CII Guardian Organization Study

8/6/2019 CII Guardian Organization Study

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CHAPTER I


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1.1. INTRODUCTION

Today the world growing very fast, the change is unpredictable. The past decades

have witnessed a paradigm shift in business. The number of competitor is increased

today. In order to face tight competition, the companies need to re-structure their

functions.

Now the taste and preference of a customer is totally changed, they are more

change seeking and value conscious. So it is necessary to a marketing professional tokeen insight into the customer taste, preference, and attitude and value expectations.

One of the fastest growing industries in the world today is the electromechanical

industry. It fulfills an essential infrastructure need of economic development sector and

plays a very important role in growth of an industry.

Relays are invented in 1835, these are effective device that operate as an

electronic switch, opening and closing under the electromagnetic conditions. Relays are

used in electronics that have a low voltage power source but require higher voltage to

turn them on and operate.

Relays are used in commercial aircraft, networking, communication device,

medical equipment like heart defibrillator, traffic signals etc. Its application is unlimited.

The company Guardian Controls limited is a joint venture of Guardian Controls

Ltd. And TYCO electronics in U.S.A, formerly CII Technologies U.S.A world leader in

high performance relays. Over the past five years TYCO Electronics has kept place by

rapidly growing to become the worlds largest passive component manufactures. In 1996

CII technologies were the world leaders in high performance switching technologies


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1.2. SCOPE OF THE STUY

The present study was conducted at CIIG. The study was done to familiarize withdifferent management activities. Hence, the study can also be used to know the

functional aspects of the departments of CIIG.

1.3. OBJECTIVE OF THE STUDY

To get familiarize with different management aspects.

To get idea about the organization

To study the functional aspects of various departments of CIIG

To observe workers at their work place and to interact with them

To find out the competitors of the company

To identify the hierarchical structure followed by CIIG

1.4. REASON FOR SELECTING THE COMPANY

The reason for selecting the CII Guardian International Ltd. is that, they are the

largest supplier of automotive, test equipments, power electronics to other industries.

Also the company is a joint venture with TYCO electronics in USA.

1.5. STUDY PLAN

The total time of organization study was four weeks. The study starts by

collecting data from the organization. I was spent two week in the organization. The first

week I was engage in collecting data through direct observation of the functioning of

organization and clear watch in companys record and files. The second week I visit each

department head, and collect information from them.

The last two week I used to processing the collected data and recording it in the form

of a .proper report


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1.6. METHODOLOGY

Research methodology is the study of research method and rules for doing research

work and it is a way to solve systematically the research problems. The methodology

used in study involves the collection of primary as well as secondary data.

Primary data

It is essentially designed to fulfill the data needs of the problem in hand. The primary

data were obtained by observation and direct interview with some executives and

managers of the company. The persons for interview are selected through simple random

sampling.

Secondary data

The secondary sources of data were collected through files, text books, profile of

the company, journals, training report etc. The internal and external sources of data are

used as secondary source. This secondary data mainly helped to understand the

organization.

1.7. LIMITATION OF THE STUDY

1. There were difficulties in obtaining data from executives and managers due to their

busy work schedule.

2. An in- depth study of the company could not be carried out due to shortage of

time.

3. The reliability of data used for study is largely depends upon the companies

reports and the information given by executives.

4. The company has the limitation to disclose their financial details, so a detailed

analysis of financial performance of the company is not possible.


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1.8. CHAPTER SCHEME

The present study is arranged in six chapters. The first chapter discloses a brief

introduction, scope and objective of the study, reason for selecting the company, study

plan, methodology, and limitation of the study and chapter scheme. The second chapter

involves the industry profile, world scenario, Indian scenario, and state scenario of

relays.

The third chapter show details regarding the company profile, objective of thecompany, history& philosophy, organization structure and different phase of

development. The forth chapter describes each departmental details, structure of each

department and functions of each department. The fifth chapter shows the SWOT

analysis, observation and suggestion of the study.


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CHAPTER - II


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2.1 INDUSTRY PROFILE

Relays are invented in 1835. Relays are simple yet effective device that operate

as an electrical switch, opening and closing under electromagnetic conditions. Relays

were used for electronics that have a low voltage power source but require higher

voltage to turn on and operate i.e. when a circuit of low power needs to be converted into

a circuit of higher power. In some instance, the reverse is true. Relay is an

electromechanical device that is electrically controlled to interrupt the input conditions

in a prescribed means by the relative movement of mechanical elements under the actionof a current in the input circuits.

Relays are manufactured in India for domestic and general purpose. Domestic

purpose relays are manufactured at DUETSHE INDIA Ltd, Bangalore. These relays are

used for communication and for aviation. High performance relays are used in aviation,

telecommunication for testing equipments and in defense.

A relay is an electrically operated switch. Many relays use an electromagnet to

operate a switching mechanism mechanically, but other operating principles are also

used. Relays are used where it is necessary to control a circuit by a low-power signal

(with complete electrical isolation between control and controlled circuits), or where

several circuits must be controlled by one signal. The first relays were used in long

distance telegraph circuits, repeating the signal coming in from one circuit and re-

transmitting it to another. Relays were used extensively in telephone exchanges andearly computers to perform logical operations

2.2 WORLD SCENARIO

Relay manufacturers are struggling to meet growth projections as they face

capacity utilization challenges due to falling demand from various end-user industries. In

addition, manufacturers left with excess capacities are hesitant to invest in new
http://en.wikipedia.org/wiki/Electrichttp://en.wikipedia.org/wiki/Switchhttp://en.wikipedia.org/wiki/Electrichttp://en.wikipedia.org/wiki/Switch


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equipment. Small and mid-sized manufacturers, in particular, are expected to feel the

impact of this challenge due to the competition posed by larger manufacturers possessing

state-of-the-art infrastructure. The cost of consumables, replacement of machine parts,

labor wages, defect trends, and the increased process yield requirements are driving the

small and mid-sized manufacturers to adopt automated manufacturing processes in order

to increase turnaround time and profitability.

Improved SSRs Finding Acceptance in New Applications

"Reed relays and EMRs( electromechanical relays) are facing increasing

competition from the growing SSR(solid state relays) technology that is increasing in

market share due to improved efficiency," says the analyst. "Awareness regarding its

increased efficiency, smaller size, longer lifecycle, and reducing prices encourage design

engineers to use SSRs in a variety of applications." SSRs offer higher switching speeds

and also operate on less voltage, and are being seriously considered for next-generation

computing and telecommunications applications.

Applications in the automotives industry is also an opportunity for the SSR

manufacturers as all leading automobile manufacturers are competing with each other to

load more electronics into their automotives. The automotive industry offers harsh and

humid environments and requires high reliability relays, which SSR manufacturers are

ready to provide. Global positioning systems (GPS), in-vehicle entertainment systems,

security devices, and driver assisting systems (DAS) among other applications are

expected to become significant revenue generators for the relay market.

Strengthening Customer Relationships Will be Key for Future Success

Understanding that satisfied customers are inextricably linked with profitability,

manufacturers of relays world over are striving to become more customer oriented in

their approach. The relay manufacturers that keep abreast with the technological

advancements and also understand the changing requirements of their customers are

projected to generate greater revenues in the future.

Consistent high quality service and reliability are likely to play a key role in retaining

customers. Though currently most of the growth opportunities for relays are in the test


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bound to grow e tin the coming years. Hence there is enough potential for more number

of units in this line.

2.4 STATE SCENARIO

The development of relay all over in a very short time, demands on the power

system grid increased as generators grew in size and capacity. This resulted in higher

voltages to transport the power farther away from the source to serve ever expanding and

more complex loads over the world and Indian scenario affect the state scenario.

.


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CHAPTER III


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3.1 COMPANY PROFILE

It was in 1985, Guardian International limited was started as a joint venture

between Guardian control limited and CII technology in USA (Communication

Instrument Inc.). Initiation of the company was done by the establishment of Guardian

control limited in the year 1985, which in 1995 merged with M/S communications

instruments incorporated, USA. CIIG is a joint venture with TYCO electronics, where in

the management, labor, land is till a part of CIIG where as the other manufacturing

assets are completely owned and given by TYCO products. Serve a diverse marketincluding communications, defense, aerospace, medical, industrial commercial and

general purpose, applications etc.

The CII Guardian International limited entered the electromechanical industry,

settled very fast in Cochin Special Economic Zone, Cochin. The company mainly

manufactures high performance relays are hermetically sealed device ideally switched

for demanding environmental conditions. These relays are backfilled with inert gases

and utilize glass to metal sealing technology. The manufacturing facilities at

Thodupuzha, in the suburbs of Cochin have more than 300 employees and a team of

experienced engineers and technical person.

Ministry of science and technology, Govt. of India recognize research and

development facility of Guardian International Ltd. as the largest supplier of automotive,

test equipments, power electronics, households appliance and other industries.

Manufacturing facility is spread over 35,000 square feet, with environmental controlled

assembled area. Guardian has its own tool room and fabrication room. Delays are

inspected for all operating parameters and random samples are tested in the test

laboratory.


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Mission and vision

Mission

Guardian group is committed to provide quality products and services through

innovation, employee participation and process improvement.

Vision

To ensure customer satisfaction by delivering products on time, every time defect free

at competitive prices.

ISO- some importance concepts

Today ISO 9001 certification is becoming almost essential for Indian business houses to

export their products. One of the requirements of ISO standard is an effective

management representative who would be responsible for effective documentation,

implementation and coordination of all major activities.

The ISO certification is applied to quality management system encompassing quality inall functions such as marketing, design, purchase, assembly, testing, packing, shipping,

installation, after sale service and all other activities of an organization. ISO certification

is the mechanism by which customers have confidence in a company and is most

effective when carried out by a national certification body.

Awards

1. 1997- Guardian International Limited was certified ISO 9001-2000 by KPMG

for manufacturing and marketing of electromechanical relays under the American

National Standard institute society for quality control.

2. 1991- c-dot. Approved the telecom grade miniature PCB relay developed by in

house R&D efforts.

3. 1992- The government of India recognized the research and development of

Guardian group.


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4. For the performance and test approval under the provision of JSS 50102,

awarded by the ministry of defense, Government if India

Products

The company is largely producing electromechanical relays. They produce high

performance low power relays that are hermetically sealed device. Production facility at

CIIG manufactures three types of relays. The special features of these relays are that

they are MIL. qualified hermetically sealed relays.

Type and application of relays

1. Tyco. To-5 Relays

- aviation

- testing equipments

- communication network

-

2. Crystal can relays- defense application

- aviation

- media level switching

3. Kilovac

Used in biomedical instruments

4. General purpose relays applications

- traffic signals

- signaling device

3.2 OBJECTIVE OF THE COMPANY

1. Customer satisfaction by minimizing customer complaints and sales return (limit

customer compliments quarter to less than 3).


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2. On time delivery with significantly reduced lead time (achieve an overall yield

rating of 95%)

3. To increase productivity (turnover / men days) by 10%.

4. Provide reasonable opportunities for employees to participate effectively in

improvement activities (introduction of policies, practice or welfare measures to

increase employee participation).

5. Overall yield improvement by reducing process rejections (achieve an overall

yield rating of greater than 97%).

3.3 HISTORY & PHILOSOPHY

The Guardian Controls ltd. the first company of guardian group of companies

was founded by Mr. P.K.KOSHY in 1985 and is located in the lush green village

Thodupuzha in the suburbs of Cochin. Guardian Controls Ltd. went into commercial

production in 1989. GCL has a wide range of products covering almost the entire gamut

of applications. Guardian relays play a vital role in the telephone switching system by its

fast and reliable operation.

The technology used in relay production is the CII technology in USA. The

company guardian controls ltd. at first collaborated with CII technology in USA.

However, later the industrial giant Tyco acquired that technology from USA and

Guardian Controls Ltd. became a joint venture with Tyco electronics since 2002. Over

past five years, Tyco electronics has kept place rapidly growing to become the worlds

largest passive components manufacturer, based on the internet technology leadership ofAMP products. Tyco electronics has added a full complement of leading component

branch including RAYCHEM, ELCON, P and B, and MIA.COM. In 1993, the company

pay first dividend to shareholders.


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3.5 DIFFERENT PHASE OF DEVELOPMENT

Today the company stands with a good goodwill; this is done through different

development stages.

1985- The company was established in technical collaboration with STC

components ltd. UK

1986- The memorandum of understanding was signed with Kerala State

Industrial Development Corporation (KSIDC).

1989- Padmasree Paul Pothan, Chairman laid the foundation stone of the

company.

1989- The commercial production was commenced on November 1.

1991- C-DOT approved the Telecom Grade miniature PCB relay developed

by in house R&D efforts.

1992- The Government of India recognized the R&D of Guardian Controls

on December 2

1993- First dividend to shareholders.

1996- Joint venture agreement signed with CII Technologies USA on January

1.

1996- Trial production at CIIG facility at CSEZ, Cochin.

1997- GCL was certified ISO 9001:2000 by KPMG (now Intertek) for

manufacturing and marketing electromechanical relays under the American

National Standard Institution, Society for quality control.

2000- ISO 9001:2000 certifications was awarded to CIIG on April 7 by

KPMG for manufacturing and marketing electromechanical relays under the

American National Standard Institute.

2002- Acquisition of CII technology by Tyco Electronics USA.

2003- DSCC (Defense Supply Center, Columbus) approved for CIIG.

2008- ISO 9001-2008


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CHAPTER - IV


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4.1 PRODUCTION DEPARTMENT

Production department manufactures different types of relays according to the milstandard as per the production order. Manufacturing department receiving the piece parts

from stores and assembles to finished products.

4.1.1 Structure of production department

Figure 4.1

Production manager

Assistant Engineer Assistant Engineer

Supervisor Supervisor


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4.1.2 Functions of production department

The function production department is to produce the goods, i.e. convert input into

useful output. The different types of relays manufactured are coil winding, kilovac, 136-

relays, To-5 relay, minigrid relays and crystalcan relay.

Coil Winding

The systematic procedure of coil winding is given below,

1. coil winding

2. coil taping

3. coil stripping

4. Lead wire & jumper welding

5. Coil finishing

6. Encapsulation (coil moulding)

7. Pull test8. Preflashing & lead trimming

9. Coil loading

10. Hipot test

11. Printing &baking

12. Visual & resistance checking

13. QA inspection

Each station has maintained a machine set up log/ machine operation log. Fixture record

% O/S flow of work to be done based on flow chart & route card.


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KILOVAC RELAY

Main types of kilovac relays manufactured in CIIG are A type & B type. A type

means single pole single throw normally open and B type means single pole single throw

normally closed. The main use of these relays is in medical equipments. Coil core,

assembly, armature, epoxy, cover, accurator spring, contact assembly labels are the main

parts of kilovac relays. Each work station has maintained a machine operation log,

fixture, record & OIS (operator instruction sheet). Work to be done as per the flow chart

and route card.

The systematic procedure of manufacturing kilovac as per the route card is as follows;

Station 1 - Coil resistant checking, Hi-pot test

Actuator assembly, baking

Station 2 - Relay adjust

Station 3 - Relay cycling

Station 4 - High voltage test -- processing of relays and baking of relays

Station 5 - Electrical testing

Station6 - Welding

Station 7 - Date code printing, baking

Station 8 - High voltage test-- baking and processing

Station 9 - Hipot voltage testbaking and processing

Station 10 - Electrical testing

Station 11 - Relay cleaning

Station12 - Visual and mechanical inspection relay, labeling

Station 13 - QA inspection

Station14 - packing

136-Relay

The 136 relay manufacturing process are;

1. coil winding

2. Coil taping


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3. Trimming and taping

4. Taping and resistance checking

5. Shim cutting

6. Core assembly

7. Core / Coil / frame assembly

8. Armature assembly

9. Motor assembly

10. Adjust armature

11. Contact stacking

12. Stationary contact stacking

13. Pile up assembly

14. Pile up to motor assembly

15. Soldering

16. Clean flux

17. Adjust relay

18. Date and ID code printing

19. Cover fixing

20. Electrical inspection

21. Dielectric inspection

22. Visual inspection and packing

To -5 Relay( Transistor outline -5)

To-5 relays are high performance and high reliability hermetic sealed relays

which is mainly used for communication networks, aviation purpose etc. To-5 relay parts

have mainly two parts, header assembly and motor assembly. In it work in progress is

controlled with a route sheet. The quality produced, date, operator number must be filled

in route card before parts are moved to the next station. The operator has to check

whether the previous operator has completed and signed of the route card.


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Header assembly

1. Trimming

2. Forming

3. Stationary contact welding

4. Shearing

5. Movable contact welding

6. Return spring welding

7. Backstop welding

8. Header adjustment

Motor assembly

1. Armature / actuator assembly

2. Core / armature

3. Lower support welding

4. Motor assembly welding

5. Assembling & peen armature / Core assembly to motor6. Resistance testing & welding motor to header

7. Coil lead welding

To-5 Relays are also available with internal diode for coil transient suppressor.

Mini Grid relays

Mini grid relays are same like To-5 relay, which is only change in the design. These

relays are hermetically sealed with a welded enclosure to perform reliably in the most

severe operating conditions. These relays have two major parts i.e. header assembly and

motor assembly.


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Header assembly

1. Trimming

2. Stationary contact welding

3. Sub- assembly welding

4. Return spring welding

5. Welding the sub assembly to the header

6. Back stop welding

7. Header adjust

Motor assembly

1. Armature

2. Armature / Core assembly

3. Lower support welding

4. Weld motor assembly

5. Assembly & Peen Armature

6. Weld motor to header

7. Weld coil lead

Crystal Can Relay

The main use of this relay is defense application, aviation medium level switching

etc. manufacturing process of crystal can relay can be divided into two; header assembly

and motor assembly.

Header assembly

1. Assembly & brazing the make break and assemble spring and header.

2. Vapors degreasing with a solvent, named hydro chloro fluro carbon.

3. Pre-adjusting the header spring position and its alignment.

4. Adjust header

5. Vapor degreasing.

6. Ultrasonic wash.


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Figure 4.2

Executive HR

JR. Executive

HR Assistant HR Assistant

4.2.2 Functions of HR department

Basic functions

1. Recruitment

2. Manpower planning.3. Welfare functions.

4. Grievance handling.

5. Discipline.

6. Industrial relations.

7. Job descriptions.

8. Training.

9. Performance appraisal.

Statutory functions

1. Factory license renewal

2. Companies holydays calendar making

3. Labor welfare fund

4. Professional tax to Panchayat

5. Taxes to SEZ


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6. Kerala State Pollution Control Board Certificate

7. Waste dumping inside the CSEZ campus

8. CSEZ identity cards are there for employees

Employee selection procedure

HRD is recruiting the lower level employees, workers and operators and

promoting the employees based on their promotion. Employees are selected strictly

based on their educational qualification, work experience, technical know how and age.

Remuneration

All of the executives, trainee workers and operators earn salary on the last working

day of every month.

Salary consists of;-

a) Basic pay

b) Fixed DA

c) HRA

d) Conveyance & other allowance

Allowance

1. Dearness Allowance (DA) -- This is given to permanent employees with fixed

DA calculated at the rate of 15% of basic salary.

2. Conveyance allowance

3. Washing allowance

4. Shift allowance

5. Overtime allowance

Statutory liabilities


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1. Provident Fund - From the basic salary the company and employee

contribute 12% into the provident fund account equally. Out of the 12%

contributed by the company, 8.33% is transferred to the pension account.

2. Employee state insurance - Company pays around 4.5% of total salary of an

employee to ESI, and the employee contribution is 1.75% of total salary.

3. Gratuity - For getting this benefit to an employee, he / she needs minimum 5

years of service.

Trade union

In this company there is only a trade union called CSEZ workers Association (CITU).

Leave

Casual leave ; 8 days for executives and workers

Privilege leave ; 18 days per year

Sick leave ; 4 days for executives and workers

Training

The CIIG provide training programs for their employees. There is four types of training

methods are followed

Orientation training

On the job training

External training

Internal training

Training period


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1. Senior engineer & Managers - 6 months

2. Engineers & Management trainee - 1 years

3. Supervisors, trainee - 1 years

4. Field engineers - 1 years

5. Operator trainee ( ITC/ ITI) - 1 years

6. Operator trainee ( SSLC/ PLUS 2 ) - 2 years

4.3 MARKETING DEPARTMENT

The main and major aim of marketing department is to identify the market

demand and supply the goods as per the demand. Marketing department in CIIG is

differential, which mainly focuses on promoting the goods produced and gather a

realizable order for the company such that at notime there is stagnation experienced in

the enterprise due to lack of orders and such that the delivery can be made as per the

predefineddata. When we compare CIIG with other similar industries, the advantage is

that it is located in the Special Economic Zone (SEZ), which exempts most of the duties

and taxes imposed by the government. The labor overhead charges occurring in CIIG is

low as compared to the foreign industries. The main marketing point is the QPL of the

products on the defense websites where the generalized past numbers and the Tyco past

numbers can be compared and can be verified by anybody.

The marketing department plays a vital role in the production planning as a

constant feedback of the quality of finished products is verified regularly to check the

possibility of finishing the production of the user specified products in time.

4.3.1 Structure of marketing department


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Figure 4.3

Vice President

SR. Manager

JR. Engineer

Market Assistant

4.3.2 Functions of marketing department

1. Quality policy development

2. Management review

3. Internal communication

4. Contract review

5. Customer communication

6. Invoice & Shipment

7. Handling of customer complaints

8. Customer satisfaction

4.4 FINANCE DEPARTMENT


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For smooth functioning of every organization proper money management is essential.

Only through proper money management a firm can identify it strength and weakness in

the financial structure. The CIIG also give great important to its financial department.

4.4.1 Structure of financial department

Figure 4.4

G.M

Manager

Financial Executive

Staff Staff Staff

Significant Accounting policies


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the items to factory on FIFO basis. The cost of manufactured inventories comprises the

direct cost of production plus appropriate overheads.

Foreign currency transaction

Monetary items denominated in foreign currency are reported at the exchange rate

prevailing as at the date of the balance sheet and the resultant exchange gain /loss, if any,

has been adjusted to the profit and loss account, to the extent they relate to items other

than liabilities incurred for acquiring for fixed assets. Those relating to liabilities for

fixed assets have been adjusted to the carrying cost of the respective assets.

Investment subsidy

Investment subsidy received is treated as capital reserve.

Sales

Revenue is recognized when the significant risk and rewards of ownership of goods

have been passed to the buyer. Gross sales are inclusive of excise duty and are net of

trade discount.

Retirement benefit

Liabilities of gratuity for employees determined based on actuarial valuation as on the

balance sheet, date is funded with the Life Insurance Corporation of India, and the

contribution there of payable is absorbed in the accounts.

Liability for leave encashment benefit determined based on actuarial valuation as on

the balance sheet date is provided for in the account.

4.5 PLANNING AND PUCHASE DEPARTMENT


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The planning and purchasing department ensures that the right quality of goods is

available at the right time and right place without any delay. Planning and purchase

department ensures the availability of the required material at the right time at right

quantity to different departments for smooth functioning of the organization. Purchase

department interacts with different departments of the organization, suppliers, sub

contractors and service providers whenever required. This department includes incoming

store, piece parts store, general store and packing store. The incoming store receives the

materials from various vendors as per the purchase order. The received raw parts are in

the incoming stores and information given to the QA departments through receiving

reports. Based on the receiving reports QA inspects the received parts in which the

accepted item are transferred to piece parts store and rejected items are transferred back

to the incoming stores. The rejected items received by the incoming stores are sent back

to the vendors through Return Material Note (RMN) or scrap the material with scrap

note. Those parts which can be used after rework are transferred to incoming store from

QA as non-confirmed item. After rework the items are again transferred to QA for

inspection and improved items are transferred to piece parts store and if again rejection

comes they are sending back to vendors through planning and purchase department.

Manufacturing department receives piece parts against store requisition from piece

parts store. Based on production orders, CARDEX is maintained for each item in the

piece parts store. These cardex are updated for every item stored in the piece parts store.

Periodical re-inspection of the stored parts is done based on OIS. After QA certification,

the finished products are transferred to the packing store. Here each type of relay is

packed in specially designed packages so that no damage is caused while transportation.

Structure of planning and purchase department


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Figure 4.5

Manager

Assistant Engineer

Junior Engineer

Supervisor

Functions of purchase department

1. Material planning

2. Import purchase

3. Local purchase

4. Customs clearance

5. Evaluation of supplier

6. Supplier control

4.6 QUALITY ASSURANCE DEPARTMENT


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The major function is to make assurance in the quality of products. For it inspection is

necessary.

1. Piece parts Inspection

The parts required for production are received and stored in the incoming store

with receiving reports. This report is received by planning and purchasing departments.

After receiving the reports QA verifies all the documents and samples are taken for

inspection as per the standards. The sampling is done as per the sampling plan. After

inspection the plants are labeled into three categories. They are a) accepted b) rejected c)

non-conforming. Accepted parts are transferred into piece parts store along with the

report. The rejected parts are transferred into the incoming store along with receiving

reports. The non-conforming items are items which can be reworked and stored in the

incoming store. These items after proper cleaning are again transferred back to piece

parts inspection for re-inspection.

The equipment used for inspection are;

Dogmatic outside micrometer

Dogmatic caliper

Profile projector

Bend testing fixture

Microscope

Bearing pin

Multimeter

Digital height guage

Chattilon guage

RAM optical instrument

Fisher scope

Corecimeter

2. Product inspection

Here they inspect the product


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Testing methods

Vibration test

Moisture test

IR & Dielectric test

Miss test

Gross leak test

Visual test

IC test

3. Caliberation

4. Reliability test

4.7 UTILITY MAINTENANCE DEPARTMENT

This department is more conscious about the maintenance of machinery, it

ensures to contribute key product quality characteristics and ensure continuing

process capability.

4.7.1 Structure of utility maintenance department

Figure 4.7

Manager

Engineer

Assistant Engineer

Supervisor


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4.7.2 Functions of utility and maintenance department

When mechanical instruments are purchased new, they are serialized by the

purchasing & planning department and they ensure the item is available in user

departments for production. The user department seeks the assistance of utility and

maintenance department for installation and commissioning of that equipment through

job requisition format. Mainly the utility and maintenance department deals with two

type of maintenance; preventive maintenance and predictive maintenance.

Preventive maintenance

All the machines have a preventive maintenance schedule which directly affects

the quality of the products and is prepared and maintained in the maintenance

department. This schedule is prepared by the previous maintenance history of the

equipment. Preventive maintains Intimation is used by the user department to inform

maintenance department about the complaint. The routine maintenance work is to be

carried out daily or weekly basis by the operator with the assistance of a prepared routine

maintenance instruction.

Other than those specified in preventive maintenance schedule all the other

maintenance work is carried out by the maintenance department. The completion of the

work done and the details of the workers are recorded in the equipment history card.

Break down maintenance

The user departments inform the utility and maintenance department about any

breakdown of machines or equipments using a job requisition format. The maintenance

person attends the complaints on priority and emergency basis after the job requisition if

the break down can be set right by the in house facility. The copy of job requisition is

returned to the requesters for their records. In case if the break down cannot be rectified

in house the work is transferred to an external agency through purchase and planning

department.


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When the work is completed, it is collected and after verification it is transferred

to the concerned department. The details of all maintenance done are recorded in the

equipment maintenance chart.

4.8 Enterprise Resource Planning

All department of CIIG function as a part of ERP, which functions as a root base,

thus interlinking of all departments functions effectively so as to result in a smoother

functioning of the organization. This department deals with the overall working of the

enterprise. Previously each department functioned as a single non-related entity which

resulted in restricted access of valid documents between departments. This in turn

resulted in a constriction in the working, which was eliminated with the introduction of

ERP. It inter related the department and gave access to the documents of each unit to

authorized personnel even if that particular person is not a part of particular department.

For this purpose ERP uses specialized software, which enables the unit to maintain the

record of each department in an ordered manner on an oracle database in user friendly

layman terms, hence enabling every person with authorization to access the database.

The reports from all departments are incorporated into the database. Initially a user has

to sign in on the database with a user ID and password provided. He then gets access to

the list of the data from departments which are listed below;

Sales

Purchase

Inventory

Finance

Costing

Fixed assets

Human resource

Production

Production planning

Equipment maintenance


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Shares

Customer care

System administration

Executive information system

User area

Discover

4.8.1 Functioning of software

The software used in EBZ-frame. The system administration option of CIIG maintainsthe company details, which is relevant to each department. The administrator can disable

the other options, which are available by default on the software.


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CHAPTER V


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SWOT Analysis

STRENGTH

1. The company situated in SEZ, so they enjoy lots of benefit. CIIG can run their

exporting easily and also they enjoy some tax benefits.

2. Dedicated young work force

3. Financial strength of the company

4. Capable marketing personnel5. Guardian group has nearly 25 years of experience in the design and

manufacturing of electromechanical relays.

6. Excellent infrastructure for manufacturing products.

WEAKNESS

1. 90% of company products are exported, so they have less control in domesticmarket.

OPURTUNITIES

1. To excel as a reliance company for global outsourcing requirements.

THREATS

1. Stiff competition in the market.


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OBSERVATIONS

1. CIIG produce the best relay in world market

2. The company providing direct employment

3. The company is running in a systematic and organized manner

4. The internal communication of the company is doing well

5. Majority employees of CIIG are women

6. The employees are satisfied with the working conditions and working hours of

the firm

SUGGESTIONS

1. The company should take necessary steps to expand the business

2. The marketing department can use more board displays for the promotion of the

company

3. The company should give importance to some of the welfare measures like

educational allowance and medical facilities


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CHAPTER VI


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CONCLUSION

CII Guardian International Ltd has provide employment to 400 people with an

annual turnover of 3,68,60,909 rupees. For about two decades CIIG has been in this

field. It has a manufacturing unit at Thodupuzha, around 200 people are working there.

Manufacturing facilities are spread over 35,000 square feet with environmentally

controlled assembly area.

The company is ISO 9001-2008 certified, for the manufacturing of

electromechanical relays. Several products are approved by ministry of defense and

centre for development of telemetric ( C- DOT). Guardian is the largest supplier of

telecom relays in India and well respected throughout automotive test equipments, power

electro mats, industrial control, house hold appliance and other industries.

CIIG has a joint venture with TYCO Electronics. 90% of products are expected

to TYCO. Only 10% of products are marketed in the Indian market. TYCO is a world

leader in high performance relays. Over past five years TYCO electronics has kept pace

rapidly growing to become the world largest passive components manufacturer. Based

on the internet technology leadership of AMP products, TYCO electronics has added a

full employment leading component branch including RAYCHEM, ELCON, P&A, M /

Acorn.


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APPENDICES


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CONTACT WITH

CII Guardian International Ltd.

PRODUCTION FACILITY

16- B, Cochin Special Economic Zone

Kakkanad, Cochin- 682 030

Ph: 91-484 423306, 423612Email : [email protected]

REGISTERED OFFICE

149, Girinagar, Kadavanthra, Cochin- 682 026

Ph: 914842316606 / 2317031 / 2317040

Fax: 91484- 2317032

Emil : [email protected]
mailto:[email protected]:[email protected]:[email protected]:[email protected]


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BIBLIOGRAPHY


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Documents

CII Guardian Organization Study