System is designed to generate dispatch day reports, dealers offtake,

modelwise offtake pumpsets query (if production number is given, the details of the

set is displayed)

CALIBRATION

All measuring equipment used for quality decision at company is calibrated ona scheduled basis according to the Instrument History Card. This includes standard

that are used to verify instruments. Approved outsources are identified and master list

is maintained.

MICROMETERS

Calibration is performed on a yearly basis using outside sources.

VERNIER CALIPERS

Calibration is performed on a yearly basis using outside sources.

The instruments after calibration are sent for calibration

certification/verification. If the performance of the calibrated instruments is

satisfactory, it is put into use for QC until next due or undue problems. On failure of

the calibrated instruments while in use, the calibration and testing engineer reviews

the same and suitably advises for repair or replacement. If the defect of the instrument

is non rectifiable, the same is disposed.


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QUALITY CONTROL DEPARTMENT

MATERIAL INWARD INSPECTION

The MIRI (Material Inward and Receiving Inspection) holds the name of the

material received, vendor details, the purchase order placed, purchase document

details.

A oral requisition from the stores department on the receipt of material

initiates the process. The stores department prepares and issues the MIRI document

which stands a format for QC.

The inspection is carried out by the QC engineer according to the Receiving

Inspection Method and Frequency and the test results are recorded in the MIRI. The

monthly inspection status report is prepared by the QC Engineers detailing the

rejected materials, vendor etc.

INPROCESS INSPECTION

The inprocess inspection sheet details the production to be carried out as per

the requirements from the production engineer. The sheet generated marks the start of

the inprocess inspection and the QC Engineer is the responsible for the process.

The QC Engineer checks for quantitative correctness of the materials issued to

the operator. Following the relevant documents, the QC records the proceedings like

M/c setting, tools issued to the operator in the improcess sheet.


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MARKETING DEPARTMENT

The marketing department design suitable formats to procure feedback,

suggestions and complaints periodically based on the earlier analysis reports.

Feedback of the customer is collected through Market Survey, Questionnaires or

Direct Meeting with customers (Product Rating Form)

A report is generated from the data gathered. The data are processed in a form

prescribed in the questionnaire. The completed analysis stands as a standard of

reference for the management for its future developments. It is maintained by the

marketing department.

Marketing department is responsible for dealers meeting, wall paper

advertisements, paper advertisements. At present, the organization is engaged in radio

advertisements.

FINANCIAL PERFORMANCE OF THE ORGANIZATION

THREE YEARS FINANCIAL PERFORMANCE ANALYSIS

YEARS

1999-2000 2000-2001 2001-2002

FIXED ASSETS 9,138,756.30 13,165,063.02 16,650,263.02

DEBTORS BALANCE 8,208,245.95 13,574,171.22 27,702,344.43

CREDITORS TOTAL 9,688,484.46 11,988,200.10 18,322,939.00

SALES 53,032,519.15 79,392,324.50 94,124,310.20

PURCHASES 38,786,196.53 61,037,772.53 71,034,513.84

EXPENSES 8,568,228.89 13,963,268.82 14,857,473.99

The organization was started in the year 1981. quality alone was their ultimate

goal at that time. Since submersible manufactures was not that much not that much popular

and competitive, the growth of the company was not affected. Indeed the need forsubmersibles increased rapidly due to the increase in the need for water. Ground water


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levels went very low such that conventional motors like monoblocs could not draw water

from a depth more than 30 feet. The growth in the early stages of the company is marked

with their quality and market monopoly of openwell submersibles.

During the mids the company policies such as dealership policy and

distribution policy was very attractive, so the dealers were able to easily get done their

needs from the company so as to cater their customers. The company realized the

competitive market as no submersible manufactures are in the field. Inorder to cater their

dealers and customers the company has amended its policy so as to strengthen their services

such as timely delivery, zero stock at dealer point, twelve hours clearance of serviced

warranty and after warranty pumpsets. This effectiveness they have achieved by adopting

the modern administrative tool ISO. Since as an ISO company in the year 2000, the

companysgrowth is remarkable as the staff, the worker and as the whole the company itself

is driven by the ISO system.


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SALES DEPARTMENT

ORDER RECEIVING

Orders from customers are received personally or through phone, or email.Order details are entered in the order transfer form in the system with the details such as

customer name, their requirements including model, HP, and stage, Lpm, SGS (Inspection

certification by third party), transport, accessories, pay details. The form is sent for financial

approval to the Joint Managing Director.

On JMDs approval, the order is checked for its adequacy of requirement. If

the requirements of the order are adequate, order is produced with order information,

customer details, items, quantities and shipment details. The delivery schedule is obtained

from the production engineer and communicated to the customer through established means

of communication.

If the financial approval from the Joint Managing Director is not obtained in

favor, customers are communicated over phone or mail about their credit rating, and the

order is kept pending until the commercial terms are stored out. In certain circumstances

JMD may not dispatch pending till approved and send the form further.

If the requirements are found to be inadequate, and when discrepancies are

found on special requirements, the customers are contacted to verify requirements. Special

requirements are evaluated by the MD to ensure that the company can comply. Special

requirements/changes are noted on the form. The form is then sent to the respective

department.

The same process is repeated when there is need for any amendment. OTF is

then issued to the production and assembly is scheduled.


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TRAINING DEPARTMENT

The systems manager, Mr.R.Vivekanandhan takes an additional responsibility

as manager, training and is responsible for all the training activities in the company. All thestaffs and workers are assessed on their capability and performance in the company and

suitable training is imparted to meet the modern trend.

The top management, the department head, and the personnel himself assists

in identifying the requirement for training of selected employee or staff, to ensure that

activities performed by them are up to the quality mark and makes a request to the manager,

training. The training manager assess the need for training with the confirmation from the

MD. The suitable faculty (in-house or external) handles the class to impart the necessary

training. External training conducted by reputed institutions, is also attended by the staff on

the approval of the MD, recommended by manager, training.

The feedback about the training is obtained from the trainee detailing the

faculties performance, arrangements and other information. This serves as a document of

reference for the organization to improve the quality of training in future. The training

manager maintains a record of all internal and external programme and details of the

participants who participated a record of all internal and external programmes and details of

the participants who participated in training. The trained participants are evaluated on their

performance by the end of the training or after a particular period and a report of the same,

submitted to the MD.

The training manager also takes care of the Inplant, Institutional, on-job

training imparted to college students, diploma and I.T.I certificate holders. They extend this

facility to the students to maintain a good rapport with the colleges and other educational

institutions.

REQUEST ASSESMENT & APPROVAL

TRAINING

TRAINING REPORT

TRAINING APPRAISAL

TRAINEE REPORT


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The manager, training is responsible for recruitment process also.

The manpower requirement, identified by the top management or department

heads with a view to ensure the activities are performed to the designed quality system is

forwarded as a requisition for manpower to the manager, training for further action.

The training manager assess the need with assistance from concerned

department authorities and on conformance prepares a document detailing the required

skills, education, experience etc. and proposes the same for the MDs approval.

The training manager identifies the suitable candidates and calls for a personal

interview, by a perusal of CVs. The CVs are gathered by means of data bank,

advertisements, word of mouth, references etc. The interview panel is formed by suitable

persons to conduct a formal interview.

The panel interviews the candidates and selects suitable candidates in

accordance to the requirements. A consolidated report is generated by the manager, systems

based on the panels statements. Selected candidates are appointed after the approval of

MD. Candidates, if necessary should undergo training for a prescribed period of time. The

recruitment process and the result details are prepared as report with the attachments of the

panel statements and the same is presented for MDs reference.

The recruitment process are classified as,

MANPOWER REQUIREMENT IDENTIFICATION

REQUEST ASSESSMENT & APPROVAL

INTERVIEW CALL

RECRUITMENT

REQUITRMENT REPORT


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VARIOUS WS PRODUCTS, THEIRAPPLICATIONS,

FEATURES & TECHNICAL DATA)

BORE WELL SUBMERSIBLE PUMPS (100mm)

Applications:

Domestic, Agriculture, Industries.

Salient Features:

Hydraulic parts are made of guaranteed noryl parts with scuff resistance,

Energy efficient motor, easily rewindable, Low voltage operation.

Technical Data:

Operating Head : 10m to 250m

Discharge : Up to 400l pm.

Available Motor rating : 0.37 kW to 4.5kW

Power supply : Single phase (220V) and three phase (415 V)

BOREWELL SUBMERSIBLE PUMPS (150, 200 & 250mm)

Applications:

Agriculture, Domestic, Civic Water Supply, Industries, Marine platform,

Fountain system, Booster systems.

Salient Features:

Wide range of models, Energy efficient motor, easily rewindable, pumps with

130mm diameter is also manufactured.

Technical Data:



Available Motor rating : 2.2 kW to 90kW


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Power supply : Single phase (220/460V) and three phase

(415V)

OPENWELL SUMERSIBLE PUMPS FOR OPENWELL, POND AND SUMP

Applications:

Major Irrigation, Drip Irrigation, Sprinkler systems, Rain Gun, Flood control,

Booster systems.

Salient Features:

Latest Technology, Energy efficient motor, Easily Rewindable, Low voltage

operation.

Technical Data:




Power supply : Single phase (220/460V) and three phase

(415V)

SUB SEVAK MINI SUMERSIBLE PUMPS FOR 150mm BOREWELL,

SUMP AND OPENWELL

Applications:

Agriculture, Domestic, Apartments, Hotels.

Salient Features:

Latest Technology, Easily Rewindable, Low voltage operation.

Technical Data:




Power supply : Single phase (220V) and three phase (415V)


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DOUBLE STAGE JET PUMPS FOR 100mm BOREWELL AND OPENWELL

Applications:

Individual Houses, Horticulture, Hotels, Industries.

Salient Features:

Latest Technology, Easily Rewindable, Absence of control valve, Vertical and

Horizontal constructions.

Technical Data:

Well Lift : 10m to 75m

Delivery Head : Upto 20m.



Power supply : Single phase (220) and three phase (415V)

TINY SUMERSIBLE PUMPSETS FOR SUMP, POND AND DUGWELL

Applications:

Domestic, Bungalow, Individual Houses.

Salient Features:

Latest Technology, Easily rewindable motor, Low voltage operation.

Technical Data:



Available Motor rating : 0.37kW to 0.75kW



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ZIP SELF PRIMING MINI MONOBLOC PUMPSETS FOR SUMP

Applications:

Domestic water pumping to over head tank, Gardening, Construction sites,

Home Pressure Boosting system.

Salient Features:

Extruded Aluminum Motor body, Forged Brass Impeller, Low voltage

operation.

Technical Data:

Maximum Suction Lift : 8m

Maximum Head : 32m

Available Motor Rating : 0.18 kW to 0.37kW

Power supply : single phase (220V)

CENTRIFUGAL AGRI MONOBLOC PUMPSETS FOR OPENWELL AND

SUMP

Applications:

Agriculture, Sprinkler system, Drip Irrigation, Apartments, Commercial

Complex and Booster Service.

Salient Features:

Low voltage operation, Ample capacity shaft, Greased ball bearings.

Technical Data:


Discharge : Up to 1850 m.


Power supply : Three phase (415V)


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CIRTRIFUGAL DOMESTIC MONOBLOC PUMPSETS FOR SUMP

Applications:

Domestic, Apartments, Hotel, Construction site, Industrial use

Salient Features:

Energy efficient motor, Low voltage operation, Compact air cooled motor,

Auto air releasing system.

Technical system:


Maximum Suction Lift : 7.5 m.

Available Motor rating : 0.37 kW to 1.5 kW

: Squirrel cage 2 Pole 2880 rpm Induction Motor.



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CONCLUSION

1. The training was useful to have some information about the principal

and practice involved.

2. The training provided information about the accounting practices by

WS Industries.

3. It gave knowledge about the different forms, formats, customer care,

services and products to a certain extent.

4. It helped to know the software Packages used by the company and

also about the ledger, files and folders maintained by accounts

departments.

Documents

WS INDUSTRIES