Rahul Singh

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CHAPTER - I BUSINESS EXPOSURE

I.

INRODUCTION

I am pleased to present this Industrial Visit report for B.B.A. (SY) Semester IV according to the syllabus prescribed by the University of Pune. It covers important topic and information concepts regarding the industries visited. This report covers various methodologies of study, profiles of industries, their history, vision, mission statement, future goals and objectives, their product range, manufacturing process of different products, SWOT (strength, weakness, opportunity, and threat ) analysis, observation and behaviour. Recommendations and suggestions are also mentioned in this report and some conclusions are also drawn out

I.1

ABOUT BUSINESS EXPOSURE:-

Industrial exposure is the subject introduced by the University of Pune in syllabus of B.B.A-II Semester IV for the students, so that they will get more practical and realistic knowledge about the industries. It provides an opportunity to the students to explore the industrial world. It helps introduce to the students to the general nature and structure of source selected industries and business organization. Industrial exposure will help the students to enhance their practical knowledge about the working of industries. It also helps to satisfy the curiosity among the students which they

have regarding the industry. In this competitive world students need to understand the, practical concepts, the day to day working, decision making process, various productions and operations carried out by industries, planning and control, how to anticipate future in respect of Market, Technology, Human Resource, Finance and do prediction about future market position as they are the future decision makers. Industrial exposure thus helps the students to understand the core concepts regarding the working of industry.

I.2

IMPORTANCE AND SCOPE OF BUSINESS EXPOSURE:-

Business Exposure is of vital importance in today ’s competitive business world as it helps the future rising generation by giving them insight to look forward and explores the outside world. Business exposure helps a lot to students as it provides them a new realistic and practical outlook, gives them an opportunity to understand, explore and study the business world outside. It has a large scope of practical knowledge rather than the theoretical knowledge; also many theoretical concepts are cleared and easily understood by business exposure. 1. It introduces the students to the general nature and structure of source selected industries and business organization. 2. It helps them to acquire the more practical and realistic knowledge about

the working of industries and carrying out various business activities. 3. It helps the students to understand the various different functions of the organization, industry, like how Planning is carried out, how control is observed in what way production is undertaken, how the orders are received, how the goods are dispatched, what is the marketing strategy, how funds are raised etc. 4. It helps in understanding different process regarding the production, working, working schedule. 5. It directly makes the students aware of the role of different people of different position in an organization, it tells what a manager’s job is, what is an supervisors job, what is labourers job, it makes them aware of the various duties and responsibilities regarding the work at different positions. 6. It brings awareness regarding the carrier opportunities among the students. They come to know what kind of job are there in different types of industries, what are the requirements and skills needed for different jobs and then start preparing for the same as they become carrier conscious. 7. Some industries require good health and hygiene, students are made aware of these requirements. While in some industries certain safety measures are required to be taken while working or performing certain tasks, students are made aware and conscious of these health and safety requirements. 8. It helps the students to understand the different ton activities, human force working, production, financial funds, etc. 9. It gives an opportunity to explore the industrial world and to understand.

I.1.3 OBJECTIVE OF BUSINESS EXPOSURE:-

 To explore the industry.  To understand the different function of business.  To understand different type of process.  To experience the chemistry at work.  To become aware of the role of the different people in an organization.  To become aware of carrier opportunities.  To recognize the need for health safety in the work place.  To understand different type of controlling techniques about the business.  To do short analysis of the industry.  To suggest the weakness of the industry.

I.1.4 LIMITATION OF THE STUDY: Only three days of industry visited.  Less time for inspection the industry area.  Less time for ask different question related to industry.  Less time for submitting the project.

Chapter-II

METHODOLOGY

II CONCEPT OF METHODOLOGY
 A body of methods, rules, and postulates employed by a discipline : a particular procedure or set of procedures.  The analysis of the principles or procedures of inquiry in a particular field.

II.1. Methodology can be:
 "The analysis of the principles of methods, rules, and postulates employed by a discipline".  "The systematic study of methods that are, can be, or have been applied within a discipline".  The study or description of methods  Method can be defined as a systematic and orderly procedure or process for attaining some objective.  Methodology doesn't describe specific methods; nevertheless it does specify several processes that need to be followed. These processes constitute a generic framework. They may be broken down in subprocesses, they may be combined, or their sequence may change. However any task exercise must carry out these processes in one form or another.  Methodology may be a description of process, or may be expanded to include a philosophically coherent collection of theories, concepts or ideas as they relate to a particular discipline or field of inquiry.  Methodology may refer to nothing more than a simple set of methods or

procedures, or it may refer to the rationale and the philosophical assumptions that underlie a particular study relative to the scientific method. For example, scholarly literature often includes a section on the methodology of the researchers.

II.2 PRIMARY DATA
Primary Data is the data that is not already available. The researcher collects is first-hand. II.2.1 TOOLS AND TECHNIQUE OF PRIMARY DATA  Questionnaires.  Interviews.  Focus Groups.  Observation.  Others.

II.2.2 Needs of specific groups / institutions / sub sectors

Primary Data Collection Methods:-

Observation
Ex: We observe various Industries focusing on Production management and Finance.

Focus group:Ex: Bring 6-20 people from various stakeholder groups together to discuss needs and problems of a new trade

Regulation. Personal interviews (one-on-one):1. For collection of in-depth information. 2. Telephone interviews/surveys. 3. self administered (mail or Internet) surveys.

II.3.1 Secondary data:-

Definition:
Secondary data is the data that have been already collected by and readily available from other sources. Such data are cheaper and more quickly obtainable than the primary data and also may be available when primary data cannot be obtained at all.

Class Boundaries may be different when units are same:Before 5 Years 2500-5000 5001-7500 7500-10000 After 5 Years 5000-6000 6001-7000 7001-10000

CONCEPT:Secondary Data is data or information that is already available. This data is collected by a person or organization other than the use of the data. Advantages of secondary data are that it is cheap and inexpensive. It is easily accessible. It is already available. It saves time and efforts. It is unobtrusive. It avoid data collection problems and it provides a basis for comparison. Secondary Data can be collected from various sources, which include, but are not limited to:

Books,

Magazines,

websites,

Already

published

reports,

TV,

Radio,

Newspapers, Films, Journals and publications, Research papers etc.

II.3.1.1 TOOLS AND TECHNIQUES
1) Internet search, using online resources to gather data for research purposes. This method is not usually very reliable and requires appropriate citation and critical analysis for findings. 2) Library search and indexing, this technique requires to go through written texts that have already done similar work and utilizing their researches for your dissertations. 3) Data collection organizations, for example Gallup and AC Nielsen conduct researches on a recurrent basis ranging in a wide array of topics. 4) News Papers and Magazines, journals.

Chapter-III

DATA ANALYSIS

CHAPTER-III DATA ANALYSIS

3.1 3.2 3.3 3.4

UNITED BREWERIES LTD BISLERI INTERNATIONAL PVT. LTD ION EXCHANGE INDIA LTD GOA SHIPYARD LTD

III.1 UB GROUP
III.1.1 INDUSTRIAL PROFILE
KINGFISHER PROFILE:
the beginnings of what is today The UB Group are rooted in the flagship company, United Breweries Limited, (UBL) also referred to as the Beer Division of the UB Group. Led by Mr. Kalyan Ganguly , President & Managing Director, it has around 48% market share in the country. Millennium Alcobev Pvt Ltd., (MABL), is the Joint Venture Company in which UB along with its subsidiary and Scottish & Newcastle of the UK have equal stake of 50%. United Breweries Limited, the flagship company of the UB Group, has an association with the brewing dating back over five decades, starting with 5 breweries in South India in 1915. From bullock cart-loaded barrels or 'hog heads' of frothing ale, the Beer business has gone on to become the undisputed 'king' in the Indian beer market. Its flagship brand 'Kingfisher', has achieved international recognition consistently, and has won many awards in International Beer Festivals. Kingfisher Premium Lager beer is currently available in 52 countries outside India and leads the way amongst Indian beers in the International market. It has been ranked amongst the top 10 fastest growing brands in the UK. The Beer brands manufactured and marketed by United Breweries Ltd. have always been recognized for their international quality. That's Beer at its best for the discerning consumer! A name synonymous with beer in India - Kingfisher stands for excitement, youth and camaraderie. The largest selling Beer in India, Kingfisher commands a market share of over 36% in the country with 1 out of every 3 bottles of beer sold in India being a Kingfisher brand. We are also available in 52 countries across

III.1.1.1 INFORMATION ABOUT UB GROUP
ABOUT KINGFISHER
INGREDIENT USED IN BEER Mainly ingredients used in the beer is Water, Malt, Lactic acid, Caramel, Hops, Sugar and yeastI

WATER:
Few beer drinkers appreciate that beer is nearly all water. Even the very strongest of brews contain around 90% water. Yet have you ever wondered why certain parts of the country should have become established as important centers of the brewing industry Why, for instance, should Burton-on-Trent be famed for it’s pale ales and bitters, where as Dublin and London are renowned for their mild ales and stouts? The reason, quite simply, is the quality of the water locally. In brewing, water greatly influences the final flavor of the product. Hard water is generally preferred for brewing light ale and bitter, but soft water is preferred for mild ale and stout. If you care to add chemicals to your brew, the water can be adjusted by adding Epsom salts (magnesium sulphate) to give hardness to the water or salt (sodium chloride) to soften the water and round the brews flavor. If you brew kit beers, the water quality is simply not worth fussing over, your domestic supply is good enough.

MALT:

Malt is the main ingredient that is used for making beer and of the 5 cereals(barley, wheat, oats, maize and rice) barley is mainly used because it produces the best malt and flavor. The most popular malted barley used in home beer making is pale malt. The quantity of malt used in a brew affects the fullness, flavor and alcohol level of the beer. A beer can be improved further by adding some cereal grains. Adjunct sreceom mended are:

ADJUNCTS BENEFITS
Crystal Malt Improves color and body Black Malt Promotes color and flavour Flaked Barley Adds extra flavor and body Rice Gives fuller and rounder texture

LACTIC ACID: CARAMEL:

It is used to maintain the ph value of the mash

Caramel is dark brown in color . Caramel is used in brewing as a flavor and/or color in agent. Caramelization is the removal of water from a sugar, proceeding to isomerization and polymerization of the sugars into various high weight compounds. Compounds such as dif ructose-anhydride may be created from the mono saccharine after water loss. Fragmentation reactions result in low molecular weight compounds which may be volatile and contribute to flavor. Polymerization reactions lead to larger molecular weight compounds which contribute to dark caramel color .For example, many mild’s and sweet stouts contain caramel for both flavor and color .Caramel may be used either in the kettle or in priming to make minor adjustments to the color of the beer, but the choice of malt grist and the grade of adjuncts added to the kettle will determine the fundamental color of the beer. .

HOPS:
Hops add bitterness to the beer and improve its keeping properties. Many varieties are available, but fuggles and goldings are the most popular for brewing beer, ale and stout and saaz and hallertau for lagers.

SUGAR:

Dextrose is also known as corn sugar and is available in the trade in the purified form as aspray dry or as a crystalline powder. Dextrose sugar is added directly to the brew kettle during boiling .Various grades of sucrose are used in the brewing industry. Few brewers today use raw sugar; most prefer the more consistent products of the sugar refiner. Granulated sugar, the normal end product of the refining process, may be added directly to the kettle, but usually is dissolved in a solution before being added. Malto-dextrin is the most complex fraction of the products of starch conversion. It is tasteless, gummy, and hard to dissolve. It is often said to add body (palate fullness) to beer, increase wort viscosity, and add smoothness to the palate of low-malt beers. However, it is easy to increase the dextrin content of grain beers by changing the mash schedule or using dextrin malt. Malt o-dextrin is of interest mainly as a supplement to extract brews. Invert sugar is a mixture of dextrose (also called glucose) and fructose syrup.

YEAST :
Beer yeast is available as granules in single packets or in pots. Yeast ferments rapidly converting the natural sugar (maltose) with any added household sugar (sucrose) to produce alcohol and carbon dioxide Top fermenting beer yeasts are the most common used today as they are used in all British type beers and most of the beers of Europe. There are a variety of ale yeasts available, each having a different characteristic and imparting extra flavor to your brew. These yeasts work best at a temperature of 18-24C (6575F).Bottom fermenting lager yeast gives a unique taste to lager. As lager yeast is bottom fermenting, all the activity is at the bottom of the bucket and the beer may look like it is not working. These yeasts can also work at a lower temperature than general yeasts.

III.1.1.2 HISTORY

The UB Group was founded by a Scottish gentleman Thomas Leishman in 1915. The company used to manufacture beer at that time and took its initial lessons in manufacturing beer from South Indian based British breweries. In August 1947, Vittal Mallya became the company's first Indian director. A year later he became the Chairman of the Group. United Breweries came into limelight by manufacturing bulk beer for the British troops, which was transported in huge barrels. In 1950s and 60s, the group expanded rapidly and made several acquisitions. McDowell was added as one of the Group subsidiaries. This helped UB Group to venture into wines and spirits business. Kingfisher, the Group's most visible and profitable brand, made its entry in the sixties. Thereafter, the Group moved into agro-based industries and medicines when it acquired Kissan Products and formed a long-term relationship with Hoechst AG of Germany to promote Aventis Pharma. After Vittal Mallya's death in 1983, his son Vijay Mallya assumed the mantle of the group. Vijay Mallya inducted professional management and consolidating the Group into individual operating divisions. In 1988, UB Group acquired the global Berger Paints Group with operating companies across four continents. The paints business was divested for significant value in 1996. After India adopted economic liberalization in 1991, the UB Group decided to retain interests in only those businesses that were globally competitive and did not depend upon fiscal tariff protection. Today, UB Group is the third largest manufacturer of Spirits products in the world. In 2005, the Group entered aviation sector with the launch of Kingfisher Airlines Limited. Within a short time the airlines has captured an impressive market share and has established a niche identity for itself.

III.1.1.3 VISION, MISSION STATEMENT

Mission and Quality statement
· We constitute a large, global group based in India. We associate with world leaders in order to adopt technologies and processes that will enable a leadership position in a large spectrum of activities. · We are focused on assuming leadership in all our target markets. · We seek to be the most preferred employer wherever we operate. · We recognize that our organization is built around people who are our most valuable asset. · We will always be the partner of choice for customers, suppliers and other creators of innovative concepts. · We will continually increase the long-term value of our Group for the benefit of our shareholders. · We will operate as a decentralized organization and allow each business to develop within our stated values. · We will be a major contributor to our National Economy and take full advantage of our strong resource base.

QUALITY STATEMENT:· Quality leadership is vital to the long-term success of the UB Group in an increasingly competitive marketplace. · Building quality into our workplace, products and service is essential to a successful future for our customers, employees, supplier’s

communities and shareholders. · The UB Group will work to provide products and services that always meet or exceed expectations · Management will commit resources and create an environment in which each employee can contribute skills, talents and ideas to a never-ending process of improvement and innovation in all aspects of our business.

Mergers and Acquisitions

Shaw Wallace was the 2nd largest player in spirits in India (MS - 15%). UB Group acquired 75% stake for a consideration of USD 300 million in July 2005. Valuation underpinned by growth prospects and synergies arising from combined MS. Acquisition of Bouvet Ladubay : McDowell & Co. (Scotland) Ltd (Mergers and Acquisitions)Shaw Wallace was the 2nd largest player in spirits in India (MS - 15%). UB Group acquired 75% stake for a consideration of USD 300 million in July 2005. Valuation underpinned by growth prospects and synergies arising from combined MS. Acquisition of Bouvet Ladubay :McDowell & Co. (Scotland) Ltd

Annual Confirmation
All Directors and Senior Management Personnel will annually on or before June 30 of every year or such other date as may be determined in this regard sign a confirmation that they have read and will comply with this Code.

Non - compliance

Suspected violations of this Code must be reported to the Chairman of the Board or the Chairman of the Audit Committee. All reported violations will be appropriately investigated. Directors who violate this Code may be subject to sanctions, up to and including a request to resign as Director or the Boards seeking removal of the Director, where permitted by applicable law.

Waivers and amendments

The Company is continuously reviewing and updating all its policies and procedures and therefore this Code is subject to modification. The Board must approve any amendment or waiver of any provision of this Code in writing.

Vision and Values
OUR VISION The Kingfisher Airlines family will consistently deliver a safe, value-based and enjoyable travel experience to all our guests.´ OUR VALUES 1) Safety: This is our overriding value. In our line of business, there is no compromise. 2) Service: We are all in the hospitality business; we must always seek to serve our guests and gain their trust, goodwill and loyalty. 3) Happiness : We seek to build an organization with people who choose to be happy, and will Endeavour to influence our guests and co-workers to be happy too 4) Teamwork: We will succeed or fail as a team. Each one of us must respect our colleagues regardless of their rank, and we must work together to ensure our mutual success 5) Accountability: Each one of us will be held accountable for the successful execution of our duties, commitments and obligations, and we will strive to lead.

III.1.1.4 BOARD OF DIRECTOR
DIRECTOR OF UB GROUP: Dr. Vijay Mallya
Chairman Dr. Vijay Mallya, a well known industrialist, is the Chairman of the United Breweries Group. The Group today has an annual turnover of U.S. $ 1.2 billion. The local business areas of the Group encompass Beverage Alcohol, Life Sciences, Engineering, Agrochemicals, Information Technology, Fertilizers, Print Media and Infrastructure development. Dr. Mallya is the Chairman of Public Companies both in India as well as abroad. Dr. Mallya has received awards, both in India and Overseas, having been conferred a Doctorate of Philosophy in Business Administration [honoris causa] by the Southern California University, Irvine, U.S.A. He has also been nominated as a Global Leader for Tomorrow by the World Economic Forum during their annual meeting in Davos in 1995. He has been a Member of Parliament [Rajya Sabha] elected from Karnataka State.

Business Interests of UB Group:
Beverage Alcohol: The UB Group is 3rd largest spirits marketer in the world, with overall sales of 60 million cases. The company offers 140 brands at varying price points. Some of the famous brands of the UB Group are: Bagpiper Whisky, McDowell's No.1 Whisky, Director's Special Whisky, McDowell's No.1 Brandy and McDowell's Celebration Rum. The Pegasus, which is the symbol of the United Breweries, first found its place as the Group logo in 1940. Then, the Helladic horse ± associated with beer and nectar in Greek mythology ± carried a beer cask between the wings, ostensibly because beer formed the core operations of the Group. Later, the beer cask was removed to represent the Group's multifaceted operations. Now, it is just the Pegasus.

UNITED BREWERIES LIMITED (UBL) :
In a tough competitive brewing industry, which now has all the world’s major brewers fighting for market share, UBL towers above all others. A growth of 20% in the market growing at half that rate has ensured that UBL’s stable of market leading brands command a combined market share of more than 50% in the categories in which we operate. While Kingfisher Strong has emerged as India’s most popular beer, other variants such as Kingfisher Ultra, a super premium product, are also being enthusiastically received by the market. UBL’s position in both the domestic and international beer market will be further strengthened consequent to the signing of the Shareholder Agreement with Heineken. This envisages, among other things, the production and sale of the globally acclaimed Heineken beer in India by UBL. Simultaneously, I also look forward to leveraging Heineken’s international distribution strength to further the spread of Kingfisher Beer in select international markets.

UBL Awards:
Won the Bronze Award at the 'Australian International Beer Awards' in the "International Packaged Beer Section for the year 2000." First Prize in the International Beer Awards organised by the New Zealand Hop Marketing Board. First Prize for the label work category at the Asian Grand Prix Cyrel 2000 Label award. Gold Medal at the World Beer Championship held in Chicago in 1997. World's Best Lite Lager Award at ]the Stockholm Beer Festival in 1995. World's Best Lite Lager Award at the Stockholm Beer Festival in 1994.

THE KINGFISHER BEER PRODUCT:

Kingfisher Strong Premium Beer comes from the house of United Breweries Limited. The brand was launched in 1999 to cater to the growing Strong Beer segment in the country. It has been the fastest growing beer brand in the country and has been instrumental in taking the volumes and profitability on the upsurge for the Kingfisher family & UB. Today Kingfisher Strong is India’s largest selling beer brand. Kingfisher Strong combines the unique taste and quality of Kingfisher in a Strong Beer and is positioned on the similar platform as the mother brand – Kingfisher. The tagline used for communicating the positioning platform is “Same Taste. Extra Dum”. Kingfisher Strong symbolizes the values of strength, style, youthfulness, power & mechanism. Kingfisher Strong has a national footprint and is among the top 3 strong beer brands in almost every state in the country. It has a wide repertoire of pack sizes, being present in – 650ml bottles, 330ml Pints, 330ml Cans, 500ml Cans and Draught Beer SK

III.1.1.5 DEPARTMENT

BOTTLE PRODUCING :-

Altitude Correction Factors (feet above sea level):2000 – Add 1 PSI add 2 PSI 6000 – add 3 PSI

4000 –

Bottling Procedure:

Once the final quality of the beer has been achieved, it is ready for packaging. The packaging of beer is one of the most complex aspects of brewery operations and the most labor intensive of the entire production process.

Flash Pasteurization:

Pasteurization is an alternative to sterile filtration for reducing the number of harmful micro organisms in beer. The basis for pasteurization is the heating of the beer for a pre determined period of time at specific temperatures, thereby assuring the micro biological stability of the beer. A Pasteurization Unit (PU) is defined as a one-minute exposure to a temperature of 60ºC. A PU is a measure of the lethal effect on microorganisms of the heat treatment. The aim is to attain the minimum degree of pasteurization necessary to inactivate beerspoiling organisms. Pasteurization is less common among craft brewers who are more apt to rely on sterile filtration. The two main types of pasteurization techniques are flash and tunnel. Flash pasteurization is used for continuous

treatment of bulk beer prior to filling the bottles, cans, or kegs. It is typically carried out in a plate heat-exchanger before transferring the beer to the bright-beer tank. Tunnel pasteurization is used mainly for in-pack treatment following the crowning of the bottles. Flash pasteurization is not widely used by breweries in North America (though it is very popular with the dairy and juice industries), but it has been widely adopted in Europe and Asia. There are many such systems in existence, most used for kegs, and some for bottles and cans. In flash pasteurization, the beer is heated to at least 71.5 to 74ºC and held at this temperature between 15 and 30 seconds. Flash pasteurization of beer typically uses a two- or three-stage plate heat exchanger with hot water as the heat exchange medium. The heat exchanger is designed so that a particular flow rate will achieve maximum efficiency. Consequently, the flow rate – not the temperature – must be adjusted to alter the number of PUs for a given beer.

Bottle Feeding :

The first step in bottling begins with loading the empty bottles on the unscrambling table. In craft breweries, loading with pre packed bottles is usually done manually at a rate of 80to 100 bottles per minute (bpm). The table funnels the wide mass of bottles into a single stream. Several types of mechanisms prevent the bottles from bridging as they are funneled to a single line. These include mechanical joggers, reversing chains, and good inherent design. Craft brewers often buy what is known as a "pre pack," which includes printed six-pack carriers inserted in a printed case along with the bottles.

Bottle Rinsing:

There are three types of bottle risers – twist, gripper, and rotary. Most craft breweries use twist rinsers, which are designed to invert the bottles before spraying. After being rinsed, the bottles are allowed to drain before being swung back up into the up right position and delivered to the bottle filler. Each bottle size and shape requires a different "twister," but the cost of twist rinsers is quite low. Gripper style rinsers are a more compact alternative to twist rinsers and can handle various bottle sizes and shapes without parts having to be changed. Rotary rinsers, as shown in Figure 17.2, are compact as well, and are known for their smooth bottle handling. However, rotary rinsers are the most expensive option for rinsing. A rotary rinser can also be incorporated into a filler as part of a "mono bloc" arrangement, as shown in Figure 17.3. Mono bloc machines also combine a crowner with the rinser-filler on the same chassis. Generally, mono blocs that combine a filler and crowner are better than separate units, since the bottle must be capped as soon as possible after

filling to exclude air.

Bottle Filling :
1) Filler Bowl Operations: The filling unit or filler bowl should be cleaned and sanitized before bottling. To prepare for filling, the beer lines, hoses, and filler should be cooled down using cold water. The water should be blown out before beer is introduced into the filler. The system is then pressurized, and beer is supplied to the filler bowl from the bright beer tank. Some brewers will vent the bowl pressurizing gas prior to the introduction of beer to lower the oxygen contact with the incoming product. It is better to fill the bowl from the bottom to reduce turbulence and air pickup. Brewers usually slightly over carbonate the beer to compensate for any loss of carbon dioxide during the filling operation.

2) Crowning:
After filling, the bottles are capped as soon as possible by the crowner. The caps have as prayed-on, hot-pressed PVC-based sealing insert or a coldpressed sealing insert not containing PVC. The caps are conveyed to the crown hopper by means of a magnetic belt or a pneumatic crown feed, or they can be dumped manually directly into the crown hopper. Whatever method is used, the crown hopper should be kept only half full of caps. This is to lessen the possibility of crowns becoming packed and not feeding into the chute fast enough.

3) Bottle Drying:
Before labeling, it is absolutely essential that the bottles are dry and free of condensation. This is especially important with pressure-sensitive labels that use non-water-soluble glues. Wet glue, which is typically used as an adhesive in glue applications, is much less sensitive to residual water on the bottle. An air knife can eliminate virtually all of the surface moisture on the bottles after rinse-off. If the beer is tunnel pasteurized, an air knife is still needed to remove moisture, although the warm bottle greatly aids in the drying process prior to labeling

4) Tunnel Pasteurization:
An alternative to flash pasteurization and sterile filtration is tunnel

pasteurization. Tunnel pasteurization is employed after bottles have been filled and sealed. The bottles are loaded at one end of the pasteurizer and passed under sprays of water as they move along the conveyor. The sprays are so arranged that the bottles are subjected to increasingly hot water until the pasteurization temperature (usually 60ºC) is reached by the beer in the bottles (15). The bottles are then gradually cooled with water until they are discharged from the end of the pasteurizer. Temperature changes have to be made in stages to prevent the bottles from breaking. Heating and cooling of the bottles is performed using various water circulation paths in order to utilize recovered heat. In this way, heat usage by the tunnel pasteurizer can be reduced to a minimum. Passage through the tunnel pasteurizer takes about an hour. Bottle breakage is usually no more than 0.1 to 0.2percent in the tunnel pasteurizer (11). If greater, it is usually due either to poorly madebottles or the lack of head space.

Bottle Labeling: Types of Labelers

The principal types of labelers used in the brewing industry are in-line and rotary .An in-line labeler is a type of machine for which the bottle travels in a straight forward motion, and the label or labels are applied while the bottle is moving along the bottle conveyor. One such type of in-line labeler is the tandem labeler that is typically used in multiples or "in tandem," with each machine typically capable of running 60 to 80 bpm. Maintenance of the labelers is fairly demanding; and even though parts are fairly inexpensive, they may be difficult to obtain. Tandem labelers cannot do front and back labels at the same time, and they are not well-suited for applying neck labels. Unlike other labelers, the tandem labeler does not bond labels with a full width of glue, but rather with only two vertical strips, one at each side of the label. The labels may appear puckered due to moisture condensation or may be crooked or have corners flagged (edges lifted). These limitations have increasingly contributed to the obsolescence of tandem labelers; nonetheless, their low cost and simplicity assures their continued use, particularly by craft brewers.

Types of Label Adhesive:
A further classification of labelers that should be taken into consideration is the type of label adhesive that is used in conjunction with the unit. The types of adhesives are the following:  cold glue  hot melt  pressure sensitive  roll feed

Case Packing :

Case packing is done manually or by case packers. Two people standing at a discharge table can pack up to 100 bpm. This assumes that empty cases are within easy reach and that another person closes and stacks the case. For rates above 100 bpm, an automatic case packer is required. A case packer has a linear collection table on which the bottles are automatically placed in ranks that match the packing pattern in the case. A conveyor supplies the packer with the empty shipping cases, and from the packer the conveyor carries the filled cases to the palletizing area. There are two types of case packers, "drop packers" and "pick and place packers." Drop packers are more reliable, as the bottles are dropped through flexible fingers that are inserted into each cell of the receiving case. Pick and place packers depend on pneumatic grippers that lift the bottles off the collection table and then lower them into the case. If the receiving box is not perfectly aligned, bottles may not be properly placed and there may be some resulting label damage.

III.1.1.6 PRODUCT RANGE

The Beer brands manufactured and marketed by United Breweries Ltd. have always been recognized for their international quality. That's Beer at its best for the discerning consumer!

The largest selling Beer in India, Kingfisher commands a market share of over 36% in the country with 1 out of every 3 bottles of beer sold in India being a Kingfisher brand. We are also available in 52 countries across the globe. Kingfisher Blue Kingfisher, India’s largest selling beer, brings a new zing to the beer industry Kingfisher Blue! It’s a young & sporty brand in the premium beer space, that’s sure to thrill the adventurous young and those who seek something extra from life. Kingfisher Premium Kingfisher is one of the oldest, most widely recognized and respected brands in India. Ever since its inception, the brand has not only succeeded in guarding its numero uno status, but has also been able to evolve into one of the most contemporary and aspirational youth icons of today. It is the only brand in the category to successfully straddle the mild and the strong beer category of the country, together selling in excess of 68 mn cases. Kingfisher Strong Kingfisher Strong Premium Beer comes from the house of United Breweries Limited. The brand was launched in 1999 to cater to the growing Strong Beer segment in the country. It has been the fastest growing beer brand in the country and has been instrumental in taking the volumes and profitability on the upsurge for the Kingfisher family & UB. Today Kingfisher Strong is India’s largest selling beer brand.

III.1.2 MANUFACTURING PROCESS
PRODUCTION OF BEER

Steps in Commercial Production of Beer
Five major steps are involved in the manufacture of beer They are:

(a) Malting.

The starchy grains are first malted. The malt is prepared by first soaking the grains in water and then allowing it to germinate at 170C. During germination, large amount of amylases, an enzyme, are produced which are subsequently involved in hydrolyzing the starch into fermentable sugars. After the germination is completed, the grains are dried at 650C.

(b) Mashing.

After malting, the pure barley malt is invariably mixed with other grains such as corn, rye, sorghum, wheat, etc. It is called ‘ground malt’. The latter is first mixed with warm water at about 700C and 5.0 pH. Mashing brings about partial hydrolysis resulting in the digestion of starch and protein; the partially hydrolyzed solution of mash is filtered and this filtrate is called ‘beer wort’. Beer wort serves as a rich nutrient medium for the microorganisms. Beer wort is now boiled with hops. which are the papery scales of the female flowers of the hop vine, Humulus lupulus. The hops are added for flavor, aroma and mild antibacterial activity to prevent the growth of spoilage.

(c) Fermenting.:
The beer wort is now inoculated with a pure culture of Saccharomyces cerevisiae of S. carisbergensis and allowed to ferment at low temperature (5°C-14° C) for longer period (5-10 days).

(d) Maturing:

The fermented beet wort is refrigerated at 0°C for several months usually 6-8) to remove the harsh flavor and other undesirable characteristics.

(e) Finishing:

This is the final step in which the matured beer is carbonated, filtered and finally bottled, canned or barreled. Bottled or canned beer is usually pasteurized at 60°C for about 20 minutes to prevent microbial spoilage.

III.1.3

SWOT ANALYSIS

Swot analysis Strengths:
Well established consumer market. Sold in over 52 International Flights. Every third beer sold in India is Kingfisher. India’s first global consumer ’s brand Kingfisher. Widely recognized brand. Consolidating growth. 50% market share nationally.

Weakness:Too much diversification. Heavy taxation. Government control of beer distribution.

Opportunities:Collaborations with foreign companies. R & D since the company has a strong capital.

Threats:



Stiff competition by the foreign breweries entering into India.

III.1.4 OBSERVATION, RECOMMENDATION, CONCLUSION

Observations
kingfisher is one of the reputed brands in domestic as well as international market. The operations of the beer manufacturing unit under the brand name kingfisher were well planed and systematic; some of the observations after visiting the unit are as fallows :  Most of the manufacturing process was mechanized and automatic.  Premises of the company were clean.

    

The manufacturing area had pieces of broken glass bottles lying around. All the workers were not in the recommended safety outfits. Proper recycling of manufacturing waste. Labour welfare programs followed according to the law. Concessional medical services offered to the workers. Easy loans provided to the employees.

 As most of the operations were mechanized the manufacturing process was fast resulting in more output, more sales and thus more profits.  Premises were clean thus providing employees with good working conditions.  As the manufacturing area had broken pieces of glass bottles it could lead to injuries.  Not using safety outfits could lead to major accident.  All the manufacturing waste was treated thus avoiding pollution.  As all the labour welfare programs were followed there was good working conditions for workers resulting in there satisfaction and encouraging them to work towards the attainment of the organizations goal. As the plant location was close to the market the transportation cost is considerably reduced resulting in increased profits

CONCLUSION

RECOMMODATIONS
 Manufacturing area should be regularly cleaned to avoid any major accident.  Safety outfits should be made compulsory to all the employees to avoid injuries.  Employees should be guarded against the constant noise during the manufacturing process.

III.2

BISLERI INTERNATIONAL PVT LTD

III.2.1 INDUSRIAL PROFILE

About bisleri
Mineral Water under the name 'Bisleri' was first introduced in Mumbai in glass bottles in two varieties - bubbly & still in 1965 by Bisleri Ltd., a company of Italian origin. This company was started by Signor Felice Bisleri who first brought the idea of selling bottled water in India. Parle bought over Bisleri (India) Ltd. In 1969 & started bottling Mineral water in glass bottles under the brand name 'Bisleri'. Later Parle switched over to PVC non-returnable bottles & finally advanced to PET containers Presently bisleri has 8 plants & 11 franchisees all over India. Commanding a 60% market share of the organized market. Overwhelming popularity of 'Bisleri' & the fact that it has pioneered bottled water in India, has made it synonymous to Mineral water & a household name. When you think of bottled water, you think Bisleri has developed 8 unique pack sizes to suit the need of every individual. They at present have 50ml cups, 250ml bottles, 500ml, 1L, 1.5L, 2L which are the non-returnable packs & 5L,20L which are the packs . Bisleri Water is put through multiple stages of purification, ozonised & finally packed for consumption. Rigorous R&D & quality controls has made us a market leader in the bottled water segment. Strict hygiene conditions are maintained in all plants.

Transformation processes
A transformation process is any activity or group of activities that takes one or more inputs, transforms and adds value to them, and provides outputs for customers or clients. Where the inputs are raw materials, it is relatively easy to identify the transformation involved, as when milk is transformed into cheese and butter. Where the inputs are information or people, the nature of the transformation may be less obvious. For example, a hospital transforms ill

patients (the input) into healthy patients (the output). Transformation processes include: • changes in the physical characteristics of materials or customers • changes in the location of materials, information or customers • changes in the ownership of materials or information • storage or accommodation of materials, information or customers • changes in the purpose or form of information • changes in the physiological or psychological state of customers. Often all three types of input – materials, information and customers – are transformed by the same organization. For example, withdrawing money from a bank account involves information about the customer's account, materials such as cheques and currency, and the customer. Treating a patient in hospital involves not only the ‘customer's’ state of health, but also any materials used in treatment and information about the patient.

One useful way of categorizing different types of transformation is into:
manufacture – the physical creation of products (for example cars) transport – the movement of materials or customers (for example a taxi service)  supply – change in ownership of goods (for example in retailing)  service – the treatment of customers or the storage of materials (for example hospital wards, warehouses).   Several different transformations are usually required to produce a good or service. The overall transformation can be described as the macro operation,

and the more detailed transformations within this macro operation as micro operations.

III.2.1.1 ABOUT IT, INDUSTRIAL INFORMATION
About the Industry
Corporate control over water and water distribution in India is growing rapidly: the packaged water business is worth Rs 1,000 crore, and it's growing at a huge 40-50% annually. Around 1,200 bottling plants and 100 brands of packaged water across the country are battling over the market, overdrawing groundwater. Bottled water, one of India's fastest-growing industries, is a business built on the foundation of bad governance, inequity and exploitation. It is Hard to believe, but its true. Around 1.2 billion people worldwide lack access to clean drinking water. Today, there are more people in the world's hospitals suffering from waterborne diseases than any other ailment.. Providing safe drinking water is the responsibility of the state. That they are failing miserably is evident from the fact that over 1,600 Indians reportedly die every day because of waterborne diseases. Despite these astounding figures, the Indian state has literally washed its hands of the responsibility of providing clean drinking water to its citizens. Multinational corporations would have us believe so. And the reason is not hard to find: along with imported water treatment technology like activated carbon and ultra violet (UV) disinfection (Aqua guard), reverse osmosis (Reviva) and resins (Zero-B), the water treatment market is estimated to be worth around Rs 700 crore. According to the Bureau of Indian Standards, there are 1,200 bottled water factories all over India (of which 600 are in the state of Tamil Nadu). Corporate control over water and water distribution in India is rapidly growing. As globalization opens up opportunities for private players, investing in water and/or manipulating water scarcity makes increasingly good business sense for corporations.

Objectives of the project
 The project will illustrate the working of different departments in production process.  With the help of this project we would come to know different stages of

production or transformation process. It will focus on conversion of input into output.  The project gives us an understanding of types of machines used while production in bisleri.

III.2.1.2

HISTORY

Rigorous Research and Development and stringent quality controls have made us market leaders in the bottled water segment. Bisleri has always been committed to offering every Indian pure and clean drinking water. Hence Bisleri water is put through multiple stages of purification, ozonisation and is hygienically packed for final consumption. To maintain strict quality controls in every unit, we not only purchase caps from approved vendors, we also manufacture our own bottles, in-house. To be at par with International standards, we have recently procured the latest state-of-the-art machinery which has not only helped us improve packaging quality but has also reduced raw material wastage and doubled production capacity. You can rest assured that you are drinking safe and pure water when you consume Bisleri. Bisleri is free of impurities and is 100% safe. Enjoy the sweet taste of Purity.

Bisleri Today:- The Indian consumer today enjoys the sweet and pure taste

of Bisleri mineral water. However in an effort to offer something special to our loyal consumers we have recently introduced Bisleri Natural Mountain Water water brought to you from the foothills of the mountains situated in Himachal Pradesh. This newly launched offering has widened our product range to two variants: Bisleri with added minerals and Bisleri Mountain Water.

III.2.1.3

VISION, MISSION STATEMENT

Our Vision:-Our vision is to be the dominant player in the branded water
business where the second player is less than 20% of our business.

Our Mission:- We are in the business to serve the customer. He is the most
important person. He is the only one who pays. He deserves the best quality and presentation at a worth of the price. We must have world class quality, at the lowest production & distribution cost. This will make us an unbeatable leader, and will have satisfied loyal customers. Our values:- Integrity, Leadership, Teamwork, Co-operation, Quality, Passion, Openness & Transparency. Ramesh Chauhan Chairman Bisleri International Pvt. Ltd.

Genesis:- The name that epitomizes mineral water today was first

introduced in Mumbai in the early 60's. In 1965 Signor Felice Bisleri an Italian by origin, came up with the idea of selling bottled water in India. His company Bisleri Ltd. offered mineral water in two variants - bubbly and still. In 1969 Parle bought over Bisleri (India) Ltd. and started bottling Mineral water in glass bottles under the brand name 'Bisleri'. In due course Parle switched over to PVC non-returnable bottles and finally advanced to PET containers.

Expansion:- Under the leadership and vision of Mr. Ramesh J. Chauhan, Bisleri

has undergone significant expansion in their operations. The company has witnessed an exponential growth with their turnover multiplying more than twenty times in a short span of 10 years. The average growth rate over this period has been around 40% with Bisleri enjoying more than 60% of the market share in the organized mineral water segment. Currently Bisleri has 11 franchisees and 8 plants across India, with plans of setting up 4 new plants on the anvil. The overwhelming popularity of 'Bisleri'

and the fact that we were the pioneers of the bottled water industry in India has made us synonymous to Mineral water and a household name. So naturally 'When you think of bottled water, you think Bisleri'.

III.2.1.4

DEPARMENT

Departments in Parle Bisleri Pvt. Ltd.
“Parle Bisleri Pvt. Ltd.” It is a medium scale company and it manufactures and sells “Packaged Drinking Water” The different departments of this company are: -

1.Filler Department : This is the plant in which the bottles are filled and packed under strict levels of hygiene and safety as per the EU norms • Caps Section • Performs Section

2.Plastics Department : -

This is the Department where pet material is processed to make performs using 6 Ekou injection molding machine of 180 and 330 tones as per the requirements of the Performs are available in various sizes according to the size of bottle. Caps are made from a mixture of HDPE and LLDPE using 4 Cincinnati Milacron and Windsor injection-molding machines.

3.Water Treatment Plant : -

Over here the Raw water from the bore wells is treated in several stages before it is filled thus making it very pure for human use.

4.Blowing Department : -

Over here the preforms are blown into bottles. This department has various manual and fully automatic stretch blow moulding machines.

5.Water Testing Laboratory: -

The water-testing lab ensures that the water safety standards are maintained as per the BIS and EU norms.

6.HORAI Department (Grinding Department): -

All rejected bottles, caps, jars and lumps of plastic material are sent over here for grinding inorder to re-use it. Before it can be grinded it is very carefully segregated in different groups. They also buy plastic bottles from outside and grind them for resale. It is a fully automatic plant

7.Stores Department : All the stock of finished, semi-finished goods are stored over here and are dispatched as per the orders. Up to 50 tonnes of stock are dispatched in a day

Production System Model Inputs Environment 1)Legal : Parle Bisleri being a company involved in selling water which is fit for consumption it comes under the FDA, it also follows the standards of BIS. Therefore ensuring its quality and the public perceive the right image of being 100% safe. Parle Bisleri believes in keeping up with times and they are trying constantly to increase their share market. This is the reason Bisleri has automatic Injection Molding Machine in order to increase their production capacity 3 folds. Bisleri already has 2 automatic Blow Molding machines.

2) Technological: -

III.2.1.5 PRODUCTION RANGE  Market
1) Competition :Parle Bisleri Pvt. Ltd. 1992 at that time Bisleri enjoyed almost a complete monopoly. Recently however, companies like Pepsi and Coco cola have entered the market to give tough competition to Bisleri by introducing brands like kinley and Aquafina.

2) Customer desire: Bisleri has become a household name to the extent that people instead of
calling it packaged water are calling it Bisleri

Primary resources: 1) Material : The raw water is obtained from bore wells. The bottles are made from polymers such asHDPE, LLDPE and PET.

2) Personnel : -

Bisleri requires mostly skilled and semi skilled labourers. The skilled labourers include production and plastic engineers.

3) Capital assets : -

Bisleri has got 14 injection moulding machines, 2 automatic blow moulding machines and 4 semi automatic blow moulding machines. It has also got 2 plants located side by side for production purposes.

Conversion Subsystem 1) Physical : Parle Bisleri Pvt. Ltd is considered to be a manufacturing unit as it manufactures the semi finished product i.e. bottles and caps and also produces the finished products.

2) Exchange services : -The distribution network of Bisleri is maintained

by its distributors and wholesalers. To supply to big corporates they have their own distribution network.

3) Outputs : -The final output of whole manufacturing process is we get

clean pure drinking water in bottles of different sizes according to the needs of the consumers.

Quality control subsystem
The motto of Bisleri is “play safe” and Bisleri has implemented every measure to produce the safest product possible. It has employed measures such as:1) The quality of every single raw material that goes into the products are minutely inspected in order to ensure optimum quality standards. 2) The caps of all the bottles are tamper proof so when the consumer buys a Bisleri product he ensures that the product is un tampered. 3) The production process of Bisleri is such that a human hand never touches a Bisleri product.

III.2.2 MANUFACTURING PROCESS

Production Process
1) The raw material (HDPE, LLDPE, PET) that is stored in the warehouses is transported to the processing plant near by. 2) In the cap department where caps are produced. HDPE and LLDPE which are in the form of granules are emptied into the hopper of the injection moulding machine with a colorant and the caps are produced of the characteristics green colour of Bisleri. The caps that are produced are automatically packed into cartons. This semi finished product is transported, after quality testing has been done, to what is called the filling department. In the caps department there are 7 injection moulding machines

3) In the preforms department which is located in next to the cap department it is located in the same plant. In the preforms department PET material is used to manufacture preforms which are semi finished bottles. They are produced by using injection moulding machine. After the preforms are tested by the quality assurance department, they are packed in cartons and transported to the filling department. In the preforms department there are 7 injection moulding machines 4) In the blowing department the preforms which are obtained from the

preforms department are blown to form bottles. 5) The filling department is situated in a closed and a controlled environment to maintain the hygiene. The bottles are transported from one operation to another on conveyor belt. The bottles are directly loaded onto the conveyor belt, first bottles passed through UV light to kill the bacteria, then the bottles are cleaned by pure water, then the bottles are filled to the desired quantity and then they are automatically capped, then the sticker is put on the bottles and the price, manufacturing date, batch number are printed by spraying machine on the bottle itself, then the bottles pass through a screen of white light where workers manually check all the bottles for any defects, lastly they are packed in cartons and stored in the warehouse ready for transportation to its destination.

6) All the waste bottles are separated and they collected and send to the recycling department for recycling where they are cleaned, grinded to a coarse powder which is again used in the manufacturing process thus reducing wastages and being environmentally friendly. This plant is also used for recycling of outside PET bottles and thus earning extra revenue. 7) In the water treatment plant the water form the 8 bore wells are c with the production of bottles and caps. After that the semi finished products are transported from the cap and performs division to the filling division where the caps are added to the filling machines and the preforms to the corresponding size of the bottle, these bottles are then added to the conveyor belt to complete the process of filling the bottle automatically. After the bottle is filled to the desired level the bottle is automatically capped and then sticker is put on the bottle the price is printed through a spray gun. Then it is visually inspected and after that put into cartons readily for delivery.

3) Machines and Equipment

Industrial production is closely related to available production facilities coupled with appropriate machine and equipments. Considerations:

1) Equipments can be purchased fresh or second hand 2) Equipment can be lease or rented

3) Equipment can be fabricated within the plant Machines used in
Bisleri are injection molding machines for the production of performs and caps. For making bottles blow molding machines are used to blow the bottles to th required size and shape of the bottles by the use of moulds. Automatic fillers are employed for the purpose for clean and efficient filling of the bottles with the least amount of rejection.

4) Routing
The determination of where each operation on a component part, subassembly or assembly is to be performed results in a route for the movement of a manufacturing lot through the factory. The route of the production process is designed in such a way that in process transportation is at a minimum. The plant layout is in such a way that it is easy to transport the semi-finished product. First comes the semi finished product then it is blown filled and sealed, now ready for delivery.

5) Estimating

. Estimating is a special type of forecasting. Bisleri being an old company has being estimate the demand for its production due to its past experience it is able to estimate the demand. As a general rule the demand for Bisleri is very less but the production of Bisleri continues as the demand in summer is so high that the production cannot keep pace with the production requirement. They also take help of market surveys and past trends to determine the production requirements.

6) Loading and Scheduling: -

Both scheduling and loading help in production planning. Scheduling refers to the preparation of a time table for various operations covering the beginning and finishing times of various operations. Loading refers to the time gap for various work loads booked in advance for different products. Thus scheduling guarantees the observation of delivery times and loading guarantees the maximum utilisation of the available facilities. According to the schedule of the delivery and amount to be delivered and where they are to be delivered the trucks are loaded to be sent to wholesalers and retailers

7) Dispatching: Dispatching refers to the actual issuing of orders for performing operations in

different sections or units. It involves the following steps: 1) To make raw materials, equipments, tools and machines available to the worker. 2) To issue orders and instructions in writing about the method of work and time for completion. 3) To note start and finish time of each process. 4) To evaluate the performance and progress of production schedule. 5) To introduce suitable changes in schedules Distribution of the bottles is done using trucks of different sizes if the deliver has to be done in the city the smaller trucks are used which are of Eicher. If the delivery has to be made outstation then the larger Tata Trucks are used. The normal distribution to the distributors within the city the delivery takes place 7:00 a.m. every morning except Sunday.

8) Follow Up: -

The effectiveness of any production control system is dependent upon timely and adequate information regarding actual performance. This information usually originates with the dispatcher. After the delivery has been made the marketing people visit the retailer, wholesalers, distributors for their complaints if any written and left for the consideration of their superiors.

9) Inspection: -

Inspection is an integral aspect of quality control programme. It helps in maintaining and raising the quality of products. Inspection judges production against established standards. There is a very efficient quality control process followed by Parle Bisleri Pvt. Ltd. It inspects everything from the water to the bottles very regularly, in fact it is one the main issues in quality control of the company. The first thing the quality control head does is to check the previous days rejection and to finds its individual reasons of rejection and steps if required.

10) Evaluating: -

Evaluating is the important link between control and future planning. Evaluating function provides a feedback mechanism on a longer term basis so that past experience can be evaluated with a view to improve use of methods and facilities. Operations of Parle Bisleri are inspected by FDA (food and drug associations) Bisleri also follows BIS (Board of Indian Standards).

III.2.3 SWOT ANALYSIS STRENGTHS:    

SWOT ANALYSIS:-

High quality standard Trust for brand Large range of products Aggressive marketing Distribution system spread all country

WEAKNESS: The route selling policy adopted by bisleri distribution is more expensive than more commonly followed method of appointing distributers in different towns; this reduces the profit of the company.  Reuse of bottle by local sellers and illegal manufacturers  Not meeting the demand of the customers

OPPURTUNITIES:-

1. This is a fast growing field 2. The launch of bisleri in European market in 2003 has created a lot of scope for expansion 3. Launch premium range for high class customers Mass production for huge market

III.2.4

CONCLUSION

In conclusion it can be inferred that production management is very important in today’s competitive world where cost cutting is a norm rather than exception. Production management provides a science for effective profit maximization and optimum resources utilization. Bisleri who been in the past been facing tough competition from the other brands has adopted production management in a big way in order to maintain its lead in the packaged drinking water market. By this project we have tried to highlight some of the measure taken by Bisleri in order to improve its production process.

III.3

ION EXCHANGE

III.3.1 INDUSTRIAL PROFILE AND HISTORY

PROFILE: An ion-exchange resin or ion-exchange polymer[1] is an insoluble matrix (or support structure) normally in the form of small (1–2 mm diameter) beads, usually white or yellowish, fabricated from an organic polymer substrate. The material has highly developed structure of pores on the surface of which are sites with easily trapped and released ions. The trapping of ions takes place only with simultaneous releasing of other ions; thus the process is called ionexchange. There are multiple different types of ion-exchange resin which are fabricated to selectively prefer one or several different types of ions.
1. Name- ION Exchange India Limited 2. Headquarter- Corporate office, ION House, Dr. E Moses road, Mahalaxmi, Mumbai- 400011, India . Industry Visited- Verna Electronics City, Phase II, Salcette Goa- 403722, India. 3. Product Manufactured- Water treatment machinery 4. Establishment- Formed in 1964 in UK in Became Indian in1985 5. Owner- IONINDIA 6. Type of Industry- Environmental service industry

III.3.1.1
Industrial

ABOUT IT, INDUSTRIAL INFORMATION

Ion Exchange India provides industry with total water management - from pre treatment, through process water/liquid and waste water treatment, to water recycle and recovery of valuable by products for reuse in process. Total solutions address environmental concerns of customers by incorporating water conservation, pollution control, energy saving and reduced chemical consumption. Comprehensive services, including O&M and BOO/T contracts, deliver end benefit conveniently and economically, with single-point responsibility. We have more than 40,000 installations worldwide - packaged, preengineered and custom built, of which over 500 are at thermal and nuclear power stations, fertilizer factories, refineries, petrochemical and other core sector industries. Our plants, ion exchange resins and water treatment chemicals are exported to South East Asia, Japan, Europe, Africa, Egypt, the Middle East, USA and UK, as well as to the neigh boring countries of Bangladesh, Nepal, Mauritius and Sri Lanka

Ion exchange resin beads:

Ion-exchange resins are widely used in different separation, purification, and decontamination processes. The most common examples are water softening and water purification.

In many cases ion-exchange resins were introduced in such processes as a more flexible alternative to the use of natural or artificial zealites. Most typical ion-exchange resins are based on cross linked polystyrene. The required active groups can be introduced after polymerization, or substituted monomers can be used. For example, the cross linking is often achieved by adding 0.5-25% of divinyl benzene to styrene at the polymerization process. Non-cross linked polymers are used only rarely because they are less stable. Cross linking decreases ionexchange capacity of the resin and prolongs the time needed to accomplish the ion exchange processes. Particle size also influences the resin parameters; smaller particles have larger outer surface, but cause larger head loss in the column processes. Besides being made as bead-shaped materials, ion exchange resins are produced as membranes. The membranes are made of highly cross-linked ion exchange resins that allow passage of ions, but not of water, are used for electro dialysis.

III.3.1.2 VISION, MISSION STATEMENT Vision Mission and StatementVision:1. To be the preferred supplier in our business of providing services that optimizes performance of water treatment equipment. 2. To be the leader in our business which is so vital to the people’s lives and environment.

Mission :1. To satisfy our customers by providing prompt, cost effective and quality service. 2. To provide our customers with total service solutions.

III.3.1.3

PRODUCTION RANGE

Total Water Management
We use our wide range of processes with an integrated approach to deliver total solutions for every market - household, institutional, commercial, industrial and public water supplies, urban and rural, in India and overseas. Comprehensive services such as O&M and BOO/T enable us to meet customer needs totally, offering end benefit conveniently and economically, with single source responsibility. Total Water Management We use our wide range of processes with an integrated approach to deliver total solutions for every market - household, institutional, commercial, industrial and public water supplies, urban and rural, in India and overseas. Comprehensive services such as O&M and BOO/T enable us to meet customer needs totally, offering end benefit conveniently and economically, with single source responsibility.

 Market
1) Competition :Parle Bisleri Pvt. Ltd. 1992 at that time Bisleri enjoyed almost a complete monopoly. Recently however, companies like Pepsi and Coco cola have entered the market to give tough competition to Bisleri by introducing brands like kinley and Aquafina.

2) Customer desire: Bisleri has become a household name to the extent that people instead of
calling it packaged water are calling it Bisleri

III.3.1.4 DEPARTMENT
There are four main types differing in their functional groups:
 strongly acidic (typically, sulfonic acid groups, e.g. sodium polystyrene sulfonate or poly AMPS)  strongly basic, (quaternary amino groups, for example, timothy ammonium groups, e.g. poly APTAC)  weakly acidic (mostly, carboxylic acid groups)  weakly basic (primary, secondary, and/or ternary amino groups, e.g. polyethylene amine)

There are also specialized types: 1 Uses

chelating resins (iminodiacetic acid, thiourea, and many others) 1.1 Water softening 1.2 Water purification 1.3 Production of high purity water 1.4 Ion-exchange in metal separation 1.5 Catalysis 1.6 Juice Purification 1.7 Sugar Manufacturing 1.8 Pharmaceuticals

1) Water softening:

In this application, ion-exchange resins are used to replace the magnesium and calcium ions found in hard water with sodium ions. When the resin is fresh, it contains sodium ions at its active sites. When in contact with a solution containing magnesium and calcium ions (but a low concentration of sodium ions), the magnesium and calcium ions preferentially migrate out of solution to the active sites on the resin, being replaced in solution by sodium ions. This process reaches equilibrium with a much lower concentration of magnesium and calcium ions in solution than was started with. The resin can be recharged by washing it with a solution containing a high concentration of sodium ions (e.g. it has large amounts of common salt (NaCl) dissolved in it). The calcium and magnesium ions migrate off the resin, being replaced by sodium ions from the solution until a new equilibrium is reached. This is the method of operation used in dishwashers that require the use of 'dishwasher salt'. The salt is used to recharge an ion-exchange resin which itself is used to soften the water so that lime scale deposits are not left on the cooking and eating utensils being washed.

2) Water purification:

In this application, ion-exchange resins are used to remove poisonous (e.g. copper) and heavy metal (e.g. lead or cadmium) ions from solution, replacing them with more innocuous ions, such as sodium and potassium. Few ion-exchange resins remove chlorine or organic contaminants from water - this is usually done by using an activated charcoal filter mixed in with the resin. There are some ion-exchange resins that do remove organic ions, such as MIEX (magnetic ion-exchange) resins. Domestic water purification resin is not usually recharged - the resin is discarded when it can no longer be used.

3) Production of high purity water:

Water of highest purity is required for electronics, scientific experiments, production of superconductors, and nuclear industry, among others. Such water is produced using ion-exchange processes or combinations of membrane and ion-exchange methods. Cations are replaced with hydrogen ions using cation -exchange resins; anions are replaced with hydroxyls using anion-exchange resins.

4) Ion-exchange in metal separation:

Ion-exchange processes are used to separate and purify metals, including separating uranium from plutonium and other actinides, including thorium; and lanthanum, neodymium, ytterbium, samarium, lutetium, from each other and the other lanthanides. There are two series of rare earth metals, the lanthanides and the actinides. Members of each family have very similar chemical and physical properties. Ion-exchange is the only practical way to separate them in large quantities. This application was developed in the 1940's by Frank Spedding. A very important case is the PUREX process (plutonium-uranium extraction process) which is used to separate the plutonium and the uranium from the spent fuel products from a nuclear reactor, and to be able to dispose of the waste products. Then, the plutonium and uranium are available for making nuclear-energy materials, such as new reactor fuel and nuclear weapons. The ion-exchange process is also used to separate other sets of very similar chemical elements, such as zirconium and hafnium, which incidentally is also very important for the nuclear industry. Zirconium is practically transparent to free neutrons, used in building reactors, but hafnium is a very strong absorber of neutrons, used in reactor control rods.

4) Catalysis:

In chemistry ion-exchange resins are known to catalyze organic reactions. See for instance self-condensation.

5) Juice Purification:

Ion-exchange resins are used in the manufacture of fruit juices such as orange juice where they are used to remove bitter tasting components and so improve the flavor. This allows poorer tasting fruit sources to be used for juice production.

6) Sugar Manufacturing:

Ion-exchange resins are used in the manufacturing of sugar from various sources. They are used to help convert one type of sugar into another type of sugar, and to decolorize and purify sugar syrups.

III.3.2 MANUFACTURING PROCESS
PROCESS OF PURIFICATION OF WATER

III.3.3 SWOT ANALYSIS STRENGTHS:     High quality standard Trust for brand Large range of products Aggressive marketing Distribution system spread all country

WEAKNESS: The route selling policy adopted by bisleri distribution is more expensive than more commonly followed method of appointing distributers in different towns; this reduces the profit of the company.  Reuse of bottle by local sellers and illegal manufacturers  Not meeting the demand of the customers.

OPPURTUNITIES:-

1. This is a fast growing field 2. The launch of bisleri in European market in 2003 has created a lot of scope for expansion 3. Launch premium range for high class customers Mass production for huge market

III.3.4

OBSERVATION AND BEHAVIOUR

Observation1. The capital investment is very huge but comparativel Utilization is not done of the capital. 2. More emphasis should be given on cleanliness in plant. 3. The guests who come are treated with hospitality 4. Workers do not have adequate safety measures. 5. There is no Publicity, advertising, or marketing.

1) SIGNT FILTRATION:

These is first step of purification of water in which the signt filter is removing terbility of water and composite function which present in water . Signt filter are available in two type NGMF 135 it has capacity of purify water 2000 liters/ hrs, and other is NGMF 130 it has capacity of purify water 3000 liters/hrs.

2) CONVERSION OF WATER:
After process of signt filtration it convert hard water into soft water. These process played composite function for purifying water.

III.3.5 RECOMMENDATION AND SUGGESTION
1. Cleanliness should be maintained. 2. Workers should be given more safety guard. 3. Should also start manufacturing plant at small level like a society of an apartment 4. Should appoint more friendly and energetic staff 5. Motivational drives should be carried out. 6.They should doing publicity, advertisement, marketing strategy should be followed.

III.3.6 CONCLUSION
It is a very good company is also doing well in national as well as international market but little more efforts should be taken to increase popularity.

III.4.1 INDUSTRIAL PROFILE AND HISTORY History

Goa Shipyard Limited (GSL) established in 1957, is a leading ISO 90012008 certified shipyard on the West Coast of India, functioning under the administrative control of Ministry of Defence, Govt. of India. GSL is strategically located on the banks of river Zuari in Goa, a major international tourist destination well connected by its international airport and major port enroute all important shipping lines. Beginning as a small barge building yard, GSL has garnered reputation as one of the most sophisticated ship builders in the Country. For over four decades, GSL has designed, built and commissioned a wide range of sophisticated vessels for varied applications in the defence and commercial sectors with special expertise in building modern patrol vessels of Steel and Aluminium hull structure. GSL’S inherent strengths are An ISO 9001 Certified Company World class CAD/CAM facility for basic design, simulation and advanced outfitting Sate – of-art manufacturing facilities which includes four Slipways with a maximum weight of 3000 tones and 180m long Outfitting Jetty Unique distinction of implementing ERP for all functions Steel Preparation Shop for priming and cutting of steel, aluminium & non ferrous plates. A work force of over 1600 skilled personnel and over 200 qualified engineers and naval architects.

III.4.1.1 VISION AND VALUE
1. Production & Utilisation of Resources o  To design and build sophisticated ships for Navy and Coast Guard organisations with the aim of achieving self-sufficiency in this vital technology. o  To build commercial vessels like Offshore Supply Vessels, Oceanographic & Coastal Research Vessels, Fishing Vessels, Dredgers, Tugs, etc. o  To carry out ship repairs. o  To promote use of indigenous equipment such as computers, radar, communication equipment, auxiliary machinery, electrical fittings and domestic equipment. o  To substitute gradually indigenous equipment in place of imported equipment. 2.Social Objectives o  To help build up a strong industrial base through development of ancillaries. o  Encourage Scheduled Caste/Tribe persons by giving them preference in employment in the company and in the promotion of SC/ST employees as specified by the Government. o  To ensure that the ecological balance is not disturbed due to industrialisation, through pollution control, wherever required. o  To reinforce Government’s efforts in promoting social justice to the people at large by formulating corporate policies on employment, welfare, workers’ participation, consistent with the Government’s policies. Promote use of Hindi as a medium of communication.

3. Export Promotion & Import Substitution o foreign exchange through shipbuilding and shiprepair.  Earn

4. Employee Relations & Welfare o  To improve productivity by harmonious industrial relations. o  Promote welfare activities to raise morale of the employees. o  Promote development of managerial and technical skills of the Company’s employees through development programmes and technical training. Provide training to a large number of apprentices for absorption in the Company’s own unit and in other industries. o  To improve standards of safety with the help of a sound safety organisation and training personnel at all levels in safety so as to reduce accidents and loss of manhours.  Raise Productivity by R&D and Quality Control o  Maintain high standard of quality through strict quality control measures to the fullest satisfaction of the customer and to build up an image of the Company. o  Make sustained efforts for self-reliance through continuous R&D on extensive basis and develop viable design capability. o  Generation and maximization of internal financial resources for enhancing growth and maximization of the return on investment. o  Enhancement of the Company’s share in the total industrial output.

III.4.1.2 DEPARTMENT
Services Offered:GSL offers a wide spectrum of services to its valued customers which include:  Designing and building of variety of vessels  Repair and modernization of vessels  Technology transfer.

III.4.1.3 FACILITIES

Building Bays:GSL has three large self supporting all weather building bays with a working floor area over 10,000 sq.m. With a maximum length of 200 m, an inside width of 25 m. and craneage capacity of upto 40 tonnes, these bays are fully equipped for construction, modernisation and repair of all types of naval crafts and medium sized commercial vessels. Steel Preparation Shop:Complementing the hull fabrication bays is a modern steel preparation shop equipped with CNC Plasma cutting machines, automated shot blasting and priming plant and processor-controlled bending machines. Steel, Aluminium and other non- ferrous plates are cut by computer controlled plasma arc cutting machines for a precise fit and finish.

Aluminium Fabrication Shop:Aluminium alloy fabrication and welding procedures are blended with new ship construction processes with the installation of an exclusive aluminium workshop. Highly skilled technicians and production workers ensure consistently high quality of output.

Titanium Workshop:A highly specialised titanium workshop equipped with modern welding facilities and a trained workforce fabricates and welds titanium, non-ferrous metals and other components for ship construction.

Air Conditioned Store:An air conditioned store ensures safe storage of sensitive electrical and electronic equipment.

III.4.1.4 ELECTRONIC WORKSHOP
An advanced electronic workshop bears testimony to GSL's expertise, capability and capacity to fit, test and repair a wide range of shipboard electrical and electronic equipment. CAD/CAM:-

GSL's CAD/CAM centre has state-of-the-art computer hardware and world class TRIBON shipbuilding software. All production information from the CAD/CAM centre is directly fed to the CNC steel cutting and pipe bending machines. To enhance productivity, GSL is adopting " Modular Construction Techniques".

MIS:Goa Shipyard Limited (GSL) established in 1957, is a leading ISO 9001-2008 certified shipyard on the West Coast of India, functioning under the administrative control of Ministry of Defence, Govt. of India. GSL has implemented BaaN ERP ( Now it is called Infor ERP ) in the year 2002 with a gamut of modules such as Finance, Distribution, Manufacturing, Projects , PLM & Human Resources (HR) and become a role model to BaaN ERP as we are the first project base ship building company to have implemented BaaN ERP. The MIS group functions under the " General Manager (Finance)" and caters for the IT needs of the company. The group has two cells - ERP Project & EDP Cell. We also have other specialized software's like Primaviera for projects, Tribon, CAD/CAM for ship designing & modelling and Oracle for Attendance Recording System, which have all been integrated with BaaN ERP Application server for ease of operations across applications. As part of E-governance initiatives we have implemented a fully customised workflow and Group ware applications to cater for our daily requirements of Internal communications, Approvals, leaves, claims and Gate-Passes and the like. Our network backbone comprises of Two numbers Layer 3, 10 GBPS compatible central main Switches with high backplane capacity, processor capacity , throughput, bandwidth and support of IPv6 features. These two switches are connected and configured so as to have redundancy, thus ensuring availability at all times. The Two main switches are connected to 28 One GBPS end locations through fiber in order to maintain high level of connectivity, thus ensuring nil Data Loss. For connectivity to our Unit locations we have a WAN connectivity with a dedicated data leased line and also to the outside world we have two separate Internet leased lines. For Mailing solution we use IBM Lotus Domino. Our Internet surfing is permitted with valid authentication through strong web filtering device such as Barracuda appliance. GSL has taken steps to secure the IT infrastructure by following Industry standard practices. We have CISCO devices at the gateway to secure the access from outside. All the Application servers are authenticated only with proper access. At the user end we have 400 Plus Desktop PC which are secured with

Symantec Antivirus device and application control policy to avoid the threat from various kinds of viruses and data leakage. We also have 24 Thin-Clients, connected through a Bridge Server. There are 10 number of information Kiosks spread across yard for all the employees within GSL to update and see their personal information, various dues and pays. On the common places like GSL entrance, Canteen etc. provided big display LCD's for information, welcome to guest, Retiring employees history, achievements, awardees list and Plans etc. GSL is in a continuous process to bring Computer, Cyber security & frauds awareness amongst employees by giving trainings, broadcast and publishing in the GSL in house journal. We are now in a process of implementing ISO 27001 for information security and Management Services.

III.4.1.5

AWARDS AND ACHIEVEMENT

Goa Shipyard Limited (GSL), the youngest of the Defence Shipyards in the country, today stands as the success story of the changing face of Indian Defence Shipyards. Like a phoenix, the Shipyard has arisen from a modest repair Yard to position itself as a leading shipbuilder on the west coast of India, capable of designing and building high technology and sophisticated ships to meet the crucial maritime needs of the country. The shipyard has an infrastructure that combines economy, scale, and flexibility and has ISO 9001-2008 accreditation. Equipped with an in-house design capability, it has gradually expanded itself to meet the growing shipbuilding demands of the country, particularly in its core competence area of building warships for the Indian Navy and Indian Coast Guard, efficiently meeting the customers' requirements in the field of design and construction. GSL has developed 5 variants for Patrol Vessels ranging from 50 Mtr. to 105 Mtr. and speeds ranging from 25 Kn to 35 Kn. Two series of these have been delivered to customers and are in active service and another two series of the designs are under advanced stages of construction for Indian Navy and Coast Guard. GSL is also developing the designs for ships of 75 Mtr and 115 Mtr. lengths for future requirements of the customers. It has been a saga of records for the Shipyard over the years. In its quest for excellence, Goa Shipyard won Hon'ble Raksha Mantri's Awards for Excellence

for "BEST PERFORMING SHIPYARD" for the years 2005-06 & 2006-07. The Award was constituted only in the year 2005-06 and GSL was declared "The Best Performing Shipyard" in the very first year of inception of the Award. The youngest of the Defence Shipyards in the country has thus bagged the prestigious award for the second successive term. Whilst the indigenous Ship design effort of GSL for 105M Naval Offshore Patrol Vessel have been awarded the Hon'ble Raksha Mantri's Award for excellence for 2006-07, the Shipyard was also conferred with the prestigious Mini Ratna, Category - I status, by the Government of India in March 2007. The value of production is continuously increasing over the years and the company has consistently paid handsome dividend to exchequer in last several years, when other public sectors are finding it difficult to sustain the market competition, GSL has secured and executed orders in competition with private shipyards. Till date, the yard has to its credit the delivery of 209 vessels, which include Offshore Patrol Vessels, Fast Patrol Vessels, Advanced Offshore Patrol Vessels, Missile Crafts, Sail Training Ships, Hydrographic Survey Vessels, Extra Fast Attack Crafts, Landing Craft Utility Vessels, Torpedo Recovery Vessels, Survey Craft, Passenger Vessels, Interceptor boats, etc, to name a few. Apart from the progress made in shipbuilding, the yard has also made deep inroads in the field of diversification, which includes the design and construction of training simulators for the Indian Navy and Oil Natural Gas Corporation and construction of Glass Reinforced Plastic (GRP) Boats for Ministry of Home Affairs. 26 Nos. of Fast Speed FRP Interceptor boats have been delivered to various state police departments till date and another 18 nos. shall be delivered very soon to bolster the Indian Coastal defence against intruders. The yard is presently equipped with three large self supporting & all weather hull fabrication bays, with a working floor area of over 100,000 sqm. Its modern steel preparation shop is having two CNC plasma cutting machines, one automated shot blasting and priming plant and a couple of processor controlled bending machines. The shipyard is on a modernization drive at a cost of approx. Rs. 800 crores which include installation of a shiplift and creation of GRP ship production infrastructure.

The attitude is well expressed in the words of the GSL Officiating Chairman & Managing Director, Mr. Sampath Ananthasayanam, "Ours is an endeavor to emerge as an internationally competitive yard and facilitate quality service, outstanding workmanship and delivery earlier than contractual commitments and to meet all the stringent performance requirements of the customer". True to the message, the striving towards our vision is a never-ending challenge. Today's success is only a prelude to the next chapter in our story. GSL is confidently marching head with the above promising trends to scale new heights of glory in the years to come.

III.4.1.6 RESPONSIBILITY AND AUTHORITIES
The responsibility and authorities of the officers are clearly defined in ISO Manual of the company under reference 10 QSP. Corporate Management Committee:This committee comprising of CMD, Functional Directors, General Managers and HODs, meets every Saturday to review the status of various activities/functions during the week and to take a view on various matters of policy. Shop Council:The company has four Shop Councils consisting equal no. members from the management and the workmen representatives. The functions of these shop councils are to consider various proposals/suggestions for implementation of :  Improvement in production facilities Control and avoidance of Hazards  Improvement in storage facilities in a shop Issues concerning safety of the men.  Improvement in material economy Quality improvements  Wastage control Cleanliness.

Sports Committee:This committee conducts various sports activities ever year to encourage sports and games and to keep the employees and their families fit and healthy. Fees Payable:No fee for applicants “BELOW POVERTY LINE”. Application fees Rs.10/- or as amended from time to time Per page Rs.2/Per floppy Rs.50/Samples/Models etc. – actual cost Inspection for first hour will be free & for subsequent every additional 15 minutes Rs.5/-. Power and Duties of Officers:The Board of Directors has delegated powers to Chairman & Managing Director, who in turn has sub-delegated some of his powers to Directors and all HODs in the company. The same have been promulgated vide different CMD memos from time to time. Monthly Remuneration:The system of compensation and the monthly remuneration received by the officers is as per the Government Guidelines. Similarly, the compensation paid to the employees is as per the Wage Settlement negotiated with the Registered trade unions in the company and as approved by the Board of Directors. The details of monthly remuneration paid to each officer & employee are available with Officer-in-Charge. Schemes and subsidies:Food and Medical Benefits :Employees Canteen (Employee & Supervisors) : Break fast with tea – Rs.0.50ps Lunch (Veg & Non Veg – Rs.1.50ps Snacks & tea - Rs.0.60ps Officers Lunch provided to the executives is subsidized by Rs.4.50ps Employee covered under ESI as per provisions of Employees’ State Insurance Act,1948. Employees (Out side the Purview of ESI):Domiciliary per head – Rs.2000/-pa Hospitalization self:– Actual Dependents @ 12000/- pa

Supervisors:Domiciliary one month Basic + DA Hospitalization self actual, Dependents @100000/- pa Officers :Domiciliary one month Basic + DA p.a. hospitalization – self & Dependents actual. Death Benefit cum Welfare Fund Scheme:This is a voluntary Welfare Fund Scheme under which member employee contributions at the rate of Rs. 4/- per month and the matching contributions is also paid from the Company. The object for this fund is to grant monetary assistance of Rs. 20,000/- to the nominee of the employee who expires whilst in service. Other benefits granted under the scheme are as follows :– Funeral expenses of Rs. 600/- to the nominee. Retirement benefit of Rs. 500/- (Only for retired members). Employees Assistance Programme:GSL, in collaboration with Krupa Foundation (NGO) and International Labour Organization has launched an Employees Assistance Programme to address the their personal problems like alcoholism, HIV and AIDS etc. The problems are addressed by means of : Individual Counseling. Group Therapy. Family Counseling. Self Help Group meeting (AA). Counseling for HIV & AIDS clients. Mental Health Concentration.

Employees requiring rehabilitation are referred to Krupa Rehabilitation Center (an NGO) at Anjuna. This programmed lasts for 3 months. Rs. 2,000/per month is given to the family as a subsistence allowance. Uniforms & Other Amenities:All employees/supervisors/officers are provided with uniforms, soaps, towels, monsoon gear, safety shoes etc.

Transport Facility:Transport facility is provided for all school going children of employees/supervisors/officers within VASCO city.

SERVICES OFFERED:GSL has the techno-commercial know-how in a whole range of marine products, enabling it to offer comprehensive services which encompass almost every activity that is connected with the total undertaking of shipbuilding contracts.

THE HUMAN FACTOR:Quality is ingrained in GSL'S work ethos. In fact, it surfaces even before production commences. This professionalism and work ethic of GSL's human resources is responsible for the Total Quality Management approach for all its shipbuilding projects.

TECHNOLOGY TRANSFER:-

Since its inception, GSL has accumulated a vast technical and scientific reservoir of know-how covering almost every type of service. TRAINING:The technology and scientific know-how is passed on in the training programs of personnel. A set of guidelines regulates and controls every detail of training procedures.

SHIP CONVERSION /MODERATION:Indeed, GSL is truly at the forefront of offering complete shipbuilding solutions. Today, the shipyard offers the facility of ship modernization and conversion which is fast gaining precedence over new construction. Services ranging from replacing weapons and sensors to reengineering and installing CCD (Camouflage Concealment and Deception) technology on platforms enabling combatants to increase the role worthiness and punch of existing platforms, exponentially. GSL also undertakes mid-life modernization and conversion of ships.

GENERAL ENGINEERING SERVICES:Scope of work:Controllable Pitch Propellers (CPP) System Marketing, Procurement & Sales of CPP Systems and spares Indigenization of CPP equipments & spares. After sales services and providing assistance to customers for vessels with stern gear systems supplied by acb LIPS now known as Jhon Crane Lips. In house Assy & Testing and tuning of CPP System, before supplying to the customers. Co-ordination in respect of design, manufacturing, inspection, supply of CPP Systems.

III.4.1.7 PRODUCTON AND UTILISATION OF RESOURCES:To design and build sophisticated ships for Navy and Coast Guard organizations with the aim of achieving self-sufficiency in this vital technology. To build commercial vessels like Offshore Supply Vessels, Oceanographic & Coastal Research Vessels, Fishing Vessels, Dredgers, Tugs, etc. To carry out ship repairs. To promote use of indigenous equipment such as computers, radar, communication equipment, auxiliary machinery, electrical fittings and domestic equipment. To substitute gradually indigenous equipment in place of imported equipment.

Social Objectives: To help build up a strong industrial base through development of

ancillaries. Encourage Scheduled Caste/Tribe persons by giving them preference in employment in the company and in the promotion of SC/ST employees as specified by the Government. · To ensure that the ecological balance is not disturbed due to industrialization, through pollution control, wherever required. · To reinforce Government’s efforts in promoting social justice to the people at large by formulating corporate policies on employment, welfare, workers’ participation, consistent with the Government’s policies. Promote use of Hindi as a medium of communication. Specialized Coastal Patrol Goa. Export Promotion & Import Substitution.

III.4.1.8 EMPLOYEE RELATIONSHIP AND WELFARE:To improve productivity by harmonious industrial relations. Promote welfare activities to raise morale of the employees. Promote development of managerial and technical skills of the Company’s employees through development programmers and technical training. Provide training to a large number of apprentices for absorption in the Company’s own unit and in other industries. To improve standards of safety with the help of a sound safety organization and training personnel at all levels in safety so as to reduce accidents and loss of man hours.

Raise Productivity by R&D and Quality Control:Maintain high standard of quality through strict quality control measures to the fullest satisfaction of the customer and to build up an image of the Company. Make sustained efforts for self-reliance through continuous R&D on extensive basis and develop viable design capability. Generation and maximization of internal financial resources for enhancing growth and maximization of the return on investment. Enhancement of the Company’s share in the total industrial output. GSL has the techno-commercial know-how in a whole range of marine products, enabling it to offer comprehensive services which encompass almost every activity that is connected with the total undertaking of shipbuilding contracts.

III.4.1.9 THE HUMAN FACTOR:Quality is ingrained in GSL'S work ethos. In fact, it surfaces even before production commences. This professionalism and work ethic of GSL's human resources is responsible for the Total Quality Management approach for all its shipbuilding projects.

Technology Transfer:Since its inception, GSL has accumulated a vast technical and scientific reservoir of know-how covering almost every type of service.

Training:The technology and scientific know-how is passed on in the training programs of personnel. A set of guidelines regulates and controls every detail of training procedures.

Quality Policy:The corporate Policy of GSL is to ensure total customer satisfaction for all its products and services at competitive prices on committed schedules while maintaining the highest quality standards. The exacting Quality Assurance Program of the Company has over the years been fine tuned to meet the rigorous defense and commercial quality standards. GSL's Quality Assurance Division, involved at every stage of production and testing process is responsible for all metrology, welding inspection, mechanical inspection and nondestructive testing. The Division is geared to undertake X-Ray, ultrasonic, dye penetration inspection and other non-destructive tests. Equipment used for inspection is checked and calibrated in GSL's laboratory.

III.4.2

SWOT ANALYSIS

Strength

1. An ISO 9001 Certified Company 2. World class CAD/CAM facility for basic design, simulation and advanced outfitting. 3. Unique distinction of implementing ERP for all functions. 4. A work force of over 1600 skilled personnel and over 200 qualified engineers and naval architects.

Weakness

1. Use of old obsolete machinery 2. Work force working is more in age very new young workers. 3. Not fully automated.

Opportunity

As government needs many ships and is providing huge funds for research and development there is good chance of rapid development. Also foreign countries are demanding ships and related instruments.

Threats

Many foreign companies are also trying to give India ships at a cheaper rate and also advanced quality and material, this is big threat.

III.4.3 OBSERVATION Observation1. Adequate safety measures are not provided to workers working 2. Machinery used is old and obsolete. 3. Lack of energy and enthusiasm. 4. Workers are hard working.

5. Some machines which are very rarely used are also there. 6. Quality provided is the best one. 7. Good quality raw material is used. 8. Products manufactured are durable and long lasting and provide customer satisfaction. 9. Workers working are completely satisfied.

III.4.4 RECOMMENDATION AND SUGGESTION
1. Should go for constant research and development. 2. Should use modern and hi-tech machinery. 3. Should always do motivational activities.

III.4.5

CONCLUSION

It was a very wonderful experience to visit such a big and government and shipping industry. A more than regular knowledge was achieved something different was known. Overall it was the best industry.

CHAPTER – IV BIBLIOGRAPHY AND ANNEXTURE

IV.

BIBLIOGRAPHY AND ANNEXTURE

SOURCES OF DATA COLLECTED
1. www.google.com 2. www.theubgroup.com 3. www.bisleri.com 4. www.ionindia.com 5. www.goashipyard.co.in 6. Britannica Encyclopaedia 7. Business World 8. Business Today 9. Economic Times 10. Forbes Magazine, etc.

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