A STUDY ON THE INTERNSHIP TRAINING UNDERGONE AT UNICAST ALLOYS PRIVATE

LIMITED POLLACHI

Submitted By

S.SELVAKUMAR

[Reg.No:13B150]

Of

KARPAGAM COLLEGE OF ENGINEERING

(AUTONOMOUS)

Under the guidance of

Ms.A.ABIRAMI,MBA.,(Ph.D).,

INDUSTRIAL TRAINING REPORT

Submitted to the

FACULITY OF MANAGEMENT STUDIES

In partial fulfillment of the Requirements

For the Award of the Degree

Of

MASTER OF BUSINESS ADMINISTRATION

NOVEMBER - 2014

BONAFIDE CERTIFICATE

(Autonomous)

COIMBATORE 32

DEPARTMENT OF MANAGEMENT STUDIES

BONAFIDE CERTIFICATE

Certified that this Industrial training report title UNICAS ALLOYS PRIVATE

LIMITED is a bonafide work of S.SELVAKUMAR, Reg. No 13B150, who carried out the

project under my supervision. Certified further, that to best of my knowledge, the work reported

here does not form part of any other project report or dissertation on the basis of which a degree

or award was conferred on an earlier occasion on her or any other candidate.

Ms.A.ABIRAMI Dr.R.CHANDRASEKARAN

FACULTY GUIDE DIRECTOR

VIVA-VOCE EXAMINATION HELD ON

INTERNAL EXAMINER EXTERNAL EXAMINER

COMPANY CERTIFICATE

DECLARATION

(Autonomous)

COIMBATORE 32

DEPARTMENT OF MANAGEMENT STUDIES

(Approved By AICTE/ NBA Accredited/ Affiliated To Anna University)

DECLARATION

I, S.SELVAKUMAR hereby declare that the report on UNICAST ALLOYS PRIVAE

LIMITED, submitted to Anna University, Chennai in partial fulfillment of the MASTER

DEGREE IN BUSINESS ADMINISTRATION is a record of original work done by me,

during the period of study 2013-2015 under the guidance of Ms.A.ABIRAMI

SIGNATURE

S.SELVAKUMAR

[Reg.No.13B150]

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

I record my sincere thanks and gratitude to god almighty who bestowed me his grace and

strength to complete this project

I would like to whole hearty thank and express my sincere gratitude to the Chairman

Dr. Vasanthakumar, Karpagam Educational Institutions, Coimbatore and our CEO Shri.

K. Murugaiah, for thir encouragement in the development of this project.

I express my special privilege and heartfelt thanks to Dr. Nirmalkumar, Principal and

Prof. M. Gowrishankar, Vice principal, Karpagam College of Engineering, Coimbatore for

thir guidance and encouragement.

I would like to express my sincere gratitude to Dr. R. Chandrasekaran, Director of

Management Studies, Karpagam College of Engineering, Coimbatore for the constant

encouragement and stimulating atmosphere provided to me.

I extend my sincere thanks to my guide Ms. A. Abirami, Assistant Professor,

Department of Management Studies, Karpagam College Of Engineering, Coimbatore for

continuous support throughout the develop of this project.

I also extend my sincere thanks to my family and friend for their encouragement and

support.

I would like to extend my thanks to all faculty members of my department who have

helped me a lot to complete his project successfully.

ABSTRACT

ABSTRACT

This research is mainly conducted to study about the industrial training in spinning mills

among the employees Unicast alloys private limited.

The primary objective of the study is to benefit the employees and the organization by

identifying the level of training they are facing during the work and to identify the factors which

cause the mill among the employees of the organization.

This study considers the area of workload, feelings at work, interpersonal relationship, working

conditions, monetary policies and welfare facilities.

Major recommendation is that the employees would be more satisfied if they increase the salary

and compensation benefits.

The following article aims to show the benefit of textile design research to the textile designer.

alloys design is increasingly complex, and influenced by a number of factors such as ethical

alloys, sustainability, fast versus slow fashion, new digital technology and science. It is therefore

necessary for increased research by the alloys designer into these areas in order to understand

and gain knowledge that can be incorporated into the vast alloys industry so what we produce the

most relevant cloth and fabrics that satisfies both consumer and ethical requirements.

TABLE OF CONTENTS

LIST OF CONTENTS

S.NO CONTENTS Page no

I CHAPTER I

Introduction 1

Organizational chart 3

II CHAPTER II

Organizational profile

2.1 Industrial profile 4

2.2 Company profile 6

2.3 product profile 9

III CHAPTER III

3.1 Purchase Department 11

3.2 Production Department 13

3.3 Quality Department 18

3.4 Finance Department 21

3.5 Marketing Department 24

3.6 Human Resource Department 26

Conclusion 32

Bibliography 33

CHAPTER 1INTRODUCTION

The super alloy was used to produce the single crystal turbine blades, because it is first

generation super alloy that has good properties of molten metals. First generation Ni-based single

cry stall super alloys are mainly and sometimes Co and Mo partition preferentially to the

austenitic face-centered cubic nickel-based matrix where they act mainly as solution

strengthening elements. Cr also plays an essential role in the hot corrosion resistance since it

promotes the formation of a protective oxide scale. These alloys contain a high volume fraction

of strengthening ordered based phase particles homogeneously distributed in the matrix as near-

cubical

More recently, alloy designers tried to improve again the high temperature capability of

the SC blade alloys by increasing the content of rhenium up to about. The challenge was to

achieve improved creep strength, without increasing the density and by keeping the alloy not too

much prone to the precipitation phases. Two typical third generation alloys are developed by

Cannon-Muskegon and Rene developed by General Electric. More recent development work

conducted by GE was devoted to third generation alloys containing also some additions of

ruthenium. A new generation of alloys, a typical example of which is the alloy, is developed in

France by onera and the alloys were developed in Japan.

The major phases present in most nickel super alloys are as follows gamma and gamma

prime. The continuous matrix (called gamma) is a face-centered-cubic (FCC) nickel-based

austenitic phase that usually contains a high percentage of solid-solution elements such as Co.

The primary strengthening phase in nickel-based super alloys is Ni3, and is called gamma prime.

It is a coherently precipitating phase with an ordered crystal structure.

The close match in matrix lattice parameter combined with the chemical compatibility

allows them to precipitate homogeneously throughout the matrix and have long-time stability.

Interestingly, the flow stress of the increases with increasing temperature up to about. In

addition, is quite ductile and thus imparts strength to the matrix without lowering the fracture

toughness of the alloy. Aluminum and titanium are the major constituents and are added in

amounts and mutual proportions to precipitate a high volume fraction in the matrix.

a) Elimination of grain boundaries made strengthening elements, such as carbon and

hafnium redundant. This has facilitated heat treatment and allowed for the further optimization of

the alloy chemistry to increase of the high temperature capability,

b) Elimination of grain boundaries transverse to the principal tensile stress axis has

reduced grain boundary cavitations and cracking, resulting in greatly enhanced creep ductility,

c) The preferred crystallographic solidification direction, which coincides with the

minimum in Youngs modulus and is oriented parallel to the component axis minimizes the

thermal stresses developed on engine start-up and shut-down, this has dramatically improved the

thermal fatigue resistance of the turbine hot gas path components.

In Research and Development Laboratory for Aerospace Materials is used Vacuum

Induction Melting furnace for investment casting of equated super alloy materials, directionally

solidified and single crystal materials for making aircraft engine turbine blades. This furnace has

a conventional Bridgman crystal-growing method. A speed of a few inches per hour is typical -

so that the solid/liquid interface progresses gradually along the casting, beginning at its base.

This has the effect of producing large, columnar grains which are elongated in the direction of

withdrawal, so that transverse grain boundaries are absent. Prior to casting, the chamber is

evacuated to a partial pressure of approximately 103 bar and the molds raised into the furnace

chamber, which is pre-heated to above the melting point of the charge using graphite resistance

elements. The whole assembly is then allowed to equilibrate for a number of hours prior to

casting. Vacuum Induction Melting furnace for investment casting of single crystal materials

Alloy castings an industry with tremendous growth and development is a vital part of

todays world. The reason why an alloy was taken for my study.

A reputed organization Ultimate alloys private ltd companies is being taken for this

purpose. It includes various manufacturing and trading practices of Ultimate Alloys private

limited like: carbon steel castings, aluminum steel castings etc. These aluminum steel castings

consists of various salient features like Pouring, Molding, Melting, and Felting. It also involves

in the process of importing those alloys to different countries in the world.

ORGANISATION CHART

MANAGING DIRECTOR

CHAPTER 2.1

INDUSTRY PROFILEAlloying elements are added to achieve certain properties in the material. As a guideline,

alloying elements are added in lower percentages to increase strength or hardenability, or in

larger percentage to achieve special properties, such as corrosion resistance or extreme

temperature stability. Manganese, silicon, or aluminum are added during the steelmaking process

to remove dissolved oxygen, sulfur and phosphorus from the melt. Manganese, silicon, nickel,

and copper are added to increase strength by forming solid solutions in ferrite. Chromium,

vanadium, molybdenum, and tungsten increase strength by forming second-phase carbides.

Nickel and copper improve corrosion resistance in small quantities.

Molybdenum helps to resist embrittlement. Zirconium, cerium, and calcium increase

toughness by controlling the shape of inclusions. Manganese sulfide, lead, bismuth, selenium,

and tellurium increase machinability. The alloying elements tend to form either compounds or

carbides. Nickel is very soluble in ferrite; therefore, it forms compounds, usually Ni3Al.

Aluminum dissolves in the ferrite and forms the compounds Al2O3 and AlN. Silicon is also very

soluble and usually forms the compound SiO2MxOy. Manganese mostly dissolves in ferrite

forming the compounds MnS, MnOSiO2, but will also form carbides in the form of C.

Chromium forms partitions between the ferrite and carbide phases in steel, forming .

The type of carbide that chromium forms depends on the amount of carbon and other

types of alloying elements present. Tungsten and molybdenum form carbides if there is enough

carbon and an absence of stronger carbide forming elements (i.e., titanium & niobium), they

form the carbides W2C and Mo2C, respectively. Vanadium, titanium, and niobium are strong

http://en.wikipedia.org/wiki/Steelmakinghttp://en.wikipedia.org/wiki/Niobiumhttp://en.wikipedia.org/wiki/Titaniumhttp://en.wikipedia.org/wiki/Manganese_sulfidehttp://en.wikipedia.org/wiki/Carbidehttp://en.wikipedia.org/wiki/Melt_(manufacturing)http://en.wikipedia.org/wiki/Phosphorushttp://en.wikipedia.org/wiki/Sulfurhttp://en.wikipedia.org/wiki/Oxygen

carbide forming elements, forming vanadium carbide, titanium carbide, and niobium carbide,

respectively. Alloying elements also have an effect on the eutectoid temperature of the steel.

Manganese and nickel lower the eutectoid temperature and are known as austenite stabilizing

elements. With enough of these elements the austenitic structure may be obtained at room

temperature. Carbide-forming elements raise the eutectoid temperature; these elements are

known as ferrite stabilizing elements.

Alloy steel is steel that is alloyed with a variety of elements in total amounts between

1.0% and 50% by weight to improve its mechanical properties. Alloy steels are broken down into

two groups: low-alloy steels and high-alloy steels. The difference between the two is somewhat

arbitrary: Smith and Hashmi define the difference at 4.0%, most commonly; the phrase "alloy

steel" refers to low-alloy steels.

Every steel is truly an alloy, but not all steels are called "alloy steels". Even the simplest

steels are iron alloyed with carbon . However, the term "alloy steel" is the standard term

referring to steels with other alloying elements in addition to the carbon. Common alloyants

include manganese, nickel, chromium, molybdenum, vanadium, silicon, and boron. Less

common alloy ants include aluminum, cobalt, copper, cerium, niobium, titanium, tungsten, tin,

zinc, lead, and zirconium.

The following is a range of improved properties in alloy steels (as compared to carbon

steels): strength, hardness, toughness, wear resistance, corrosion resistance, hardenability, and

hot hardness. To achieve some of these improved properties the metal may require heat treating.

Some of these find uses in exotic and highly-demanding applications, such as in the

turbine blades of jet engines, in spacecraft, and in nuclear reactors. Because of the ferromagnetic

properties of iron, some steel alloys find important applications where their responses to

magnetism are very important, including in electric motors and in transformers.

The first step in the production of single crystal turbine blade is to make its wax model. A

wax model of the casting is prepared by injecting molten wax into a metallic mould if

necessary by allowing wax to set around a ceramic core, which is a replica of the cooling

passages required. These are arranged in clusters connected by wax replicas of runners and

http://en.wikipedia.org/wiki/Transformerhttp://en.wikipedia.org/wiki/Electric_motorhttp://en.wikipedia.org/wiki/Magnetismhttp://en.wikipedia.org/wiki/Ironhttp://en.wikipedia.org/wiki/Ferromagnetichttp://en.wikipedia.org/wiki/Nuclear_reactorhttp://en.wikipedia.org/wiki/Spacecrafthttp://en.wikipedia.org/wiki/Jet_enginehttp://en.wikipedia.org/wiki/Heat_treatinghttp://en.wikipedia.org/w/index.php?title=Hot_hardness&action=edit&redlink=1http://en.wikipedia.org/wiki/Hardenabilityhttp://en.wikipedia.org/wiki/Corrosion_resistancehttp://en.wikipedia.org/wiki/Wear_resistancehttp://en.wikipedia.org/wiki/Toughnesshttp://en.wikipedia.org/wiki/Hardnesshttp://en.wikipedia.org/wiki/Strength_of_materialshttp://en.wikipedia.org/wiki/Carbon_steelhttp://en.wikipedia.org/wiki/Carbon_steelhttp://en.wikipedia.org/wiki/Zirconiumhttp://en.wikipedia.org/wiki/Leadhttp://en.wikipedia.org/wiki/Zinchttp://en.wikipedia.org/wiki/Tinhttp://en.wikipedia.org/wiki/Tungstenhttp://en.wikipedia.org/wiki/Titaniumhttp://en.wikipedia.org/wiki/Niobiumhttp://en.wikipedia.org/wiki/Ceriumhttp://en.wikipedia.org/wiki/Copperhttp://en.wikipedia.org/wiki/Cobalthttp://en.wikipedia.org/wiki/Aluminumhttp://en.wikipedia.org/wiki/Boronhttp://en.wikipedia.org/wiki/Siliconhttp://en.wikipedia.org/wiki/Vanadiumhttp://en.wikipedia.org/wiki/Molybdenumhttp://en.wikipedia.org/wiki/Chromiumhttp://en.wikipedia.org/wiki/Nickelhttp://en.wikipedia.org/wiki/Manganesehttp://en.wikipedia.org/wiki/Carbonhttp://en.wikipedia.org/wiki/Ironhttp://en.wikipedia.org/wiki/Chemical_elementhttp://en.wikipedia.org/wiki/Alloyhttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Niobium_carbidehttp://en.wikipedia.org/wiki/Titanium_carbidehttp://en.wikipedia.org/wiki/Vanadium_carbide

risers; this enables several blades to be produced in a single casting. Wax replicas consisting of a

feed arrangement, platen, starter, selector, and test bar sections were assembled.

CHAPTER 2.2

COMPANY PROFILE

UNICAST ALLOYS PRIVATE LIMITED was established in the year 1990 by B.Govindarajan it is one of the leading firms for the manufacturing and supply of alloys andcasting services. Proficient team of professionals mange the firms by implementing the suitablemanagement policies. This allows in to stream lies unicast alloys private limited businessexecution and makes it hassle free

Unicast alloys private limited range of products as well as services is known to bepremium quality. They are appreciated for their higher durability and precision engineering.These products abide by all the industry guidelines and parameter. We are able to provide twovarieties of product range standardized and customized varieties. This allows their customer tochoose products that meet th41e industrial requirement exactly. Furthermore, we store all unicastalloys private limited specious warehouses, before transit to see all to it that they come past noharm and are delivered to their client in sound state.

Their range of easting services are known to be highly reliable and we execute theseservices in a prompt and deft manner. Perfection is given to deliver the service as per the exactspecification of the client. It is high customization of their service range that has gathered a greatdemand for in the domestic market

Unicast alloys private limited as esteemed managing director Mr. B .Govinfrajajan hasalso been unicast alloys private limited mentor. It is under his guidance that we have been able tofetch reputed name for the company young company in competitive market. His kind words ofwisdom and motivation has been driving force for unicast alloys private limited

Unicast group of companies is promoted by shiri B. Govindarajan, a well knowtechnocrat having more than 3 decades of experience in the foundry industry, now is a renownedestablishment is south India that produces SG iron, grey iron &steel castings with help of highlydedicated work force &cutting edge technology.

Unicast alloys private limited establishment in 1990 a unit of united group of company isprofessionally managed company engaged in mana factoring and supplying grey &SG ironcasting in rough and sully machined condition which are strictly in compliance in its ownpremises, it has a molding capacity of 12000 mt per annum.

Their skilled work force with years of experience is the valuable asset they acclaim. Regarding,their quality accreditation they are an ISO 16949:2002 certified company. Member ofengineering export promotion council combustors district small industries association and theinstitute of Indian foundry men

NAME OF THE DIRECTOR

1 Year of establishment 19902 Name of the managing director Mr. B .Govindarajan3 Address Achipatti9post0, pollachi-642002

Coimbatore(dist) tn. India4 Phone Number 04259-2593065 Fax Number 04259-2597466 E-Mil un@unitedgroupcomanies.com7 Scope of supply Manufactured of rough and machined grey iron.

SG iron castings for chassis and engine components for automotive applications

8 Maximum production capacity 500 tons/ month weighing 0.300kgTo 35kgs per piece to national and international specification

9 Number of employees 10010 Product/components Auto motive, tractor, valve, hydraulic, and

general engineering industries11 Group of companies United foundries-rumpet unicust

alloys(Machining division) cbe.

VISION AND MISSION STATEMENT

1) Customer is their prime focus2) They are encourage active participation of employee at all level for continues

improvement3) Their aim at creating long term relationship with customer and vendor4) They will strive for continuous improvement in product quality productivity and effective

utilization of resourceOBJECTIVES:-

To maintain uninterrupted flow of materials to support the development schedules.

To procure materials economically at a cost consistent with the quality and service

required. However, generally all purchases may be attempted at the lowest cost.

To provide the necessary expertise, advice, information to the Curators and Education

Officers with regard to the best quality of material available in the market, suppliers

capability and performance etc.

mailto:un@unitedgroupcomanies.com

To develop and maintain good buyer-seller relationship.

To promote source development

To maintain Organization reputation and credibility in the market by fair dealings and

prompt payments.

CHAPTER 2.3

PRODUCT PROFILE

PRODUCTS AND SERVICES Auto motive sector Hydraulic sector Valve sector Power sector Pump sector General sector

LIST OF PRODUCTS:

1) AUTO MOTIVE INDUSTRIES

Power cylinder and pressure plates, for auto mobile engines Cam shaft crank shaft and fly wheels for portable petrol engines Engine brake casting for exports Brakes cylinder and master cylinder brake shoe and housings discs for brakes Exhause manifolds, companion flanges clutch with draw plates for heavy tracks rotary

supporting arms crunts cases and connecting cases for tillers

2) VALVE INDUSTRY

Valve boclies, bonnets, hand whets for diaphragm valves. Valve bodies, discs, glands and hand wheels for butterfly valves. Bodies and allied components for beet globe, swing check knif and wafer bodies

3) CHEMICAL AND HYDRULIC APPLICATION

Volute casting, stuffing boxes, bearing lanterns, glands for heat trans fer, refinery process,non dog slurry , process, ask handling applications

Impeller, diffuser and vanned wheels Wear plates, pressure rings and thruseplates Reciprocating pumps and closing systems Gear pumps and hydraelic application

4) EARTH MOVINGEQUIPMETS INDUSTRY

Sprockets idler wheels carriers end brushes and end collars.

5) POWER TRANSMISSION Caps and flanges for insulators

6) TRANSMISSION PRODUCTS

Gear box housing Gear blanks Worm wheels

7) GENERAL ENGINESSRING

Mould rigs for poly propylene equipment Power driven pumps Ayitator spares Terminal spares

CHAPTER 3.1

PURCHASE DEPARTMENT

Purchase Orders/RFQ

Purchase Orders / Request for Quote/Emergency Ordering/Supply Agreement. As acomponent of continual improvement, the RFQ process is intended to establish specific costs forsupplied materials. Therefore, it is extremely important that Suppliers provide costs for material,labor, burden and margin, so that through early Supplier involvement and value engineering, wecan identify and implement cost reduction opportunities. The purchase orders are done throughthe some of the countries like Switzerland, china ,Sweden etc. At a time of purchasing of orderthere will be the payment will be made only after the delivery or receivable of goods. Thepayment transactions will be made through the bank transactions. The invoice will be issued tothe buyers at the time of payment transactions.

A purchase department is the division of a business that is responsible for purchasing or

procuring goods and services for a company. The purchasing department usually interacts with

other departments in order to determine the needs of the organization.

FUNCTIONS:-

The main functions of the Purchase Department are defined as follows:

Procurement of stores through indigenous and foreign sources as required in accordance

with the rules in force.

Checking of requisitions/purchase indents.

Selection of suppliers for issue of enquiries.

.Analyzing quotations and bids etc., and preparation of comparative statement (quotation

charts).

Consultation with the Indenter for selection and approval of quotations and with

Accounts Officer for pre-audit.

Negotiating contracts.

Checking legal conditions of contracts. Consulting Administrative Officer or Secretary, of

the organization where necessary.

Issue of Purchase Orders.

Follow-up of purchase orders for delivery in due time

Verification and passing of suppliers bills to see that payments are made promptly.

Correspondence and dealing with suppliers, carriers etc., regarding shortages, rejections

etc., reported by the Stores Department.

Maintenance of purchase records.

Maintenance of progressive expenditure statement, sub-head wise.

Maintenance of vendor performance records/data.

Arrangement for Insurance Surveys, as and when necessary.

Clearance of foreign consignments.

CHAPTER 3.2

PRODUCTION DEPARTMENT

Production management means planning, organizing, directing and controlling of

production activities. Production management deals with converting raw materials into finished

goods or products. It brings together the 6M's i.e. men, money, machines, materials, methods and

markets to satisfy the wants of the people.

Production management also deals with decision-making regarding the quality, quantity

cost, etc., of production. It applies management principles to production. Production

management is a part of business management. It is also called "Production Function.

Production management is slowly being replaced by operations management.

The main objective of production management is to produce goods and services of the

right quality, right quantity, at the right time and at minimum cost. It also tries to improve the

efficiency. An efficient organization can face competition effectively. Production management

ensures full or optimum utilization of available production capacity.

"Production management deals with decision-making related to production processes so

that the resulting goods or service is produced according to specification, in the amount and by

the schedule demanded and at minimum cost."

Importance of Production Management

o Accomplishment of firm's objectives

o Reputation, Goodwill and Image

o Helps to introduce new products

o Supports other functional areas

o Helps to face competition

o Optimum utilization of resources

o Minimizes cost of production

o Expansion of the firm

The importance of production management to customers and society:

o Higher standard of living

o Generates employment

o Improves quality and reduces cost Spread effect

DESIGN AND DEVELOPMENT OF PATTERNSHIP

Once the enquiry is received the following are to be verified/checked before informing tomarketing to entertain the order Overall size of the component to fit into in our mould sizeTolerances are achievable or not check entire dimensions are clear and nothing is missing. Boxweight should be minimum 10kys and yield should be minimum 55%in case of sg and 60% incase of grey to decide material of the pattern to decide number of patterns Material specificationslike chemistry, micro-structure, Hardness, Tensile strength, elongation etc, in consultation withquality laboratory should be verified monthly requirements

While designing the pattern, ensure to facilitate better productivity in the molding todecide to have less/nil core work and the process of the core marking to have a less felting/machining work to have an easy feeding system of metal. To decide manufacturing process ofthe patter to decide the layout of the pattern to inform the purchase department suitably to orderfor the patterns giving 100% details like manufacturing process and the material, etc. along withthe approximate time for the delivery and cost estimation on receipt of the pattern, countercheckthe dimensional report sent by the pattern supplier

Depending on the reliability of the pattern supplier, the pattern should be taken up formounting Immediately on receipt of the pattern, there should be a target data be given to themanagement and marketing for sample submission. Pilot batch submission and regularproduction. After mounting of the patterns there should be a check list for various parametersbefore it is given for trials after trials the dimensions should be recorded at our end in addition tothe verifying correctness of the mothering

The sample should be sent to the customer without any deviations on the specification andthe first sample should be approved at customer end The pilot batch (quantum to be decidedbased on the weight of the castings0 should be given and get the approval from the customer forthe specifications i.e., It is our responsibility to ensure that the casting once approved by thecustomer, should not any problem at bulk production stage.

When we give pilot, we should take care of the total specifications. After approval of the pilotbatch the bulk supplies to be decided at least 3 to 4 batches to ensure that the process in set at ourend After satisfactory reports of bulk supplies of 3 to 4 batches It is handed over to production

The pattern layout drawing should be recorded offer establishing the bulk production The dataslike box weight, casting weight, number of putters piece weight, gross yield etc. Should berecorded. The identification of the match plate codes should be clearly painted in the match plate.

After the tooling/ pattern is done properly with a right mothering taking care of the aboveparameters, it solver lot of recurring defects/ rejections. There should not be any patching of thepatterns/running system by m. seal frequently as being done now. There should be 100% clarityon all the above points mentioned the basic process and to deviate the established systems All thepeople of all levels working in the department should be thoroughly educated to adopt the abovementioned procedures/ systems There should be serious focus on the 3-d modeling. There shouldbe adequate load to everyone working in the respective section attached to the pattern shop thereshould be a clear log on all the work done by each and every section of pattern shop giving cleardetails of the work done by ever one to the management. A separate attachment is givendescribing various defects that can occur due to improper pattern practice and its causes andremedies. WE SHOULD WORK WITH O DEFECTCONCEPT

MELTING

To learn design and construction of the furnaces to learn principles of the operations of thefurnace to learn-what is the metal SG and GREY to learn the properties of the metal likechemistry microstructure, Hardness, Tensile strength etc.

To learn how to prepare the metal for a required properties to learn what are the charges ofmaterials and alloys added in the furnace the achieve the required specifications of the metal Toknow and check temperature of liquid metal tapping and pouring to learn what is the treatment ofSG and how the treatment is carried out under what conditions and procedures to learn theinoculation procedure to learn the pouring practice and duration of the pouring to learn thepreparation of ladles and under what conditions, the ladles are to be used to learn the remedialactions/solutions for the identified defects to learn the remedial actions/solution for the identifieddefects. To learn how to improve the entire activities of the department keeping in mind theimprovement in productivity reduction in cost and improving the quality a separate attachment isgiven describing various defects that can occur due to improper melting and pouring practice andits causes and remedies

MOULDING

To learn the construction of molding machines and principles of working of the machinesto learn construction of the boxes and the tooling like pins, bushes clamps etc. anditsfunctionalimportance and operation. To learn jolting and squeezing timing and its impact on quality of thecastings. To look for the pattern and gating system conditions before taking up for production/core stock Check before for items taken up for production for whether chill or frame requiredTo verify and item taken up for production is an established item and see the past history of the

jobs in respect of rejection To learn and identify the defects due to the molding process To takecorrective actions and permanent solutions to avoid recurring defects related to molding separateattachment is given describing various defects that can occur due to improper molding practiceand its causes and remedies

SANDPLANT

To learn the design and construction of sand mixers and the allied equipments To learnthe condition of the mixers and whether the scrapers are in good condition and there is nodeposits of sand in the side of the wall and bottom of the mixers to maintain the mixers alwaysin good condition by proper cleaning and maintenance To learn about the additives and itsproperties and the purpose for which the additives and added to the sand To learn the proceduresand process of mixing (sand preparation)

To learn the necessary preparation of sand and the sand properties to be maintained whilepreparing To learn and ensure all the tests required in clone on line while preparation of the sandThere should be continuous thinking and improving on quality of the sand keeping in mind thedefects/rejections are n/l due to sand properties. A separate attachment is given describingvarious defects that can occur due to improper sand mixing practice and its causes and remedies

CORESHOP

To learn the working of the core sand mixers to learn the various process like, co2, nobake, oil sand, shall cores, etc., To learn what is the purpose of using a particular process for aparticular type of casting based on the size of the core and strength of the core configuration ofthe core and finish of the core surface in the castings. To learn the condition of the core boxesand to have continuous monitoring of the core boxes to avoid dimensional defects on the cores.To learn about the additives in the core sand and the purpose of the same to suggest on theimprovement of core making process, quality of the cores to have a nil rejections on account of

cores to use effectively the imported core shooter to have cost reduction and productivityimprovement separate attachment is given describing various defects that can occus due toimproper core practice and its causes and remedies

CHAPTER 3.3

QUALITY DEPARTMENT

The company includes Quality control departments, laboratories; quality assurance

intends to continuously improve quality in the framework of quality policies of the company

aiming to bring about customer satisfaction Taking advantage of educated and experienced

people, this department investigates all the inputs and outputs of the factory including raw

materials, components and products.

Subordinate departments of quality control in aluminum alloys Steel Industrial Complex

are as follows:

Steel production quality control:

In this department, quality control technicians control the arrived scrap iron and

cooperate with the production department in steel production during the steel production process

by sampling and analyzing molten steel with the desired rate and ultimately issue the casting

license after approval of the final product. At the next stage, the produced ingot will be

controlled in terms of dimensional parameters as well as metallurgical defects (crack, mac, offal,

etc.) to be receipted and delivered to the storage after the approval.

Any product that does not conform to the type of the desired steel, will be classified into

other steel categories if it could fall into them, otherwise, it will be delivered to the scrap

warehouse as the waste ingot.

Quality control of the arrived parts:

All parts produced or repaired outside the factory, will be inspected by the quality control

department after arriving at the factory and before getting receipted in terms of compliance with

the desired demands which have been informed by the applicant department in writing to be

delivered to the applicant department after confirmation. In case of any non-compliance, the part

shall be returned to the manufacturer to remove the non-compliance.

QUALITY POLICY

Maximum overall plant effectiveness by aiming at;

Zero break down, zero defects ad zero accident

Continuously improving machines and methods to maximize overall efficiency and

quality

Customer satisfaction by timely providing product of desired quality.

Total employees participation and team work

Environment policy

The sufficient lighting system is arranged with out any shadow to enable the workers to

work efficient during night shifts

The specter meter is housed in an air conditioned humidity controlled room to meet its

hot working condition

Fire exiting wishers and fire buckets filled with sand are placed in areas of work where

vulnerable for fire to meet any fire accident

LABORATORY AND QUALITY CONTROL:-

To understand dearly the specifications in respect of the chemistry. Physical properties,

metallurgical properties and Dimensional aspects and the materials used for testing to learn the

method and process adopted in the laboratory for testing chemistry wet analysis and Spector .To

learn the testing procedures adopted for metallurgical properties and physical properties.

To learn the operations of the equipment and the instruments used for testing the above

properties to learn the reading of drawing in respect of dimensions. To learn what is a sand, its

properties, its influence on the casting defects and finish to learn the equipments used for sand

testing To earn the procedures of testing of sand for various properties to suggest remedial

measures to cure the defects on permanent basis to ensure the calibration of the instruments/

equipment for its rightness to over check and counter-check the consistency of the individuals

capabilities of various parameters said above this should be recorded on regular basis for

traceability purposes to learn and understand the process capabilities for its consistencies and

adopt accordingly

To ensure an in built quality in the various manufacturing activities to work towards o

defect targets both in house and customer end, to have a correct and immediate feedback to the

customer complaints to create 100% customer confidence and satisfaction by introducing the

various checks particularly related to our type of products on case to case basis To introduce the

best and full proof process check right from the in-coming material stage to out-going product

stage to ensure for a product as per the customer specifications No deviations is entertained

without the customer acceptance To have a thorough recording system for a better feedback to

achieve continuous improvement on the product To maintain the systems as required for Iso and

other approval

CHAPTER 3.4

FINANCE DEPARTMENT

The Finance Department work closely with the management act as professional advice

and control service for the financial activities of the Company, Departmental Meetings are held

regularly, in which work related matters are discussed. Additionally the detail work in progress

of each section in monitored through meetings between the Senior Staff and the juniors for which

they are responsible.

The Finance Department helps the other departments to meet their service objectives by

acquiring services and goods, allocating the companys financial resources, processing financial

transactions, and providing information and analysis as a basis for decision making.

The Mission of the department is

The Finance Department is committed to providing the highest levels of financial

services to the Company.

This includes insuring that proper controls and procedures are in place to manage

properly.

We constantly evaluate and balance the types and levels of services provided

Efficiencies are developed through staff training opportunities, teamwork and by

providing employees with a challenging and fulfilling work environment

Objectives:-The broad objectives of the Finance Department are to provide a timely, efficient

and cost effective service:

Continuing to improve the level of operational efficiency of the Finance Department.

Maintaining effective working relationships with the rest of the Company.

Continuing to improve the quality of financial information supplied to departments.

Meeting the Reporting deadlines set by GAC

Ensuring wide compliance with the Financial Regulations.

FINANCIAL POSITION OF THE COMPANY (Rs in lakhs)

Audited Audited Audited

31.03.11 31.03.11 31.03.111. Working capital 641.00 741.00 941.002 Tangible networth 689.00 875.00 1080.003 Term loan 74.86 58.50 35.024 Current assets 1232.33 2212.42 1918.485 Current liabilities 1142.49 1931.42 1582.22

WORKING RESULTS

Particulars Audited Audited Audited

31.03.11 31.03.12 31.03.13

1 Sales 2249.27 4003.65 4218.38

2 Gross profit 516.85 165.70 216.64

3 Depreciation 124.02 124.78 150.27

4 Interest 66.59 118.55 108.22

5Operating profit 198.27 290.48 366.91

6 Taxes 9.72 41.54 50.98

7 Net Profit 84.19 135.87 174.32

STRUCTURE OF FINANCIAL DEPARTMENT

CHAPTER 3.5

MARKETING DEPARTMENT

Marketing is the management of process involved in identifying, anticipating and

satisfying consumer requirements profitably.

Marketing is the process by which companies create customer interest in products or

services. It generates the strategy that underlies sales techniques, business communication, and

business development. It is an integrated process through which companies build strong

customer relationships and create value for their customers and for themselves.

FEATURES OF MARKETING:-

Marketing is aimed at finding out consumer needs and meeting these needs.

Marketing must consider profit as its main objective.

Marketing is ongoing all the time. The marketing process has no start or end

Businesses must be prepared to respond to the consumer reactions and changes all the

time

STRUCTURE OF MARKETING DEPARTMENT

IMPORTANCE OF MARKETING:-

Marketing is playing a more and more important role in the success of a business. It can

be said that no marketing means any business.

There are generally some key factors which have made marketing so important for

businesses today.

THE FACTORS CAN BE SEEN AS IN THE FOLLOWING TABLE:

Factors Explain How

1. Economicgrowth

Economic growth leads to an increase of consumers incomes. So demandfor products and services will be increased. Through marketing, businessescan promote their new products and services

2. Fashion Considerable changes in fashion and consumer taste force businesses toproduce more new products and services. Marketing makes it possible forbusinesses to reach these changing customers

3. Technology New technology has helped the business to create new or high qualityproducts. It is marketing that can make customers be aware of these newproducts.

4. Competition Facing more and fiercer competition, businesses must rely on marketingstrategy to win in the marketplace.

CHAPTER 3.6

HUMAN RESOURCE DEPARTMENT

A typical Human Resource Department is carries out the following functions:

MANPOWER PLANNING

It involves the planning for the future and finding out how many employees will be

needed in the future by the business and what types of skills should they possess.

It depends on the following factors

The number of people leaving the job

The projected growth in sales of the business

Technological changes

Productivity level of the workers

JOB ANALYSIS AND JOB DESCRIPTION

HR Department is also involved in designing the Job analysis and Job description for the

prospective vacancies. A job analysis is the process used to collect information about the duties,

responsibilities, necessary skills, outcomes, and work environment of a particular job.

Job descriptions are written statements that describe the:

duties,

responsibilities,

most important contributions and outcomes needed from a position,

required qualifications of candidates, and

reporting relationship and co-workers of a particular job.

DETERMINING WAGES AND SALARIES

HR Department is also involved in conducting market surveys and determining the wages

and salaries for different position in an organization. These decision may be taken in consultation

with top management and the Finance department.

RECRUITMENT AND SELECTION

One of the most important jobs HR department is to recruit the best people for the

organization. This is of crucial importance as the success of any organization depend on the

quality of its workforce.

PERFORMANCE APPRASIAL

Once the employees are recruited , the HR Department has to review their performance

on a regular basis through proper performance appraisals.

Performance appraisal is the process of obtaining, analyzing and recording information

about the relative worth of an employee. The focus of the performance appraisal is measuring

and improving the actual performance of the employee and also the future potential of the

employee. Its aim is to measure what an employee does. On the basis of performance appraisal

the HR Department will set up an action plan for each employee. If the employees needs any

training then he provided that.

TRAINING AND DEVELOPMENT

HR department is constantly keeping a watch over the employees of the organisation. In

order to improve the efficiency level of the employees they have go undergo regular trainings

and development programmes. All trainings and development needs are carried out by this

department. Training might include on the job or off the job training.

EMPLOYEE WELFARE AND MOTIVATION

Happy employees mean a healthy organization. HR Department conducts various

employee welfare activities which might include employees get together, annual staff parties etc.

HR department also reviews organizational policies and its impact on the motivation of the

employees.

ADDRESSING EMPLOYEES GRIEVANCES

HR department is the link between the workers and the management. Employees

grievances related work environment are usually entertained and resolved by the HR

Department.

LABOUR MANAGEMENT RELATIONS

For the smooth operation of any organization, it is crucial to have good labour

management relations. HR department has to ensure that these relations are cordial. In case of

any labour-management conflict the HR Department will play a vital role in bringing both

management parties to the negotiation table and resolving the issue.

IMPLEMENTING ORGANIZATIONAL POLICIES

HR Department has to coordinate with line manager and see that the organizational

policies are being implemented in a proper manner. Disciplinary action can be initiated against

employees who are not following organizational rules and regulations. All these actions are

conceived and implemented by the HR department.

DISMISSAL AND REDUNDANCY

HR Department has to take firm actions against employees who are not following the

organizational code of conduct, rules and regulations. This can result in the dismissal of the

employee.

Sometimes, an organization may no more require the services of an employee. The

employee may be made redundant. HR Department has to see that organizational and

government regulations are being followed in this process

THE ROLE OF HRM

Keep in mind that many functions of HRM are also tasks other department managers

perform, which is what makes this information important, despite the career path taken. Most

experts agree on seven main roles that HRM plays in organizations. These are described in the

following sections.

DEVELOPMENT OF WORKPLACE POLICIES

Every organization has policies to ensure fairness and continuity within the organization.

One of the jobs of HRM is to develop the verbiage surrounding these policies. In the

development of policies, HRM, management, and executives are involved in the process. For

example, the HRM professional will likely recognize the need for a policy or a change of policy,

seek opinions on the policy, write the policy, and then communicate that policy to employees. It

is the key to note here that HR departments do not and cannot work alone. Everything they do

needs to involve all other departments in the organization. Some examples of workplace policies

might be the following:

Discipline process policy

Vacation time policy

Dress code

Ethics policy

Internet usage policy

COMPENSATION AND BENEFITS ADMINISTRATION

HRM professionals need to determine that compensation is fair, meets industry standards,

and is high enough to entice people to work for the organization. Compensation includes

anything the employee receives for his or her work. In addition, HRM professionals need to

make sure the pay is comparable to what other people performing similar jobs are being paid.

This involves setting up pay systems that take into consideration the number of years with the

organization, years of experience, education, and similar aspects. Examples of employee

compensation include the following:

Pay

Health benefits

401(k) (retirement plans)

Stock purchase plans

Vacation time

Sick leave

Bonuses

Tuition reimbursement

RETENTION

Retention involves keeping and motivating employees to stay with the organization.

Compensation is a major factor in employee retention, but there are other factors as well. Ninety

percent of employees leave a company for the following reasons:

Issues around the job they are performing

Challenges with their manager

Poor fit with organizational culture

Poor workplace environment

Despite this, 90 percent of managers think employees leave as a result of pay. [2] As a result,

managers often try to change their compensation packages to keep people from leaving, when

compensation isnt the reason they are leaving at all. Strategies to retain the best employees

based on these four factors.

TRAINING AND DEVELOPMENT

Once we have spent the time to hire new employees, we want to make sure they not only

are trained to do the job but also continue to grow and develop new skills in their job. This

results in higher productivity for the organization. Training is also a key component in employee

motivation. Employees who feel they are developing their skills tend to be happier in their jobs,

which results in increased employee retention. Examples of training programs might include the

following:

Job skills training, such as how to run a particular computer program

Training on communication

Team-building activities

Policy and legal training, such as sexual harassment training and ethics training

TRAINING EFFECTIVENESS EVALUATION

The HOD personnel evaluate the effectiveness of the training through the performancemonitoring of the employees concerned. This is recorded in the training evaluation report.On thejob training skill imparting training

The concerned HODs evaluate there training programs after at least two months of thecompletion of the training. This is recorded in training evaluation report

Through awareness training programs it is ensured that all the employees are aware of therelevance and importance of their activities and how they contribute the achievement of thequality objective of the organization

EMPLOYEES MOTIVATION AN EMPOWERMENT.

Suggestions review committee is set up under the leadership of director, comprising allHODs and the operators from each and every department suggestions adjudges as the best arerewarded to motivate the employee to achieve quality objective in periodical review ofsuggestions and to create on environment to promote innovation

CONCLUSION:

The training programs under gone in the company UNICAST ALLOYS PRIVATE

LIMITED helps to know about the organizational structure and how it works. It was a good

experience to me and I gained a lot of knowledge and exposure about the industrial activities and

administrations performed in the company. Through this study it was found that the UNICAST

ALLOYS PRIVATE LIMITED has a predominant role in India. Yet, if the company adopts some

more different strategies to satisfy and motivate their employees accordingly to the current

trends, then this will pave the ways for a greater proportion of growth and development of the

organization in future period.

I learnt about Factories Act, The Maternity Benefit Act, The Payment of Wages Act and

few other acts. And also the concepts of selection and recruitment process, Training methods,

Labour welfare in HR department. I could understand the concepts of Bill of Materials,

Inventory, Stores management and Quality circles in Production department. The concepts of

market segmentation, sales promotion activities and Information system concepts in an industry

were understood practically.

BIBLIOGRAPHY

1) N.P Agarwal & S.K. Mangal (1998) reading in finanace management Print well

publishers,vol.1,P.No:140-176

2) Wayne F Cascio, (2011) managing human resources MC Graw Hill

publishers,P.No:58-93

3) Beckhard, Richard (1969) organisation development strategies and models MC Graw

Hill Publishers,P.No:135-152

WEBSITES:

http://www.chennaialloyssteel.com.

http://www.mahindra.com.

http://www.shaholloys.com.

http://www.keytometals.com.

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INDUSTRY PROFILEHUMAN RESOURCE DEPARTMENTMANPOWER PLANNINGJOB ANALYSIS AND JOB DESCRIPTIONDETERMINING WAGES AND SALARIESRECRUITMENT AND SELECTIONPERFORMANCE APPRASIALTRAINING AND DEVELOPMENTEMPLOYEE WELFARE AND MOTIVATIONIMPLEMENTING ORGANIZATIONAL POLICIESDISMISSAL AND REDUNDANCY