CHAPTER I

INTRODUCTION

1.1 INTRODUCTION ABOUT THE INDUSTRY

In World, we are living differ from other planets because of water. Every living creature
needs water as envisaged by Sage Thiruvalluvar that signifies ‘There will be no world if there
is no water’. Increase in population, per capita consumption, industrial activity, agricultural
operation, environment necessity, hygienic condition and a host of other processes add the
demand day by day. Nature provides us usable water by means of rain, river and snow. Earth
stores it over the surface and under the soil. Stored water can be brought to the beneficiary’s
place by the use of pump only. Hence in everyone’s life pump is indispensable. Because of its
importance, and it still occupies the second place as the largest manufacturing engineering
products in the world. Where Of course first being the motor which drives the pump.

1..2 INTRODUCTION OF ORGANISATIONAL STUDY

Organizational study is an effort towards understanding the organization, its policies,

structure, hierarchy, its functions and methodology adopted. It gives us brief descriptive of the
overall functions of the company.

IMPORTANCE OF ORGANIZATIONAL STUDY

To understand the nature of the business carried out and working environment of the
organization.

The study encompasses the systematic and careful application of knowledge about how people
perform their work and task within organizations.

OBJECTIVE OF THE STUDY

 To understand the structure and functioning of the organization.

 To under stand the delegation of authority and responsibility.
 To understand the various policies and programs of the organization.
 To understand the inter-department relationship of various department in the
organization.

1
 CHAPTER 2

COMPNY PROFILE

Name: Terra pumps pvt ltd.

Address: No.472, Maniyakaranpalayam Road,

Sridevi Nagar, Coimbatore – 641 006.

Phone No: 93601 12352

Mail Id: [email protected]

Type of company : private

Name of the proprietor : Mr.Saravanan

Year of established : 2001

Mission

Vision

BACKGROUND OF THE INDUSTRY

Water pumps which is already second in market is growing at a significant pace in India.
Demand for water pumps in the country is proliferating due to rigorous growth in agriculture

2
and other water intensive industries. Government of India has introduced various policies to
assist the growth of agricultural output in the country. These policies vary from subsidized
electricity to exemptions by use of solar water pumps. The announcement of such kind of
policies has inspired farmers within the country to install independent irrigation facilities to
make a consistent availability of water. Consequently, these schemes are also directly pushing
the demand for water pumps in India and where Agriculture sector is dominating in Indian
economy as it accounts for over 53% share of country’s total work force. Declining water
level and rising per capita water demand are major challenges being faced by population
associated with agriculture sector and its related segments. On the other hand, per capita
water availability has reduced to about one third since 1940, resulting into growing demand
for water pumps and necessity of water, where agriculture water pump is the leading
segment. Other factors such as rising urbanization, infrastructure investment and
industrialization (especially in water & waste water, oil & gas sectors) are also driving the
water pumps market. Urbanization in India has been witnessing strong growth, where urban
population is further forecasted to be increased from 290 Million in 2002 to 500 Million by
the end of 2017. Export segment of water pumps have also grown immensely during past
few decades.

According to “India Water Pumps Market Forecast & Opportunities, 2018” Indian
water pump market revenues are expected to grow at the CAGR of around 13% between
2013-18. Indian water pumps market is segmented into two categories that is Positive
Displacement pumps and Centrifugal pumps, where centrifugal pumps market is
dominating. The leading companies operating in water pumps market in India are Kirloskar
Brother Limited, KSB Pumps, CRI Pumps, and Shakti Pumps. Increased energy crisis and
government regulation are motivating water pump manufacturers to develop energy efficient
products. States such as Gujarat, Tamil Nadu and Maharashtra has strong industrial base,
hence, leading in demand for industrial pumps, while Punjab and Uttar Pradesh are
agriculture based states and consequently agricultural pumps are more in demand from these
states.

CONTRIBUTION TO ECONOMY

Pumps contributes significantly for the growth of the Indian economy. They have proved high
criticality in productivity of the core sectors of the economy. The Pumps sector has a net value
addition ratio in manufacturing of over 20 per cent in following years. India already exports

3
Pumps worth over US$ 1.55 billion, serving various engineering segments and to over 100
countries. The exports in pumps segment are growing at a healthy rate of around 10-12 per cent
annually. Additionally the Indian market is already worth over Rs 5,000 crores in pumps & Rs
4,500 crores in valves. India is already selling & supporting niche scientific & engineering
technologies to developed economies in areas such as in aerospace engineering, auto
components, biotechnology etc.

Today India has attained near self-sufficiency in Pumps for Nuclear Power, complete self-
sufficiency in captive power generation, pulp & papers, energy efficient pumps in utilities &
in the agriculture sector. Considerable manufacturing segment of this sector is focusing on
catering latest application in Bio-Pharma field, such as of Infusion Pumps.

Given the fact that among ‘machineries’, pumps are said to be produced and used in largest
numbers, second only to electric motors. The overall scenario in Indian economy also favours
growth & development in Indian Pumps & Valves industry, thereby opening huge potential of
international collaborations.

CHALLENGES

Indian pump exporters are facing intense competition from the foreign counterparts in catering
to global needs. In the recent years, the Indian pump industry has been forced to be proactive
with foreign players bringing in superior pumps to the market. The domestic industry today is
in fact looking up for overseas opportunities and quite a few have also made a good impact in
the international scenario. In order to identify the problems faced by the Indian pump exporters,
a specific study has been made on the global marketing strategy adopted by the Indian pump
manufacturers

 The players operating in the market facing some acute challenges like governmental
policies, taxation regime and lack of investments which are hampering their
development
 Agricultural power subsidy & farmer sops pose a major hindrance in market growth
Consumer outlook prevalent in the market is another major challenge
 Rise in cost of inputs act as a major bottleneck in the development of the Indian pump
industries
 Initiatives and regulations prevalent in the market too have an impact on the growth
and development of the industry

4
  Threat from unorganized players
 Increase in raw material prices
 Low awareness amongst farmers

MARKET SIZE

The pump market in India is valued at INR 5,490 crore in 2010, and it is expected to reach INR
12,330 cr. by 2014, growing at a Compounded Annual Growth Rate (CAGR) of 22 percent5.
The pump industry is composed of a large number of Small Scale Industries (SSI) units, large
manufacturers and many overseas manufacturers. The industry is fragmented, with the
presence of both organised and un organised players, and competition from international
companies who have set up their base in India. Indian pump manufacturers appear to
completely fulfill the domestic demand for pump usage, with more than 600 manufacturers
producing around 1.2 million pumps annually. The industry is balanced in terms of demand-
supply, with domestic companies meeting 95 percent of the requirements and imports
constituting the remaining 5 percent

In India, pumps are used in the domestic, industrial and agriculture sectors. The Indian
agriculture sector is the largest consumer of pumps, with pumps being used in several
applications such as irrigation and water distribution; in the industrial and domestic sectors,
pumps are used for water supply, sewage, chemical supply, etc.

Agriculture: The agriculture sector is the largest contributor to the total demand for pumps and
accounts for approximately 35 percent of the total pump market in India. Currently, the
agriculture sector is characterized by the penetration of low-cost pumps. Various policies and
subsidies by the government to promote the use of efficient and quality pumps are likely to
boost the demand for agricultural pumps. Industrial: The industrial sector contributes around
35 percent market share for the pumps sector9. Since pumps represent the largest single use of
electricity consumption in industries (approximately 31 percent) 10, the focus in this segment
is on high quality pumps, with regular upgradation to the latest technologies. Pumps find
application in various industries, including oil & gas, power projects, chemical, food &
beverage, marine applications, pulp & paper, pharmaceutical etc. With a large number of
projects in the pipeline, the power sector is expected to prove a major demand driver for
pumps11. Domestic: The market share for domestic pumps share is relatively low at 30 percent,
as compared to agricultural and industrial pumps12. Pumps, in this segment, are used for public

5
water supply, sanitation, household utilities and business establishments. The emerging middle
class and the continuous movement of population towards metro cities are expected to drive
the growth of pumps in this segment.

MAJOR COMPETITORS

C.R.I PUMPS Pvt .Ltd

AQUA GROUPS

KSB GROUP

TEXMO IDUSTRIES

SUGUNA MOTORS AND PUMPS

COMPANY PROFILE

HISTORY

Terra is the typical ancient form of Tamil word ‘THEKKANAM’ meaning south and was
started in the year -1981 primarily to manufacture submersible pumps for bringing out the

6
underground water through the bore wells. The company Terra Industries was the first
company to exclusively manufacture submersible pump sets Terra submersible are first in
Coimbatore to obtain ISI marking and license .For all his achievements our founder was
honored with Six National awards including the “UDYOG PATRA” from the honourable
President of India. It is needless to say that ‘Green Revolution’ and ‘Food Sufficiency’ as
claimed by us, is now possible only because of the installation of large quantity of pump sets,
especially the submersible pump sets category. The promoters of ‘TERRA’ are all well
qualified Engineers and had very good experience and expertise in the field since 1972.

The company's vision is 'Service to Mankind' by way of providing energy efficient products
with in-house technology and designs to serve agricultural and domestic consumer community.
The company also has sister concerns namely, 'Marks Industries', 'Terra Pumps Private
Limited' and 'Terra Enterprises' that are involved in manufacturing and trading activities.
Each product manufactured by the firm has established itself successfully in the competitive
market scenario, because the company's core competence is 'Product differentiation'

VISION AND MISSION

The company Terra with its vision 'Service to Mankind' and its mission as “A new
perspective in pump design” set by their founders is their motivation to continually develop
and improve in their growth.

PRODUCTS

 Terra Borewell Submersible Pumpsets for 100 mm Bore wells (4”)

 Terra bore well Submersible Pump sets for 130 mm Bore wells (5”- 4” Combination)
Terra bore well Submersible Pump sets for 130 mm Bore wells (5”)
 Terra bore well Submersible Pump sets for 140 mm Bore wells (5.5”)
 Terra bore well Submersible Pump sets for 150 mm Bore wells (6”)
 Terra Closed Couple Submersible Pump sets
 Terra bore well Submersible Pump sets for 180 mm Bore wells (6”- 7” Combination)
 Terra bore well Submersible Pump sets for 200 mm Bore wells (6”- 8” Combination)
 Terra bore well Submersible Pump sets for 200 mm Bore wells (8”)
 Terra Bore well Submersible Pump sets for 240 mm (V10), 280 mm (V12), 330 mm
(V14) Bore wells

7
  Horizontal Split case Pump sets (HSC)
 Vertical Turbine Pump sets (VT)
 Terra Submersible Motors - NEMA Standard
 Stainless Steel Submersible Pumps
FINANCIAL PERFORMANCE

The organization was started in the year 1981. Quality alone was the ultimate goal at that time.
Since submersible manufacturers was not that much popular and competitive, the growth of
the company was not affected. Indeed the need for submersibles increased rapidly due
to the increase in the need for water.

Ground water levels went very low such that conventional motors like
monobloc’s could not draw water from a depth more than 30 feet. The growth in the
early stages of the company is marked with their quality and market monopoly of open
well submersibles.

During the mid’s the company policies such as dealership policy and distribution
policy was very attractive, so the dealers were able to easily get done their needs from
the company so as to cater their customers. The company realized the competitive
market as no submersible manufacturers are in the field. In order to cater their dealers
and customers the company has amended its policy so as to strengthen their services
such as timely delivery, zero stock at dealer point, twelve hours clearance of serviced
warranty and after warranty pump sets. This effectiveness they have achieved by adopting
the modern administrative tool ISO. Since accredited as an ISO company in the year
2000, the company’s growth is remarkable as the staff, the worker and the whole the
company itself is driven by the ISO system.

PLANT AND MACHINERY

The company is installed with all modern and precise machineries required to
manufacture the pumps in high caliber. Most of the works are done in the factory itself by using
CNC machines. Special purpose machines are used to do jobs of intricate nature.

8
Interchangeability of components and suitability of spares are the main criterion in the shop
floor. Jigs and fixtures are freely used to keep the standards and productivity. Utmost care is
taken in the planning stage itself to keep the rejection at the lowest level and also to get the job
done in minimum time with less effort. Computers are installed at every stage to monitor the
processes. Generators of adequate capacity are installed for uninterrupted power supply.
Instruments of high accuracy are used along with standard gauges for inspection. Efficient
engineers are provided at each level to monitor and also to contribute their knowledge for
continuous improvement. Testing benches more than the required are installed for taking care
of each and every pump set for its performance and longevity.

QUALITY ASSURANCE

The company is adopting the Quality management system ISO-9001 duly certified and
monitored by KPMG - the quality registrar approved by the American Society for Quality. BIS
standard marking IS 8034 applicable for bore well submersible pumps, IS 14220 applicable for
Open well submersible pumps, IS9283 applicable for submersible motors and IS 9079
applicable for moonset pumps are the other quality certificates obtained by the Company. As
many as 367 models having the rating between 0.37kW to 90kW are covered in the BIS
certification markings. TERRA is having the prestige of holding more models in manufacturing
of pumpsets with BIS markings than any other industry. As the energy is becoming costlier
day by day TERRA is making only energy efficient pumpsets benefiting both the customer and
the country.

TERRA is the first in India to obtain IS 14220 certification mark assigned for open well
submersible pumps. Some models of pumpsets in the market itself are called ‘TERRA’ types
and from that the supremacy of TERRA can be ascertained. TERRA jet pumps require no
control valve and it is the discovery of ‘TERRA’. Similarly TERRA occupies forefront in many
designs and developments.

REGISTRATION

The company’s products are approved by many Government and Quasi Government
departments. Notable among them are Tamilnadu Water Supply and Drainage Board, Kerala
Water Authority, Karnataka SC & ST cooperation, Panchayat Raj, department of Andhra
Pradesh, Indian Railways, Central Public Works Department of India. Airport Authority of

9
India and Maharashtra Jeevan pradhikaran. The company is a member in the Engineering
Export promotion Council of India.

A few other bodies in which membership shared are Confederation of Indian Industry,
Indian Water Works Association, The Indian Chamber of commerce and Industry and Southern
India Engineering Manufacturers Association. All technical journals of world class connected
with motor, pump, Electricity etc... are subscribed. A library housing the books related with
technology, standards, management etc... are has also been put up in the premises for reference
and guidance.

CREDENTIALS

The company is awarded with as much as six numbers of National Awards for its
Quality and Humanity Service. Dr. Shankar Dayal Sharma then President of India presented
‘UDYOG PATRA’ award, Dr.Raby Roy – then Loksabha Speaker presented ‘LOKSHREE’
award and Mr. Ramvilas Paswan then Minister for Labour for Government of India presented
‘UDYOG SHREE’ award. The highest honour the TERRA believes is the reputation it has
earned among the millions of its users, vendors and well wishers. TERRA will keep this high
esteem empowered on it forever.

ORGANISATION STRUCTURE OF TERRA PUMPS PRIVTE LIMITED

10
 MD JMD

UNIT-1 UNIT-2 UNIT-3 MANAGER

MANAGER
MANAGER MANAGER MANAGER  PURCHASE
 ADMIN
 SYSTEMS
 ACCOUNTS
PRODUCTION PRODUCTION PRODUCTION  SALES
 DESIGN

 OFFICE  OFFICE
ASSISTANTS ASSISTANTS
QA
 ACCOUNTANTS QA QA
 SYSTEM
 DESIGN ENGINEERS PROGRAMMER
ENGINEERS ENGINEERS
ENGINEERS
 AREA SALES
EXECUTIVES

SALES
JUNIOR JUNIOR JUNIOR
ASSISTANTS
ENGINEERS ENGINEERS ENGINEERS

WORKERS WORKERS WORKERS

SKILLED SKILLED SKILLED

DESPATCH
SEMI SKILLED SEMI SKILLED SEMI SKILLED CLERK
APPRENTICE APPRENTICE APPRENTICE

11
 4. OVERVIEW OF FUNCTIONAL DEPARTMENTS

4.1 MARKETING DEPARTMENT

The marketing department is responsible for creating, preparing, and establishing marketing
strategies and policies for each title by coordinating the efforts of publicity, promotion,
advertising, online, and sales.

MARKETING MANAGER’S ROLES AND RESPONSIBILITIES

 Preparing all sales presentation materials: audio recordings, fact sheet collation, and
promotions.
 Creating and producing additional account-specific presentation materials.
 Creating pricing strategies.
 Researching and establishing relations with new markets.
 Planning and maintaining sales and marketing schedules, including title launch and
planning meetings.
 Measuring the effectiveness of strategies once completed.
 Development of marketing goals and strategy.
 Conducting marketing researches and monitoring customer needs.
 Promotion and advertisement.

4.1.2 MARKETING RESEARCH ACTIVITIES

The marketing department design suitable formats to procure feedback, suggestions and
complaints periodically based on the earlier analysis reports. Feedback of the customers is
collected through market survey, Questionnaires or Direct Meeting with customers
(Product Rating Form).

The operations are classified as,

 FEEDBACK PLANNING
 FEEDBACK
 ANALYSIS
 FEEDBACK ANALYSIS REPORT
MARKETING & DISTRIBUTION STRUCTURE

12
  The marketing department is responsible for creating, preparing, and establishing
marketing strategies and policies for each title by coordinating the efforts of publicity,
promotion, advertising, online, and sales.
 TERRA pump sets are sold throughout India and abroad by its distributors and dealers.
The branches owned by the company are used for stocking, imparting technical
knowledge among the users, dealers and fitters, providing service backups and passing
the advice, suggestions and criticism from the end users to the concerned authorities for
improvement and upgrading. The job of TERRA will not end with the sales but also to
see the customer is benefitted maximum out of it. The customer care is taken in keeping
the pump set with minimum maintenance.
 Every effort is taken to accommodate the standard components available in the market
to off-set the delay in getting from the source. It is the policy of TERRA that customer
should not suffer because of spares. Apart from that the spares for pumpsets even for
the models that are produced 15years back will be available at the factory. As a gesture
TERRA can arrange for its customers the other accessories required for pumpsets such
as control panel, cable, pipes and installation works at minimum cost.

PRODUCTS PROFILE

Submersible Pumps

A. For Borewell Pumps

 Available in various size for 80mm, 100mm, 140mm, 150mm, 200mm, 250mm
and above dia borewells.
 The rating of power ranges from 0.37KW TO 90KW.
 The other pumpsets with rating offered for agricultural and water supply
schemes are 2.2KW TO 66KW.
 Suitable for continuous operations.
 Consumes less power.
 Vibration free and noise less operations.

B. For Openwell Pumps

 Available in vertical and horizontal type pumps.

13
  2.2KW to 15KW in case of agricultural moonset pumps.
 Horizontal type is suitable for low head operations and vertical types is for high
head operations.

C. For Minipumps
 For domestic use and gardening purpose the types of pumpset manufactured and
their ratings are, ‘Sub-Sevak’ mini submersible pumps from 0.37KW to 2.2KW.
 For ‘TINY’ submersible pumps in 0.37KW end 0.75KW.
 Deep Double Stage Jet Pumps from 0.37KW to 1.5KW.

Monoblock Pumps

A. Centrifugal Monoblock Pumps

 It is also called as a Domestic Centrifugal Pumps from 0.37KW to 1.5kw.
 DSM-Suction Monoblock PUMPS in 0.37KW and 0.75KW and.
 Double Stage Centrifugal Monoblock from 0.37KW to 1.5KW.
 Excellent performance even at low supply voltage.

B. Mini Mono block Pumps

 For ‘ZIP’ Mini Mono block in 0.18KW and 0.37KW.
 Very compact and light weight.
 Foot value is not needed.

For large volumes and low heads ‘Fish Pond’ pumps are also manufactured. Beside
those the company is having the capability to manufacture pump set of any nature and
specifications. Pump sets for different voltages, different frequencies and dual voltages are
manufactures regularly.

PRODUCT FEATURES

 All the motors manufactured operate at very Low voltages and are specifically designed
to withstand the wide voltage fluctuations prevailing in rural areas.

14
  The company offer submersible pump sets for agricultural use that are specially
designed, to save energy for operations under 240/460 Volts single phase power system.
 Absence of control valves in jet pumps.

 Mini submersible pumps fitted with as many as 10 impellers help develop higher heads
to use in flats etc. contrary to monoblocs which has only one impeller.

 Absence of threaded joints in both pump and motor to facilitate for easy dismantling
and assembling during service.

PRODUCT PRICING

S.NO PRODUCTS PRICE

1 Terra Bore well Submersible Pump sets for 100 mm Bore wells (4”) Rs 13,299*
2 Terra bore well Submersible Pump sets for 130 mm Bore wells (5”- Rs 14,699*
4” Combination)
3 Terra bore well Submersible Pump sets for 130 mm Bore wells (5”) Rs 18,437*

4 Terra bore well Submersible Pump sets for 140 mm Bore wells (5.5”) Rs 20,588*

5 Terra bore well Submersible Pump sets for 150 mm Bore wells (6”) Rs 17,620.00*

6 Terra Closed Couple Submersible Pump sets Rs 25,398*

7 Terra bore well Submersible Pump sets for 180 mm Bore wells (6”- Rs 29,945*
7” Combination)
8 Terra bore well Submersible Pump sets for 200 mm Bore wells (6”- Rs 49,468*
8” Combination)
9 Terra bore well Submersible Pump sets for 200 mm Bore wells (8”) Rs 68,501 -
82,638*
10 Terra Bore well Submersible Pump sets for 240 mm (V10), 280 mm Rs 53,910 -
(V12), 330 mm (V14) Bore wells 85,246*
11 Horizontal Split case Pump sets (HSC) Rs 68,000 –
1,00,000*
12 Vertical Turbine Pump sets (VT) Rs 40,000 -
70,000*

15
 13 Terra Submersible Motors - NEMA Standard Rs 8,000 –
16,000*
14 Stainless Steel Submersible Pumps 14,000 -30,000 Rs 14,000 -
30,000*

ADVERTISING OF TERRA PRODUCTS

They advertise their products through dealers meeting, wall paper advertisements, paper
advertisements. At present, the organization is engaged in radio advertisements.

16
FINANCE DEPARTMENT

The business of a finance department typically includes planning, organizing, auditing,

accounting for and controlling its company’s finances. The finance department also usually
produces the company’s financial statements.

Department process flow chart

GM Accounts

Manager accounts

Asst.Manager Accounts

Accountants

HUMAN RESOURCE DEPARTMENT

TERRA gives more importance to its team members it possesses, believes that an
organization is mainly recognized by the team rather than the buildings and machines it houses.
The team is imparted with the training both related with the technology and personality.
Everyone is empowered with the liberty to give expression. Criticism and suggestions are
welcomed equality. The worthy will be implemented.

DEPARTMENT PROCESS FLOW CHART

Recruitment

Selection

Training &
Development

Performance appraisal

Compensation

17
ROLE OF HR MANAGER & DEPARTMENT

 Compensation management
 Benefits evaluation and administration
 Recruitment and talent acquisition
 Training and development
 Performance appraisal and management
 Employee labour relations
 Provides expert HR advice to the business by working in a consultative
approach with key internal stakeholder/s to ensure business alignment. Identify
key organizational issues and take corrective actions to resolve issues.
COMPENSATIONS

Apart from the statutory obligations every one is given the medical claim for the
accident that may occur inside or outside the premises irrespective of the nature. Preventive
vaccination is also done by conduction special camps. On many occasions the team members
have offered voluntary blood donations.

A sports club is also functioning in the premises and it has participated in many tournaments
and brought some laurels to the company. Every team member’s family is invited for a dinner
and get-together at least once in a year preferably on a festival day for getting a better
interaction. An atmosphere is created in everyone’s mind that the company’s interest is the first
than the one’s self.

4.3.3 TRAINING AND DEVELOPMENT

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

training and it’s responsible for all the training activities in the company. All the staffs and
workers are assessed on their capability and performance in the company and suitable training
is imparted to meet the modern trend.

The top management, the department head, and the personnel himself assists in
identifying the requirement for training of selected employee or staff, to ensure that activities
performed by them are up to the quality mark and makes a request to the manager, training.

The training manger assesses the need for training with the help of the documented
reports and if he finds necessary, arranges for training with the confirmation from the MD. The

18
suitable faculty (in-house or external) handles the class to impart the necessary training.
External training conducted by reputed institutions, is also attended by the staff on the approval
of the MD, recommended by manager, training.

The feedback about the training is obtained from the trainee detailing the faculties’
performance, arrangements and other information. This serves as document of reference for
the organization to improve the quality of training in future. The training manager maintains a
record of all internal and external programmers and details of the participants who participated
in training. The trained participants are evaluated on their performance by the end of the
training or after a particular period and a report of the same, submitted to the MD.

The training manager also takes care of the Inplant; Institutional, on-job training
imparted to college students, diploma and I.T.I certificate holders. They extend this facility to
the students to maintain a good rapport with the colleges and other educational institutions.

The training process are classified as,

 REQUIREMENT IDENTIFICATION
 REQUEST ASSESEMENT & APPROVAL
 TRAINING
 TRAINING REPORT
 TRAINING APPRAISAL
 TRAINEE REPORT
The Manpower requirement identified by the top management or department heads
with a view to ensure the activities are performed to the designed quality system is forwarded
as a requisition for manpower to the manager, training for further action. The manager, training
is responsible for recruitment process also.

The training manager assesses the need with assistance from concerned department
authorities and on conformance prepares a document detailing the required skills, eduction,
experience etc. and proposes the same for the MD’s approval.

The training manager identifies the suitable candidates and calls for a personal
interview, by a perusal of CV’s.The CV’s are gathered by means of data bank, advertisements,
word of mouth, reference etc. The interview panel is formed by suitable persons to conduct a
formal interview.

19
 The panel interviews the candidates and selects suitable candidates in accordance to the
requirements. A consolidated report is generated by the manager, systems based on the panel’s
statements. Selected candidates are appointed after the approval of MD.

Candidates, if necessary should undergo training for a prescribed period of time. The
recruitment process and the result details are prepared as report with the attachment of the panel
statements and the same is presented for MD’s reference.

4.3.4 RECRUITMENT & SELECTION

The recruitment processes are classified as,

 MANPOWER REQUIREMENT IDENTIFICATION

 REQUEST ASSESSMENT & APPROVAL
 INTERVIEW CALL
 RECRUITMENT
 REQUIREMENT REPORT

4.3.5 WELFARE ADMINISTRATION

The company has the unique distinction of constructing a huge pump for rain water harvesting.
Modern methods are used for stocking and handling and even the raw materials are stored in
the stock yard pallets. And the medical claims and insurance are provided in case of any
accidents to the employees during the work time.

EMPLOYEE BENEFITS

Terra pumps private ltd includes various types of non-wage compensation provided
to employees in addition to their normal wages and salaries. Certain benefits in Terra
industries include housing for the higher grade officers employees in the company, group
insurance ,health, life ,disability income protection, retirement benefits, sick
leave, vacation including both paid and non-paid. The purpose of these employee benefits is
to increase the economic security of staff members by doing so they ensure in improving
worker retention and increase in productivity in the organization. Often, perks are given to
employees, free refreshments, leisure activities on work time.

20
SALARIES AND WAGES STRUCTURE

There are around 200 to 250 employees in Terra pumps private limited including the top grade
managers to the lower level semi-skilled labours and apprentices and their salary and wages
structure are varied depending on their experience and the designation

Executives’ salaries ranges from ₹20k - ₹30k monthly

Engineering Marketing Executive ranges from ₹13k - ₹17k monthly
Diploma Holder Mechanical Engineer ranges from ₹11k - ₹12k monthly
Semi-skilled labours ranges from 7K – 10k monthly

Employee Benefits
Terra pumps private ltd includes various types of non-wage compensation provided
to employees in addition to their normal wages and salaries. Certain benefits in Terra
industries include housing for the higher grade officers employees in the company, group
insurance,health, life ,disability,income protection, retirement,benefits,sick,leave, vacation in
cluding both paid and non-paid. The purpose of these employee benefits is to increase the
economic security of staff members by doing so they ensure in improving worker retention
and increase in productivity in the organization. Often, perks are given to employees, free
refreshments, leisure activities on work time.

PRODUCTION AND OPERATIONS DEPARTMENT

PRODUCTION DEPARTMENT

The production department coordinates the production and manufacturing of each title.
Production acts as a liaison between editorial, managing editorial, design, production, and
outside vendors to create and distribute the final product.

The Production is the most important department in the organization and is paid utmost
attention. The Employees involved in production adhere to the organization on contract basis
and are paid based on the number of pump sets they manufacture.

21
 The production of the components are carried out using both CNC and lathe machines.
The CNC machines are imported from Korea and are used in case of mass production and the
Lathe machines are obtained from Kirloskar. Two CNC machines are operating in the main
unit, one with single spindle and the other double spindled. In the case of double spindled CNC
machine, two separate processes are carried out and two separate monitors are there to control
them. Auto door function is also there in double spindled CNC machine. The CNC machines
are provided with the conveyor for collecting the chips and these chips are reprocessed into
components whereas the ordinary lathe machines are not provided with the conveyor and the
chips collection is performed manually.

PRODUCTION DEPARTMENT PROCESS FLOW

22
 MD JMD

UNIT-1 UNIT-2 UNIT-3

MANAGER MANAGER MANAGER

PRODUCTION PRODUCTION PRODUCTION

QA QA
QA
ENGINEERS ENGINEERS
ENGINEERS

JUNIOR JUNIOR JUNIOR

ENGINEERS ENGINEERS ENGINEERS

WORKERS WORKERS WORKERS

SKILLED SKILLED SKILLED

SEMI SKILLED SEMI SKILLED SEMI SKILLED

APPRENTICE APPRENTICE APPRENTICE

ROLES AND RESPONSIBILITIES OF PRODUCTION DEPARTMENT

23
  Trafficking of all materials between design and editorial/managing editorial.
 Following up on late and/or special schedules.
 Estimating of paper quantities and production costs.
 Negotiating with suppliers.
 Assisting on special projects as necessary.

PRODUCTION-PROCESS

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

taking into account the previous week productions pending order and stocks. Materials needed
to produce as per production plan are acquired from the stores and issued to the operator and
the same is recorded in in process inspection note book. The inspected finished components
are stocked in stock yard/stores as suitable.

The production process are :-

 PRODUCTION PLAN
 QUALITY CONTROL
 ACQUISTION AND ISSUE OF MATERIALS
 PRODUCTION
 STOCKING OF FINISHED GOODS

RECEIVING AND PROCESSING ORDERS

Orders from customers are received personally or through phone, fax, or email. Order details
are entered in the order transfer form in the system with the details such as customer name,
their requirements including model. The form is sent for financial approval to the joint
Managing Director.

On JMD’s approval, the order is checked for its adequacy of requirement. If the
requirements of the order are adequate, order is procured with order information, customer
details, items, quantities and shipment details. The delivery schedule is obtained from the
production engineer and communicated to the customer through established means of
communication.

24
 If the financial approval from the Joint Managing Director is not obtained in favor,
customers are communicated over phone or mail about their credit rating, and the order is kept
pending until the commercial terms are sorted out. In certain circumstances JMD may not
despatch pending till approved and send the form further.

If the requirements are found to be inadequate, and when discrepancies are found on
special requirements, the customers are contacted to verify requirements. Special requirements
are evaluated by the MD to ensure that the company can comply. Special requirements/changes
are noted on the form. The form is then sent to the respective department.

The same process is repeated when there is need for any amendment.OTF is then issued
to the production and assembly is scheduled.

ASSEMBLY PROCESS

The schedule is prepared according to the OTF Stocks of the finished product, store
stocks and machined components are taken into account. Based on the schedule, production
log book entry is done by production engineer. Pump assembly details work instruction are
also included in the production log book entry.

The pump and motor are assembled based on the procedures. The fitter ensures the
perfect functioning of the product. Pump Serial No. is generated by the pump fitter. Motor
Serial no. is generated by the welder at the initial process. Then it goes for final inspection.

The assembly process are as follows,

 PRODUCTION SCHEDULE
 PUMP ASSEMBLY DETAILS WORK INSTRUCTIONS
 PRODUCTION LOG BOOK ENTRY
 ASSEMBLY OF PUMP/MOTOR
 FINAL INSPECTION

MAINTENANCE

All machinery requires preventive and routine maintenance at regular intervals as

detailed in preventive maintenance and machine accuracy. Out sources are called referring to

25
the machinery history note book, and preventive maintenance action is performed. The
accuracy level for each machine is verified each time at the time of maintenance.

CNC operators handle the programming errors, if any. As preventive maintenance is

adopted, complete breakdown of the machines are avoided at the maximum. Contractors are
there to carry out the maintenance. Apart from all these, daily maintenance of the machines is
performed by the operators such as oiling, cleaning, etc.

The operations are classified as follows,

 MACHINERY MAINTAINED
 PREVENTIVE MAINTENANCE

QUALITY CONTROL TECHNIQUES AND PROCEDURES

Quality control is a process employed to ensure a certain level of quality in a product

or service. The basic goal of quality control is to ensure that the products, services, or
processes provided meet specific requirements and are dependable, satisfactory, and fiscally
sound.

MATERIAL INWARD INSPECTION

The MIRI (Material Inward and Receiving Inspection) holds the name of the material
received, vendor details, the purchase order placed, purchase document details. An oral
requisition from the stores department on the receipt of material initiates the process. The stores
department prepares and issues the MIRI document which stands a format for QC.

The inspection is carried out by the QC engineer according to the Receiving Inspection
Method and Frequency and the test results are recorded in the MIRI. The monthly inspection
status report is prepared by the QC Engineers detailing the rejected materials, vendor etc.

The operations are classified as,

 MATERIAL INWARD AND RECEIVING INSPECTION

 INSPECTION REQUISITION
 INSPECTION
 MONTHLY INSPECTION STATUS
 PRODUCTION AND QA

26
INPROCESS INSPECTION

The in process inspection sheet details the production to be carried out as per the
requirements from the production engineer. The sheet generated marks the start of the in
process inspection and the QC Engineer is the responsible for the process.

The QC engineer checks for quantitative correctness of the materials issued to the
operator. Following the relevant documents, the QC records the proceedings like M/c setting,
tools issued to the operator in the in process sheet.

The QC engineer checks the first piece as per the process setting and records the name in
in process inspection sheet. The QC engineer checks the components as per in process
inspection frequency and records the following details

a. Quantity inspection
b. Quantity accepted
c. Nature of rejections and Quantity in the In process Inspection Sheet and inspection
status (blue/green color) is marked on the component by QC engineer.
The QC engineer prepares the consolidated in-process Scrapped Material Report, Rejection
Details Report and the components are sent to the stores.

The operations are classified as,

 INPROCESS INSPECTION SHEET

 INITIATION
 M/C SETTING AND TOOLS INSPECTION
 FIRST PIECE INSPECTION
 ROUTINE INSPECTION
 INSPECTION REPORT
 STORES

FINAL TESTING
The products which are finished goods are taken into the various final testing process in order
to check the proper working and in case of any defects in the product and the process includes

27
Initiation

The final testing OK certification is a statutory requirement before the products are
dispatched. This effected once the assembly is completed.

Test Type

a. REGULAR TEST

b. ISI TEST

Regular Test

The regular test is carried out as per final test plan by Calibration and Testing
Engineer/Production Engineer. The results are recorded in Test Record Note Book.

Isi Test

ISI test is carried out as per BIS procedures by Calibration and Testing
Engineer/Production Engineer. The test results are recorded in Terra Test Report Note Book.

Conformance

If the test results are found OK, the final product is tagged OK, before which it is set for painting
and finishing.

Non Conformance

If the test results are non-satisfactory, the n/c final test is recorded in Final Inspection N/C
Register and the product is returned to assembly for rectification. The production stands the
same till it is tested OK. The testing details are maintained in the system also. It includes
production number, body number, model, HP, phase, sanguard size, opening amps, maximum
amps, closing amps, etc.

DESPATCH

After the tests the motors and pump sets are then set for dispatch of the products with certain
procedures

28
Initiation

The final product is dispatched on the produce of invoice or other supporting

documents.

Final Check

Final product is checked for corrective ness of production no., tested OK tag, name
plate etc. with reference to the invoice or other supporting documents.

Forwarding Note Preparation

The forwarding note is prepared if necessary, for those sets dispatched through private
and public transporters.

Out pass generation

The Out pass is generated as a final document to dispatch the products with reference
to the invoice or other supporting documents. The out pass prepared through the system
encompasses the following

 Customer details
 The product details
 Quantity details
 OTF details
 Production No. details
 Packing Details
 Transporters Details
The out pass also serves as a checklist for despatch.

System is designed to generate dispatch day reports, dealers, offtake, modelwise offtake,
pump sets query (if production number is given, the details of the set is displayed).

Calibration

All measuring equipments used for quality decision at company is calibrated on a

scheduled basis according to the Instrument History Card. This includes standards that are used
to verify instruments. Approved outsource are identified and master list is maintained various
instruments and the calibration procedures.

29
 The instruments after calibration are sent for calibration certification/verification. If the
performance of the calibrated instruments is satisfactory, it is put into use for QC until next due
or undue problems. On failure of the calibrated instruments while in use, the calibration and
testing engineer reviews the same and suitably advises for repair or replacement. If the defect
of the instrument is non rectifiable, the same is disposed.

External micro meters and internal micrometers are used for the calibration of the
gauges. Wattmeter, ammeter, voltmeter are calibrated by an agency namely ICTC (Instrument
Calibration Testing Centre) and the other instruments by peninsula agency.

The stores department will be responsible for stocking all the necessary tools, spares, raw
materials and equipment required to service the manufacturing process. There is a store keeper
in the stores, after receiving a delivery note he will issue the materials for production. He
maintains a stores ledger.

Stores Inwards

The materials received vide PO/verbal order, are verified for quantity correctness,
proper maintenance at the goodown (heat, rain, pressure, etc), defects due to transportation by
the stores personnel. Depending on the nature of the materials received, the material inward
and receiving inspection form is computer printed and issued to QC personnel for the
correctness of quality and dimensions. Various items are found in the stores includes
impeller,circlip,sleeve,LBbush,coupling,keysstuds,sandguard,endwings,name,plate,nuts,bolts,
washers,neckrings,rubber items, emery sheet, drill bits,soap,paste etc.

The material inward and receiving inspection holds the name of the material received,
vendor details, the purchase order placed, purchase document details. The Quality inspection
is carried out by the QC Engineers, and assures the quality of the material received. The items
found to be defective are sent back.

On the tested ok by the QC engineers, the materials are accepted into stores and suitably
stored for issue. The MIRI report is duly filed and retained by the stores personnel as a
document for future reference.

On QC inspection, if the materials are found to be defective, the received materials are sent
back to the vendor. Rejection goods report is generated by the stores- in- charge and the same
is forwarded to purchase department.

30
The operations are classified as,

 RECEIPT OF MATERIALS
 MATERIALS INWARD AND RECEIVING INSPECTION
 INSPECTION
 STORING OF MATERIALS/ PURCHASE RETURN AND REJECTION GOODS
 DISPATCH OF MATERIALS
 REPORT
The items that are received for stores include both finished and unfinished items. The
unfinished items are then taken over for rework purpose. The details such as the agency or the
person taking the items for rework purpose, the item particulars such as the item name, quantity,
and the job to be done are maintained as DC note.

INVENTORY MANAGEMENT

The stores department will be responsible for stocking all the necessary tools, spares, raw materials and
equipment required to service the manufacturing process. There is a store keeper in the stores, after
receiving a delivery note he will issue the materials for production. He maintains a stores ledger.

Stores Issue

The production, service and machine shop makes a request entry in the system to
procure the materials required from stores. The physical stock available in the stores at the time
of requisition is made known to the requestor so as to decide the quantity requested. On
generation of the request a person physically moves to the stores to collect the requests made.

The stores personnel views the request in his system and issues the material and data
punches the quantity issued as a mark of issued. The stocks are immediately reduced from the
stores by the quantity issued. In the event of Non availability or shortage of materials, the
stores personnel indicate the same to the purchase department for procurement.

The stores personnel are aided with the above reports so as to verify himself the correctness
of the physical stock at his disposal. The purchase manager also views the reports at any given
time and plans for regular procurements of those materials which have come down the re-order
level.

The above said operations are classified as,

31
  MATERIAL REQUISITION
 STORES ISSUE
 MATERIAL BELOW ROL
Various files such as purchase requisition slip(for tools), Approved vendors, vendor
rating, monthly indent(except for Ammeter, voltmeter), pattern list(casting vendors), new
vendors, drawing files, vendors alphabetically arranged, proforma details, monthly
requirements are maintained for reference.

PRODUCTION PLANNING PROCESS

 Material Planning consists of ascertaining the need of the various departments in the
matter of materials and stores
 Procurement of Stores includes purchase of materials of required quality and quantity
at reasonable prices.
 Receipt & Inspection of Stores includes taking delivery of materials from carrier,
checking of quantity and quality.
 Store Keeping includes stocking of materials in the wards, their handling, issuing on
demand by indentors and maintaining proper records.
 Distribution of Stores includes timely dispatch and distribution of materials to various
users by adopting quick and right mode of transportation.
 Inventory Control includes maintaining an economic level of investment in inventories.

SYSTEMS DEPARTMENT

ROLES AND RESPONSIBILITIES

The manager, systems is the sole responsible for the functioning of the system in an
orderly manner. The prime duty of the manager is to identify the application of computers in
the various fields within the company for an improved and effective communication. Now he
is assisted by computer literates who have been placed at least once in each department.

The manager ensures the smooth functioning of the programs and also rectifies the
problems encountered, if any. Any system requirement identified by the staff or the
management is reported to the manager, systems. A system study is done by the manager to
assess the requirement of the software and a feasibility report is presented to the MD for
approval of designing a system.

32
 On confirmation, the systems manager proceeds in developing the software and
implements the same. The proper functioning of the software developed is checked, verified
and necessary modifications are done, if necessary to the entire satisfaction of the end-user and
management.

DEPARTMENT PROCESS FLOW

Systems Manager

Systems
Engineer/Programmer

MODERN MANAGEMENT TECHNIQUES

TERRA INDUSTRIES is an ISO 9001 company. The procedures, rules and

regulations of the various departments in the organization are driven by ISO system.
Middle level management takes utmost care to maintain the quality and standard of the
products manufactured in the company. The top level management also exerts pressure
constantly to assure and maintain optimum quality standards for the product range. The
output quality is standardized in order to maintain consistency to a certain extent in
the manufacturing cost.

Terra Industries holds first place among, the submersible manufactures and this enables
the company to establish its stability in the market. The organization concentrates in setting up
a good HR division. Performance appraisal and performance appreciation makes the project
successful. Human relations in the organization have good standards. This helps to have the
stability of the manufacturing unit. The periodical measuring of the individuals improves the
functional properties of the individuals and this gear up the organization’s performance. Top
level management reduces the gap between the employer and the employee through proper
training programmes.

LEARNING’S FROM THE ORGANIZATION

33
This internship project has been a great experience and helped me to learn a lot from day to
day experience at work. This experience has helped me to learn new things that are
implemented practically by the company to excel their work.

This Internship gave me the exposure to new and interesting professional situations where I
came to learn about handling the task given to me and to complete the task within the specific
period of time. With this internship I came to learn about the various department and its
activities and how the jobs are carried out in those departments.

This training also gave me real opportunities for practical application of skill and also a Hands-
on education regarding to the academics. And it greatly improved my knowledge on
production and operations department I also came to know the manufacturing process of
motors and pump sets and their stages till it is dispatched from the store.

And this also helped me in communicating with the co-workers in the organization about the
jobs carried out every day and their work experiences in the company and how they get adapted
to the organization culture in order to benefit for both the organization and the employee.

CONCLUSION

34
 The internship in TERRA INDUSTRIES, COIMBATORE enabled me to understand
the over all functions of various departments of medium size industry. As an intern, it was a
great opportunity to know the working environment. I have gained knowledge about the
industrial and study deal with the welfare schemes and incentives that are given to the workers
to improve the production capacity of the organization and the process of manufacturing the
motors and pump sets and its stages in detail. To conclude from this internship, I gained some
practical knowledge, regarding the functions undertaken by different departments in the
company. This internship also helped me to see the quality control and other evidence
maintained by each department in the company rather than studying theoretically. It really
helped me to understand the business activity of day-to-day nature and was a highly useful one.

35