CHAPTER 1

INTRODUCTION

a) Introduction about the study:

Organizational study is the art of getting a practical knowledge of the practices done

in an organization. Nowadays practical studies are given more importance than theoretical

study. Organizational study helps a student to know how things are handled in an

organization. This will help a person to gather more practical knowledge in the field of

business. This covers almost whole of the organization’s departments. Each and every section

of the organization is covered collecting the maximum information that can be collected. This

study was for a period about 45 days.

Organization study is an exercise for the students who are undergoing M.B.A

program. It provides the student with the first hand idea on the practical working of the

organization. The students get an environment where he/she can actualize the knowledge he

has acquired in his curriculum. The exercise is an opportunity for the student to understand

the organizational structure, the major departments, flow of information and various other

functions in an organization.

An organization study is an excellent way to determine if the industry and the

profession is the best career option to pursue. Interns not only gain practical work experience

in a field that they intend to pursue but also build experience in international platforms. It

helps individual to combine theory with practical work experience.

Organizational study helps develop professional work habits; provides an

understanding of corporate cultures, gives an opportunity to analyze international business

settings, offers Platforms to compare differences in work styles.

It is on agreement between us and a company or organization for a fixed period of

time such as a semester or quarter .Agree to work for them and they agree to mentor and

teach us internships can offer valuable insight into practical field or career.

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The institutional training programs is to gain knowledge of various management

activities and strategies involved in the day-to-day activities and strategies involved in the

organization. It is the bridge between campuses to corporate is the need these days. It enables

us to be future corporate is the journey from being a person to professional.

We get corporate trainers offers what comes directly from corporate. It also easy to

develops our communication skills to convey well & personally offering impact in existence.

These programs are helping us to know the industry requirements. Starting from interview

preparation and proving our self to be productive with personality for the organizations from

day one. This practical situation will help use more than theories which we studies. It will

help use to develop our skills through the practical experience. These activities help at the

time of its entry into organizations until we leave the organizations.

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b) Industry profile :

World latex industry

Asia, dominates the world latex industry producing over 90% of the world output.

However, latex concentrate has been in the grip of price volatility for the most part of time

due to erratic supply, with prices currently ruling high at around US$ 2.2 in the producing

countries.

World supply of latex concentrate has been estimated at around one million tonnes a

year in dry rubber content terms. This comes to about 13% of the global supply of natural

rubber. Of the world output of latex concentrate, over 90% comes from Asia and the rest

from the African and Latin American countries. Centrifuged latex of 60% rubber content is

the largest variety produced in the world. This level of rubber content is optimum for making

many products through dipping, moulding and extrusion. Consequently, latex concentrate of

60% dry rubber content has remained the preferred material of the latex goods manufacturers.

Asia’s prominence

Asia is now the centre-stage of world latex industry. Countries of Thailand, Indonesia,

Malaysia, India and China are rich sources of NR latex and the products made out of it.

Annual output of latex concentrate is substantial, but its global requirement is more

pronounced. Latex products have become part of civilized life, as they offer living comfort,

healthcare and cozy toys for children. These are made in almost all developed and developing

countries. Being a much sought after raw material, latex concentrate has been in the grip of

price volatility for the most part of the time.

Low supply, high price

The price of latex concentrate has been ruling above US$ 2 a kg in the markets of

major producing countries like Thailand and Malaysia for over the past six months. It is quite

remunerative for the producers and processors, but the products manufacturers find it too

good to make finished products at fair price. Even at US$ 1.8 a kg early in January 2010, it

was pricey. Since then the price has moved up and ruled around $ 2.2 in the producing

countries. The fluctuation is obviously the result of inadequate supply. High demand for dry

rubber grades limits the availability of field latex for processing into concentrate. The price

of latex has been going up and down from time to time in tune with the surge and fall in

supply.

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When the global economy is slowly recovering from the slump, there has been a

general rise in demand for goods and services. The economic downfall of 2008 and the slow

recovery thereafter have made a number of rubber-based products to turn dear, especially in

the healthcare sector. In the midst of such robust demand, outbreak and advancement of the

pandemic Influenza-A (H1N1) in many parts of the world have pushed up the demand further

for products like latex gloves. Global consumption of gloves has been estimated to be at

around 140 billion pieces a year. According to a preliminary estimate, this may grow by 10%

over the next five years. Consequently, demand for latex would rise further.

The position of major producers Thailand, Malaysia and India is briefly examined

here.

Thailand, the topper

Thailand was the world topper in production of latex concentrate in 2009 with

703,817 tonnes in dry rubber content terms, accounting for about 70% of the world output. Of

this, 100,262 tonnes was consumed by the domestic industry and as much as 595,550 tonnes

was exported. Almost 75% of the latex concentrate reaching the world market was from

Thailand.

Many of the major latex consuming companies in Thailand are multi-product

producers. Examples are Sri Trang Agro-Industry Public Company, Thai Rubber Latex

Corporation, Thai Hua (Public) Ltd. Co. and Von Bundit Co.Ltd. They figure among the

leading centrifuged latex producers in Thailand with diversified activities with production of

dipped goods and other latex-based products. As crop from their plantations is not enough for

captive consumption, field latex is procured from other plantations, traders and rubber

producers co-operatives to feed the latex processing units. Such companies make more gains

from the overall activities.

Malaysia, a major importer

Malaysia produced 110,913 tonnes of centrifuged latex in 2009 out of the total

rubber output of 857,020 tonnes. As domestic production of latex concentrate is quite

insufficient to feed the industrial units, a large quantum is imported. Production of latex

goods is an important industrial activity in the country. There are over 160 units in the latex

products manufacturing sector making medical, household and industrial gloves, catheters,

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latex thread, balloons, finger stalls and foam products. They have fairly large scale of

operation.

Malaysia has been facing significant decline in natural rubber production from 1990.

However, the country wants to maintain its position as a world supplier of rubber and rubber

products. Large quantum of dry rubber and latex concentrate is imported into the country, for

domestic consumption and for export. In 2009, as much as 399,357 tonnes of dry rubber and

402,616 tonnes of latex concentrate were imported. With 110,913 tonnes of domestic

production, the latex concentrate availability rose to 513,529 tonnes.

Two multinational synthetic latex producers, Synthomer of the UK and

PolymerLatex of Europe have set up production plants in Malaysia. Together, they produce

230,000 tonnes of nitrile latex a year. In addition to meeting the Malaysian demand, the rest

is supplied to other countries in the Asian region.

India, significant player

Latex centrifuging is an important segment of the raw rubber industry in India.

Dipped goods, adhesives, carpet backing and the foam mattress segments raise good demand

for centrifuged latex. India is currently the third largest processor of centrifuged latex in Asia.

Import of latex does not normally take place in India as the import duty remains

high at 70%. Nevertheless, there is an avenue to import latex without duty. Products

manufacturing units in the Export Processing Zones can import raw material without duty.

Dipped goods producers in the Zone imported around 4,000 tonnes of latex concentrate in

2009 taking advantage of the duty exemption facility. Generally, units in the Export

Processing Zones import latex only when the domestic price exceeds the world price by a

significant margin.

Latex centrifuging

There are 73 latex centrifuging factories in India. A handful of them function in the

public and co-operative sectors. Rest of the units remains in the private sector. Capacity

utilisation of the centrifuging plants in almost all the units is around 50%. This is mainly

owing to the non-availability of enough field latex for processing. Over 85% of the country’s

rubber crop is processed into sheet rubber. Though capacity utilisation is low, latex

processing units are able to make profitable operation aided by the prevailing very good

price, in excess of US$ 2 a kg.

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A good number of these units obtain field latex from own rubber plantations. But the

captive supply is quite insufficient for economic operation of the processing factory. Hence

they source preserved field latex from rubber traders, Rubber Producers Societies and from

plantations of reasonably good quantity of latex production. There are also commercial latex

processors who do not own rubber plantations. They utilise commercially available field latex

– mainly from planters who have sizable quantum on offer and from Rubber Producers’

Societies. Over 500 Rubber Producers’ Societies out of the total of 2,277 collect latex from

the member small growers and preserve it for sale to the latex centrifuging units. Each

Producer’s Society has membership of 50 small growers and the society is able to gather a

sizable quantum every week for offer to the processors.

Better price

Several small growers find it advantageous to sell the crop as field latex since the

price obtained is good enough, equal to the price of RSS 5 grade sheet rubber. Sometimes

they get a better price, when latex processors offer a premium to attract enough supply.

Selling the crop as field latex has many advantages. It reduces saves the on coagulation,

washing and sheeting the coagulum and drying the sheets in the smoke house, which takes a

minimum of four days. Transportation of the crop is also not involved as the buyers collect

field latex from the plantation premises immediately after tapping.

There are also 25 creamed latex processors in the country. Creamed latex is mainly

used in making latex foam and latex thread. The creaming units also function profitably as

the price obtained for creamed latex is remunerative. Latex concentrate finds ready market in

India. Its major user is the foam products sector. There are 154 units producing latex foam

and 75 producing coir foam.

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c) Company profile :

KURIAN ABRAHAM LIMITED

(Latex Unit,Thucklay)

Kurian Abraham group of companies, founded 5 decades back,is the

pioneers and undisputed leaders in the rubber processing industry in India.The foresight,

vision and quest for quality propelled the group to establish itself as the single largest

processors of centrifuged latex and other latex based products for domestic and global

marketing.

The group grow rubber trees, tap ,preserve and process the rubber latex for

consumption in the dipped goods industry.Concentrated Natural Rubber Latex,crumb

rubber ,crepe rubber,examination/surgical gloves are the range of products manufactured and

marketed by the group.

The Concentrated Natural Rubber Latex supplied by Kurian Abraham

Limited ,Latex Unit is used in industries manufacturing inspection /surgical

gloves ,condems,ballons,foams and rubber bands.The gloves,condoms and foam industries

are the major customers of Kurian Abraham Limited,Latex Unit.(KAT)

The KAT unit was founded in 1973 with two centrifuge machines with an

average production of 6 tons per day.Over the last 38 years the unit has undergone

infrastructure expansions and technological up-gradations resulting in today’s production

capacities of 100 tons per day.

The production of CNRL involves collection of field latex from

estates,preservation at the collection points ,transportation to the factory,selection of

AFL(Ammonia Field Latex)lots for centrifuging,filtering in tanks,desludging,centrifuging,

chemical addition ,standardization and packing including marketing.

The important characteristics that contribute to the quality of CNRL are

DRC(Dry Rubber Content),VFA(Volatile Fatty Acid)No.,MST(Mechanical Stability

Time),KOH No and viscosity.On the basis of these characteristic, the CNRL produced and

marketed by KAT are the following grades:

CNRL grade standard

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CNRL grade super

CNRL grade special

CNRL grade X

CNRL grade 52% DRC

Classified 35% DRC

CNRL grade LATZ

A part of the centrifuging process is subcontracted to an external facility

owned by the Kurian Abraham group.The desludged latex is sent from KAT to the unit that

centrifuges,packs and provides packed CNRL back to KAT for taking into main stock of

finished products.

The finished product CNRL is packed in reconditioned MS drums ,inside

coated with bituminous paint and exterior painted with enamels.The standard quantity in a

drum is 205 litres net.The drum is sealed using tamper proof bung caps.

The standard grade CNRL packed in KAT is under product certification

license of Bureau of Indian Standards since 1992.The ISI marking process helped to

strengthen the quality control activities of KAT and from this base level of quality

management , the organization came a long way in improving the processes and process

controls and thus gaining appreciable recognition as the best reliable quality latex supplier in

India.

d) Product profile

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The late Mr. Kurian Abraham started Kurian Abraham Private Limited as a

proprietary concern in the year 1955. The firm was engaged in marketing latex. In 1958 a

factory was set up for processing latex. Today KAT is one the largest processors of

centrifuged latex in India with an output capacity of 100 metric tones per day.

Products

Latex

Pre - vulcanized letex

Skim crepe/ block

Latex

KAT's double centrifuged latex and specialty latex grades meet the exacting

requirements of the manufacturers of condoms, gloves, catheters, elastic threads, foams,

balloons, toys, rubberized coir etc. In fact it is the first ever Indian latex processor to receive

an ISO 9001:2000 accreditation as well as the ISO 14001: 2004 accreditation for

environmentally friendly stringent manufacturing practices. Until now, the general

impression was that it is was not possible to get ISO 14001 certification for rubber based

industries as the processing of natural rubber latex is bound to generate large quantity of

effluent. Nevertheless, KA-Latex's steely resolve and commitment for environmentally safe

manufacturing practices and procedures has nullified this myth and proven that even in the

rubber industry ISO: 14001 accreditation is very much feasible.

The company's latex, sold under the KA Latex brand not only has a significant share

in the Indian market but is also exported to countries across the world such as the US,

Europe, South America,Turkey and Sri Lanka.

Pre - Vulcanized Latex

An exciting development on the processing horizon is the introduction of pre

vulcanized (PV) latex in India. KAT is first in the country to enter into a technical agreement

with the world major in PV latex - Revertex of Malaysia to offer world-renowned Revertex

and Revultex grades of PV lattices in India.

Their PV Lattices are distinguished by their long shelf storage life, online process life,

consistency and stability. They have end use applications in gloves, condoms, catheters, baby

teats, continuous sheeting, adhesives, carpet backing, cast articles including theatrical masks

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and toys. These lattices are specially formulated and tested to perform on modern high speed

manufacturing lines and custom built lines of individual manufactures, with minimum batch-

to-batch variations. They meet all the currently known and impending regulations on cyto-

toxins, carcinogens and proteins - giving the Indian rubber industry an altogether fresh

impetus.

Skim Crepe

Skim Crepe is produced from skim latex. Skim latex is produced as a byproduct

during the preparation of centrifuged latex concentrate. It has a dry rubber content of only 3

to 7%. However, it also has a very low dirt content. Coagulation of skim latex is done by

acid treatment. It is important that the ammonia content is kept as low as possible. The skim

coagulum is washed and milled. This produces sheets between 1.2 and 1.5 mm thick and 24

cm wide. The washing process removes from the coagulum considerable amounts of the

serum constituents which can cause rotting. The sheets are dried in drying rooms for 2.5 to 4

days at 37°C . The sheets are packed as bales and marketed as "skim crepe".

Skim Crepe Block

Skim Crepe Block is made from skim crepe sheets which is made into blocks and

palletised for shipment. These blocks will be properly dried in drying chambers at around 100

+degree centigrade. Properties will be similar to skim crepe except it is more convenient to

transport as well more dried than the skim crepe. The quality is almost at par with ISNR 20

except slightly high nitrogen content.

CHAPTER 2

a) Objectives of the study:

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To know the organizational framework .

To know how manufacturing process is carried by the company.

To know the functions of various departments.

To know the authorities and responsibilities of each personnel.

To know the working environment.

b) Scope of the study:

The study is being conducted at Kurian Abraham Pvt.Ltd(Latex Unit),Thuckalay.

And this study tell us an overall view of organization and functions carried out by different

departments like manufacturing, maintenance, human resource, accounting & administration,

etc.,.

c) Area of the study:

The study had been undertaken at Kurian Abraham Pvt.Ltd(Latex Unit),Thuckalay

and the respondents were the assistant factory manager and the employees from different

departments like accounts and administration,human resource, testing and laboratory,etc,.

d) Limitations of the study:

1. The primary data collected from limited respondents.

2. Lack of time is a major limiting factor.

WORK ENVIRONMENT

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Work environment requirements are initially elicited , discussed and finally

determined by a group of top management members,having regard to the need to ensure

positive influence on motivation,performance and satisfaction of employees.

Human and physical factors of environment determined and managed are:

Suggestion system

Personnel safety

Use of protective equipment

Facilities to wash,change,eat and rest

Hygiene and cleanliness levels

Noise and vibration levels

Light and airflow needs

Pollution level in the work areas

CHAPTER -3

DEPARTMENT PROFILE12

A) HUMAN RESOURCES DEPARTMENT

DEPARTMENT CHART :

Responsibilities of HR manager:

Determining competency needs of personnel with the approval of director.

Recruitment of personnel.

HR deployment & induction.

Human aspects of work.

Education & training of personnel.

Maintaining personnel data.

Annual performance appraisal.

Continual improvement of HR process.

Authorities of HR manager:

Prepare education and training plans.

Organize training events.

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DIRECTOR

HR MANAGER

ASSISTANT

Update training records & personnel data sheet.

Review annual performance appraisals & follow up actions.

Labour welfare facilities:

The labour welfare facilities and fringe benefits provided by KAT to its labours are

quite appreciable such as,

Two sets of free stitched uniform every year

Washing allowance

Provident fund

Medical allowance

Tea allowance for labours

Bonus

Gratuity

Fringe benefits:

Medical allowances.

Loans without interest for motor vehicles

Children education allowance

Family tour.

Working time:

In KAT,the working time varies workers to workers according to the nature of work.It

can be listed as follows:

Machine workers:

i. A shift - 6:00am to 2;00pm(40 workers)

ii. B shift - 2:00pm to 10:00pm(30 workers)

iii. C shift - 10:00pm to 6:00am(20 workers)

Intervals - 10:00am to 10:30am ; 6:00pm to 6:30

Office staff:

9.00am to 5.00pm

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Lab:

i. A shift- 6.00am to 2.00pm

ii. B shift- 1.00pm to 9.00pm

Others:

i. A shift = 6:00am to 2:30 pm

ii. B shift = 1:30 pm to 10:00pm

Total number of employees:

KAT employed totally hundred permanent workers as 85 male workers and 15

female workers .It also employs temporary workers.There, 24 contract workers are working

currently.

Leave facilities:

KAT provides leave facilities to its workers concerning their personal life.They are

given as follows:

Factory workers:

o Earn leave - 20 days

o Casual leave - 5 days

Office Staff:

o Casual leave - 7 days

o Medical leave - 8 days

Managers:

o Leave -25 days

Female staff:

o Maternity leave - 84 days

Payroll process:

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Office staff are paid salary on the first working day of every month.Labours are paid

wages as monthly payment on the date of 5.If it is a holiday ,it will be paid on the next

working day.All the payments are made only through bank.The payment details are as

follows:

Staff:

Basic pay

DA 12%

Medical allowance 4%

Provident fund 12%

Labours:

Basic pay

DA 12%

Medical allowance 4.5%

Provident fund 12%

B) FINANCE DEPARTMENT

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DIRECTOR

GENERAL MANAGER

ACCOUNTS MANAGER

ACCOUNTS ASSISTANT

DEPARTMENT CHART:

Responsibilities of finance manager:

Preparation of budget.

Cash flow management.

Banking.

Expenditure control.

Preparing finance & account’s related reports.

Authorities of finance manager:

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Reviewing & processing financial sanctions.

Release of payments.

Assets and liabilities:

KAT acquired a very good position in the latex industry. It makes

around 250 to 300 crores of turnover every year .And earns net profit of 6 crores.The

following figure shows the different types of assets and liabilities.

Types of assets:

Fixed assets

* Land (Non depreciable)

* Plant & machinery

* Furniture & fixture

* Vehicles

Current assets

* Debtors

* Loans & advances

* Bank

* Cash

* Stock in trade

Investments

Non tangible assets

* Goodwill

* Miscellaneous expenses

* Technology known

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Types of liabilities:

Share capital

Reserves & surplus

Current liabilities

Loans & advances

Profit & loss

Investment:

KAT invests its surplus in mutual funds / money market.The investments are made as

temporarily only.Mostly it invests for the period of 6 months.

Sources of funds:

Some times funds are generated through the company’s profit.Mainly they use

shareholders’funds/ directors’ funds / sales funds.

Tax payment:

KAT pays all types of taxes accurately on time such as excise duty,advance

tax,income tax,service tax,sales tax,purchase tax,etc.,.They paid taxes for the year 2010 –

2011 and 2011-2012 as 33.22% and 32.5% respectively.

Working capital management:

As latex is a seasonal product ,KAT needs working capital during the months of

August to February.But,from March to July ,working capital is not needed.

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C) WORKS/FACTORY DEPARTMENT

DEPARTMENT CHART:

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DIRECTOR

EDP IN CHARG

E

ACCOUNTS &ADMINIST-

RATION

CHIEF CHEMIST

ASST MANAGER (COMMER-

CIAL)

PRODUCT-ION CHEMIST

STORE IN CHARGE

FACTORY MANAGER

MAINTE-NANCE

PURCHASE ASSISTANT

BRANCH IN CHARGE

DESPATCH ASSISTANT

SUPERVISOR

AUTHORITIES AND RESPONSIBILITES OF FACTORY

MANAGER

Authorities:

1. Approval of purchase order.

2. Approval of capital purchase to amount of Rs.10000 or below.

3. Approval of cash purchases upto Rs.5000.

4. Approval of level ‘c’ documents.

5. Stop production.

6. Changes to production plan.

7. Extend working hours.

8. Approve overtime.

9. Interaction with statutory authorities and other external bodies.

10. Review and disposition of non-conforming products.

11. Resolving customer complaints.

12. Approving cash requirements.

Responsibilities:

1. Overall functioning of factory.

2. Day to day administration of factory.

3. Identifying training needs for those reporting to him.

4. Supervision of activities of assistant manager-commercial,chief chemist,production

chemist,etc.,.

5. Identification of monitoring and measuring devices in co-ordination with chief

chemist.

6. Identification of resources requirement for the factory.

7. Man power planning and deployment.

8. Providing technical clarification in co-ordination with chief chemist.

9. Ensuring achievement of planned production.

10. Ensuring complaint to statutory and regulatory requirements

11. Ensuring safety of personnel and working conditions.

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12. Ensuring upkeep of factory premises.

13. Human resource management pertaining to factory.

14. On job training to department heads.

15. Disbursement of salaries and wages.

16. Providing information to management pertaining to factory operations.

17. Continual improvement.

Activities:

It includes purchase planning, production planning, statutory compliance, review

and analysis of data(factory level), control of sub contracted centrifuging, etc,.

The works department consists of seven sub departments such as,

a) Production

b) Information Technology

c) Maintenance

d) Stores

e) Commercial

f) Testing & Laboratory

g) Sales & Planning

The department charts and the authorities and responsibilities of each personnel for

each department are as follows:

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a) Production Department

Department chart:

Responsibilities of Production chemist:

To control the production process.

Timely execution of production plan.

Ensuring cleanliness inside the factory.

Referring to work instructions and specifications.

Identifying training needs for those reporting to him.

Ensuring the fitness of production equipment.

Authorities of production chemist:

Extend the production time to complete the production.

Stop further process in case of production long sheet or daily report.

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PRODUCTION CHEMIST

PRODUCTION SUPERVISOR

WORKMEN

FACTORY MANAGER

Clear the CNRL for packing.

Approval of indents.

Determining the quality of chemical and other materials.

Responsibilities of production supervisor:

Timely execution of direction from the director.

Adhering to production plan.

Housekeeping.

Packing the correct batch.

Addition of chemicals.

Selection, setup, dilution and additions.

Authorities of production supervisor:

Assigning the personnel for work.

Clear the product for next process.

Quality policy:

Commit to consistently ensure customer satisfaction by exceeding quality levels of known

expectations; employing continually improved processes; and strictly adhering to agreed

delivery schedules.

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RECEPTION OF FIELD LATEX AT VARIOUS

COLLECTION CENTERS

DESLUDGING

PUMPING TO RECEIVING TANK

CENTRIFUGING

QUALITY CONTROL TESTING

CONCENTRATED LATEX IN STORAGE TANK

SKIM LATEX

PRESERVATIVES

ADDITION OF DAHP(Dry Ammonia Hydrogen Phosphate)

PRODUCTION PROCESS :

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Aspects of Production Planning

KAT considers the followig aspects for the planning of production.

Market demands details received from Sales & Planning manager.

Availability of raw materials.

Capacity utilization.

Current customer order.

Orders for special products.

Ammendments to production plan may arise due to

* Changes in customer requirements.

* Priorities in order execution

* Exigencies at KAT.

Safety measures:

The equipments provided by KAT to its workers to ensure their safety to prevent

accidents are Gloves, shoes, chappals, acid-gas masks, safety belts, hip ropes, protective

cloth, face shields and helmets.

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b) Administration & Accounts Department

Department chart:

Responsibilities of A & A officer:

Consolidation of stock and statutory statements.

Maintenance of time card.

Indenting for cash requirement.

Disbursement of salaries & wages.

Assuring statutory remittances.

Compilation of leave statements.

Authorities of A & A officer:

Procuring N forms, cess permit and delivery note.

Issue of stock and cash statements.

Responsibilities of assistant:

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FACTORY MANAGER

A/C’S & ADMINISTRATIVE

OFFICER

ASSISTANT

Maintaining statutory registers.

Consolidation and dispatch of empty drum statement.

Despatch of all general statements.

c) Information & Technology

Department chart:

Responsibilities of EDP-in charge:

Preparation & consolidation of statements.

Maintenance of records.

Proper control of electronic documents.

Storage and protection of CDs and floppies.

Scanning of virus as per schedule.

Taking the hard copies as per requirement.

Responsibilities of data entry operator:

Correct feeding of data.

Taking the hard copies as per requirement.

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FACTORY MANAGER

EDP-INCHARGE

DATA ENTRY OPERATOR

d) Maintenance Department

Department chart:

Responsibilities of junior supervisor:

Execution of preventive maintenance.

Check up of generator, DM plant and water softener.

Checking the quality of items purchased.

Authorities of junior supervisor:

Approve the quality of item purchased.

Recommand for repairs/replacements when needed.

Activities:

It includes maintenance of buildings & work areas, utilities , centrifuges and

stirrers, open drum storage yards, sludge pits, open drains, latex storage tanks,computers,etc.,

and AMC maintenance.

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FACTORY MANAGER

JR.SUPERVISOR-MAINTENANCE

WORKMEN

e) Stores Department

Department chart:

Responsibilities of senior supervisor:

Identifying storage areas.

House keeping.

Insurance of products.

Reverification of stored products.

Maintenance of stocks.

Handling storage resources.

Identifying training needs for those report to him.

Reservation of product.

Maintaining records.

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FACTORY MANAGER

SENIOR SUPERVISOR

SUPERVISOR

WORKMEN

Authorities of senior supervisor:

Approval of gate pass.

Issue of products.

Initiation of purchase requisition as per Re Order Level.

Dispatch products.

SUPERVISOR –DESPATCH:

Responsibilities :

Despatch of products as instructed by commercial assistant.

Maintaining the stock CNRL.

Identifying the storage area for CNRL.

Protection of CNRL under storage.

Co-ordination with commercial assistant.

Authority:

Load the products.

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f) Commercial Department

Department chart:

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FACTORY MANAGER

ASST.MANAGER(COMMERCIAL)

DESPATCH ASST.PURCHASE ASST. BRANCH IN-CHARGE

ASSISTANT FIELD SUPERVISORASSISTANT

ASST,FIELD SUPERVISOR

Responsibilities of assistant manager:

Budgeting the purchase of latex.

Transport arrangement of despatches.

Daily arrangement of schedules for lifting of AFL and general items.

Implement corrective / preventive action.

Identifying training needs to those reporting to him.

Conducting supplier evaluation and identification of new supplier.

Authorities of assistant manager:

Release of purchase budget of latex.

Negotiating the general purchase.

Approving the transport quotations.

Release a purchase order.

Rate of supplier performance.

Commercial department itself includes two sub - departments.They are as

follows:

i. Purchase department

ii. Despatch department

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i. Purchase department:

Activities:

Provision of resources to the latex supplier through branches.

Demonstration of latex preservation to the approved suppliers through

branches.

Co-ordinating with branch for latex procurement.

Check list for latex load dispatch from branch.

Settlement of payment to the latex suppliers.

Purchase of drums.

Verification of purchasing data and release of purchase order.

Monitoring of purchase order.

Evaluation and approval of suppliers.

Performance monitoring of suppliers.

Reorder level and minimum stock level to ensure materials are available.

Purchase planning.

Important suppliers:

The suppliers of KAT are from different states.Mainly they are from Kerala.KAT

purchases its raw materials from about 250 suppliers.The important among them are:

Velimali estate.

Kavuvalla agencies.

Kundarathala agencies.

Arun agencies.

Arasu agencies.

Woodhope estate.

34

ii. Despatch department:

Activities:

Batch and drum selection for despatch.

Verification of trucks documents & driver license.

Loading and preparation of gate pass.

Planning and monitoring of despatches.

35

FACTORY MANAGER

LAB CHEMIST

CHEMIST

ASSISTANT CHEMIST

LAB ASSISTANT

LAB BOY

CHIEF CHEMIST

g) Testing And Laboratory

Department chart:

It structured same as the R & D department.

36

Responsibilities of chemist:

Preparation of solution used for testing.

Checking of AFL received.

Reporting of testing done.

Maintenance of statutory registers and records.

Authorities of chemist:

Assuring the use of correct test methods and calibrated measuring devices.

Assuring proper testing & timely reporting.

Monitoring the DRC of sources sample and lot sample and reporting of various.

Recording and reporting of test results.

Activities:

Testing color of CNRL.

Testing odour.

Testing total solid content.

Testing dry rubber content.

Testing ammonia,VFA methods, potassium hydroxide, magnesium content, etc.

Preparation of standard solutions.

37

D) SALES & PLANNING DEPARTMENT

DEPARTMENT CHART:

Responsibilities of sales manager:

Generate customers, maintain customer relationship.

Submit offers.

Conduct negotiation.

Accept orders, issue confirmation and work order to factory.

Realization of payment of bills.

Fixing price to the products.

Issue daily dispatch schedule and sole documents.

Correspondence with customers.

Responsibilities of sales assistant:

Preparation of daily dispatch schedule.

Maintaining sales order register.

38

DIRECTOR

SALES MANAGER

SALES ASSISTANT

Maintaining of customer related files, bills etc.

Checking of bills.

Target:

Though latex is a seasonal product,it is a demand oriented product. The target to

produce latex for one year is 1lakh field latex.

Fixing annual sales target:

The manager has to plan and fix the annual sales target at the month of March every

year. The manager has to consider the following aspects while planning & fixing annual

targets.

Actual sales & production of previous year.

Market demand.

Competing market contribution.

Resection rate.

Seasonal crop variation.

Customer Focus:

A customer focus is inherent to the business processes of the organization.The

present requirements of customers are determined and met. The quality of

products ,services,communications and relations,to the extent practicable,is also maintained

at a level that exceeds the customer expectations.

The emerging market trends including the possible future requirements that are

likely to be specified by customers and statutory/regulatory agencies are monitored and

timely actions taken to position the organization with ability to meet such requirements in

future.

Perceptions of customers as to what extent their needs and expectations are

met,are monitored and measured.

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Methods of overcoming competitors:

KAT is overcoming its competitors by focussing on the following three

areas.

Better customer relationship.

Good customer service.

Quality of product.

No Advertisement:

As latex is a raw material for producing gloves, balloons, etc. there is no

advertisement.

Major customers:

KAT has about 150 customers from various districts,states and also from

nations. Kurian Abraham group itself acts as one of their major customers as it produces

gloves,condoms,rubberband,etc.,.

The other important customers are:

TTK LIG-America

HLL- Trivandrum.

Kurlon.

Suretx.

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E) ISO 9000 CELL

DEPARTMENT CHART:

Responsibilities of management representative:

Ensuring proper implementation & control of QMS.

Reporting the performance of QMS.

Ensuring promotion of awareness of customers requirement.

Monitor and ensure effectiveness of corrective action.

Reporting of audit results.

Authorities of management representative: Proper issue of QMS documents.

Issue of management review meeting agenda and minutes.

Issue of internal audit schedule.

Responsibilities of the assistant: Maintaining statutory registers.

Consolidation and despatch of empty drum statements.

Despatch of all general statements.Activities:

1) Analysing internal audit results.

41

DIRECTOR

MANAGEMENT REPRESENTATIVE

ASSISTANT

2) Organizing management reviews and follow-up actions.

F) R & D AND QUALITY ASSURANCE DEPARTMENT

DEPARTMENT CHART:

42

FACTORY MANAGER

LABORATORY CHEMIST

CHEMIST

ASST.CHEMIST

LAB ASSISTANT

LAB BOY

CHIEF CHEMIST

Quality objectives of chief chemist:

Determining product requirements including regulatory requirements.

Planned approach to measuring quality including selecting measuring devices.

Use of correct specifications and methods for measuring and monitoring the quality.

Ensuring the release of conforming products.

Quality Objectives of chemist:

Monitoring statutory registers and records.

Ensuring good laboratory practices.

Ensuring use of correct test method and calibrated measuring devices.

Correctness of product characteristic verification.

Accuracy of recording data.

Quality objectives of assistant chemist:

Preventing mistakes in testing.

Right handling of lab accessories.

Ensuring the correctness of test result.

Pre-Vulcanized Latex Technology:

KAT gives greater importance to R & D department.Due to this it has introduced a new

technology to produce pre-vulcanized latex . Pre-vulcanized latex is unperishable one.So that

,the customers can store it for long duration and there is no need for customers to mix

chemicals for their further production.

No Ammonia Latex:

KAT has taken a conscious decision to reduce the amount of pollutants.No ammonia latex is

in research which is meant for non-pollutant latex.Within a short period it will come to

market and will make the environment healthy.

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CHAPTER - 4

SWOT ANALYSIS:

STRENGTHS :

KAT is a large factory.

ISO 9001-14001 certified.It is the only factory which has been certified for both the

quality and no/less polluting environment.

It has a great scope for export.

It also has a good infrastructure.

KAT has a strong financial position.

No problem if demand is low that it has Customers from its own group of Kurian

Abraham Pvt.Ltd.

WEAKNESS :

High cost of production.

Labour shortage which results high labour cost.

OPPORTUNITIES :

Pre-vulcanized latex technology.

Joint venture with Malaysia.

Infrastructure development.

Foreign customers.

It has an opportunity of labours from North India.

THREATS:

Fluctuation in prices.

Raising cost of raw materials.

Low power generation by government as the industry heavily relies energy resources

like electricity.

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CHAPTER - 5

FINDINGS, SUGGESTIONS AND CONCLUSIONS

a) Findings :

Kurian Abraham Pvt.Ltd,Latex Unit , Thuckalay is on a steady growth path.It is the

oldest and the most trusted latex unit of our country.

Its in-house R & D facility for advanced product design,development and testing ,

plays a critical role in bringing about a high level of customer satisfaction and reliability of

products.Their fully equipped labs for complete testing of products have enabled to develop

products in compliance with Indian and international standard specifications.

KAT’s in-house research , design & development competencies, world – class

manufacturing facilities , continuous training, skilled labour and professional management

give them edge over competition.

b) Suggestion :

Though KAT provides good welfare facilities to its labours and its

employees, the total number of permanent employees / workers are comparatively low. So, it

would be better to get feedback from the employees/workers to find out their actual

expectations.If there is any default from the management,it can be analysed and decisions can

be taken to rectify them.This will lead to sustain the efficient employees / workers

permanently with them.

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C) Conclusion :

The organizational study on Kurian Abraham Pvt.Ltd,Latex unit,Thucklay,

has really enabled me to understand the organizational structure of the corporate world to an

extent,the ways and means how it functions.KAT is one of the leading industries in the

manufacturing of latex.

It was found during the study that is indeed a healthy organization with a lot

of well unique functions, the industry basically being an latex industry has a large investment

and a good no.of people working in it,there is a well established organizational structure with

the top level management,the middle level management and the bottom level management.

KAT has introduced good labour welfare facilities which care the needs of

workers and consequently increases the love and affiliation of the workers toward the

organization.

KAT is the only manufacturing industry which owned the pre-vulganized

latex technology having joint venture with Malaysia.

KAT has customers not only from India but also from foreign countries like

China ,USA,etc.,.It also has a good infrastructure and it is strong in its financial position.It is

the largest processor of centrifuging latex in India.Thus,KAT has earned a good name in the

society.

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APPENDIX

47

48

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RG

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ISA

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N S

TR

UC

TU

RE

Fina

nce

Wor

ks /

Fact

ory

ISO

900

0 C

ell

Sale

s And

Pl

anni

ngR

&D

And

Q

ualit

y A

ssur

ance

Adm

inis

tratio

n &

Acc

ount

sM

aint

enan

ce

Com

mer

cial

Prod

uctio

n

Stor

esTe

stin

g La

bora

tory

Purc

hase

Des

patc

h

DIR

ECTO

R

BIBILIOGRAPHY

COMPANY DOCUMENTS

WWW.OOPPOOTTIL.COM

WWW.RUBBER.COM

WWW.ALLRUBBER.COM.AU

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ISA

TIO

N S

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UC

TU

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Adm

inis

tratio

n &

Acc

ount

s