AN ORGANISATION STUDY AT AUTOKAST LTD ,

CHERTHALA , ALAPUZHA
Report Submitted In Partial Fulfillment of the Requirements for the Award of
the Degree of Master of Busiess A!"iistratio of
Mahatma Gandhi Universit
Su#"itte! #$
SUMESH MONICHEN
%Re& o' ()***+
U!er t,e Gui!a-e of
Ms CHRISTY ABRAHAM
!ASSIS"A#" PR$F%SS$R&
DEPARTMENT O. MANAGEMENT STUDIES
MANGALAM COLLEGE O. ENGINEERING
ETTUMANOOR, KOTTAYAM
'
DEPARTMENT O. MANAGEMENT STUDIES
MANGALAM COLLEGE O. ENGINEERING
ETTUMANOOR, KOTTAYAM
CERTI.ICATE
"his is to (ertif that the report entitled an organi)ational stud at AU"$*AS" +td is
a bonafide re(ord of the wor, done b SUM%S- M$#I.-%# as a part of the
Pro/e(t 0or, during the third Semester at the degree of Masters Degree in 1usiness
Administration of Mahatma Gandhi Universit 2
Project Guide Head of the
Department

Dean of the Department
3
De-/aratio of t,e Stu!et
I4 SUM%S- M$#I.-%#4 "hird Semester M1A student of Mangalam .ollege of
%ngineering4 %ttumanoor 4 *ottaam do hereb de(lare that this report titled4
5$RGA#I6A"I$#A+ S"UD784 under the guidan(e of Ms2 .-RIS"7
A1RA-AM4 fa(ult guide is the result of m original wor, during the
$rganisation stud2 I have not submitted the same for the award of an other
degree4 diploma4 title or re(ognition before2 All the data 9 both primar and
se(ondar 9 are true to the best of m ,nowledge2
Pla(e: *$""A7AM
Date: #ame of the student
SUM%S- M$#I.-%#
;
ACKNO0LEDGEMENT
First of all I than, the god almight for giving this opportunit for me to do a
pro/e(t in the name <organi)ational stud= in the (ompan AU"$*AS" +"D2 "his pro/e(t
gave me a wonderful e>perien(e in the field of (asting industr2
I would li,e to e>press m heartfelt than,s to Dean of the department4
Prof2 ?ohn 2" @arghese4 and Dr2 Sibu . .hithran4 M1A4 M2Phil24 Ph2D24 FDP !IIM*&4
AM"!AIMA&4 MAIMSI!USA& -$D4 management studies for all a(ademi( fa(ilities
e>tended to me2 I am immensel than,ful to m internal pro/e(t guide Ms2 .hrist
Abraham4 Assistant professor of the Management department4 for her (reative and
health suggestions regarding this pro/e(t wor,2
I e>press m sin(ere gratitude to Mr2?ithesh Asst2Manager - R department for
permitting me to do this stud on Auto,ast +td2 I would li,e to e>tend m gratitude to the
guide Mr2 Sudarsan of the organi)ation who guides me to do the pro/e(t as I (ould get a
wonderful live e>perien(e in the field of business2 0ithout their support this stud would
not have been possible2 +ast but not the least I would li,e to than, m friends4 famil and
rest of the fa(ult members of m (ollege who gave me the full en(ouragement2
Sumesh Moni(hen
A
LIST O. CONTENTS
Sl2no
.ontent
Page no
1


)
2
(

*
INTRODUCTION
O#3e-ti4es of stu!$
S-o5e of stu!$
Met,o!o/o&$
Li"itatios
RE6IE0 O. RELATED LITERATURE
Re4ie7 of re/ate! /iterature
T$5es of or&aisatio
DESIGN O. STUDY
Desi& of stu!$
T$5e of !ata -o//e-tio
Data aa/$sis too/s a! te-,i8ues
INDUSTRY PRO.ILE
COMPANY PRO.ILE
PRODUCT PRO.ILE
B
ORGANISATION STRUCTURE


DEPARTMENT PRO.ILE
H R De5art"et
Mar9eti& !e5art"et
Pro!u-tio !e5art"et
:ua/it$ -otro/ !e5art"et
Materia/s !e5art"et
.ia-e !e5art"et
S0OT ANALYSIS
.INDINGS AND SUGGESTIONS
CONCLUSIONS
BIBLIOGRAPHY
C
CHAPTER 1; INTRODUCTION
D
INTRODUCTION
"he primar purpose of this stud is to fulfillment of the requirements for the
degree of M1A2 For this I (ondu(ted m $rgani)ation Stud in Auto,ast +imited4
.herthala for a period of one month2 "he era of liberali)ation has opened up new vistas
for Indian %(onom2 In the fast (hanging e(onomi( s(enario it is imperative for ever
aspiring entrepreneur to have a vivid understanding of the fun(tional appli(ation of the
new age business2 $rgani)ational studies is Ethe e>amination of how individuals
(onstru(t organi)ational stru(tures4 pro(esses4 and pra(ti(es and how these4 in turn4 shape
so(ial relations and (reate institutions that ultimatel influen(e peopleE organi)ational
studies (omprise different areas that deal with the different aspe(ts of the organi)ations
OB<ECTI6ES O. THE STUDY
'2 "o familiari)e with a business organi)ation2
32 "o familiari)e with the different departments in the organi)ation and their
fun(tioning2
;2 "o enable mself to understand how the ,e business pro(ess are (arried out in
organi)ation2
A2 "o understand how information is used in an organi)ation for de(ision ma,ing at
various levels2
B2 "o relate theor with pra(ti(e2
C2 "o a(quire good wor, habits and sense of responsibilit2
D2 "o observe4 anal)e and interpret the relevant data (ompetentl and in a useful
manner2
SCOPE O. THE STUDY
"his pro/e(t report (overs the fun(tioning of all ma/or departments of Auto,ast
+td4 .herthala2 "he findings of the stud would give valuable information about
improving the (urrent performan(e of the organi)ation towards its goal a(hievement2 It
also in(ludes the organi)ational stru(ture of the firm2
-elps to understand the organi)ational stru(ture of the firm2
F
-elps to get a pra(ti(al ,nowledge about the fun(tions of different
departments of Auto,ast +td2
It helped to appl the management theories into pra(ti(e
-elps to fo(us on positive and negative aspe(ts of the (ompan
METHODOLOGY
"he data are obtained from primar and se(ondar sour(es2
Primar data are (olle(ted through personal interviews and personnel dis(ussion
with managers and other offi(ials of the organi)ation G also through observation2 "he
information obtained relates to what is (urrentl happening in the organi)ation2 "he
stud needs to have a personal visit to the different departments of the .ompan2
Se(ondar data are from published and unpublished re(ords of the firm2
Published sour(es in(lude annual report of the (ompan4 newspaper arti(les4 /ournals of
the firm et(2 Unpublished sour(es of data are files and re(ords maintained b the
(ompan2
LIMITATIONS O. THE STUDY
"he stud is limited to m e>perien(e and ,nowledge2
Another limitation of the stud is the (onfidential nature of the data in the firm2
"he stud was (ondu(ted for a limited period and the time is a ma/or limiting
fa(tor for an in depth stud2
"here ma be errors due to the bias of the respondents2
Sin(e the offi(ials were bus4 it was diffi(ult to spare there time with them for
detailed dis(ussion2
H

CHAPTER )

RE6IE0 O. LITERATURE
'I
RE6IE0 O. RELATED LITERATURE
Management is universal in the modern industrial world2 %ver organi)ation requires the
ma,ing of de(isions4 the (oordinating of a(tivities4 the handling of people4 and the
evaluation of performan(e dire(ted toward group ob/e(tives2 Management has be(ome
more important as labour has be(ome more spe(iali)ed and as the s(ale of operations has
in(reased2 "e(hnologi(al developments have (ontinuall (reated new (hallenges2 "he
(omple>ities of human relationships (onstantl (hallenge those who perform managerial
fun(tions2 "he dnami( of management4 therefore4 should be (hara(teristi( of an stud
of its theor and pra(ti(e2
$rgani)ational stru(ture refers to the wa that an organi)ation arranges people and /obs
so that its wor, (an be performed and its goals (an be met2 0hen a wor, group is ver
small and fa(eJtoJfa(e (ommuni(ation is frequent4 formal stru(ture ma be unne(essar4
but in a larger organi)ation de(isions have to be made about the delegation of various
tas,s2 "hus4 pro(edures are established that assign responsibilities for various fun(tions2
It is these de(isions that determine the organi)ational stru(ture2 In an organi)ation of an
si)e or (omple>it4 emploeesK responsibilities tpi(all are defined b what the do4 who
the report to4 and for managers4 who reports to them2 $ver time these definitions are
assigned to positions in the organi)ation rather than to spe(ifi( individuals2 "he
relationships among these positions are illustrated graphi(all in an organi)ational (hart2
"he best organi)ational stru(ture for an organi)ation depends on man fa(tors in(luding
the wor, it doesL its si)e in terms of emploees4 revenue4 and the geographi( dispersion
of its fa(ilitiesL and the range of its businesses2
$1?%."I@%S
"he organi)ation aims at the a(hievement of the following aims:J
''
To ,e/5 "aa&e"et: J "he organi)ation helps management to have a (ontrol
over various business fun(tions2 "he wor, is divided properl and (ontrol (enters are
established2 "he authorit is delegated and responsibilities are fi>ed2 It helps management
to have a (oJordinate administration2
To i-rease 5ro!u-tio: J "he duties are assigned a((ording to the prin(iple of
division of labour2 "he effi(ient sstem of organi)ation en(ourages ever emploee to
ma,e his best (ontribution in raising output the in(rease in output and (ontrol of wasteful
e>penditure helps to de(rease the (ost of produ(tion2 "he profitabilit of the (on(ern will
also go up2
Co;or!iatio of e"5/o$ees: J "he organi)ational stru(ture will su((eed onl if
emploee (oJoperate with others2 "he manager introdu(es various in(entives s(hemes
and gives monetar and other benefits to the emploees so that the wor, in a team spirit2
TYPES O. ORGANISATION
'2 +ine organi)ation
32 Fun(tional organi)ation
;2 +ine G staff organi)ation
+I#% $RGA#I6A"I$#
"his is one of the oldest forms of organi)ational stru(ture and all other forms are
modifi(ations of it and dire(tl or indire(tl based on it2 +ine stru(ture is basi( and
indispensable to all ,inds of organi)ed efforts that are made to a(hieve (ommon goal2 It is
still (onsidered as the ba(, born of group efforts2 In this organisation authorit flows
from the top levels to lower levels through all managerial positions2 "hese positions are
(reated around basi( or (ore a(tivities that are essential to a(hieve organisational
ob/e(tives2 In the line authorit4 ea(h manager is atta(hed with the relationship of
superior and subordinate2 "here is a dire(t verti(al relationship among them2 In the line
stru(ture4 there are no spate servi(es or supportive units and these a(tivities are also
in(luded in line departments2
FU#."I$#A+ $RGA#I6A"I$#
'3
"he fun(tional stru(ture of an organi)ation is based on the (on(ept of fun(tional
foremanship developed b F 0 "alor2 "his ma be (onsidered as an improved and
effe(tive form of line and staff organi)ation2 "his is be(ause this parti(ular stru(ture has
been developed to (ounter inadequa(ies and drawba(,s asso(iated with line and staff
organi)ation parti(ularl in respe(t to role4 relationship and position of e>perts in an
organi)ation2
In a fun(tional stru(ture4 the a(tivities of an organisation are grouped into various units
on the basis of fun(tions that are to be performed with regard to that group of a(tivities2
%a(h fun(tional head is given full authorit over those fun(tions irrespe(tive of the level
at whi(h the are performed2
+I#% A#D S"AFF $RGA#I6A"I$#
$n a((ount of inadequa(ies and drawba(,s asso(iated with the line form of organi)ation
and the growing (omple>ities of modern business4 (ertain modifi(ations ma be
introdu(ed in the line form to ma,e it effe(tive2 Another new form is developed whi(h is
,nown as line and staff organi)ation2 "his ma be (onsidered to be a more refined and
e>tended form of line organi)ation2
2
';
CHAPTER 2
DESIGN O. THE STUDY
'A
2=1 Desi& of t,e stu!$
"his stud (onstitutes the data (olle(tion and analsis of data2 "his stud is essential as
it fa(ilitates the smooth sailing of various operations4 thereb ma,ing resear(h as
effi(ient as possible ielding ma>imum e>penditure of effort4 time and mone2
Area of t,e stu!$
"he area is sele(ted within AU"$*AS" +"D2 .herthala2
Sa"5/i& !esi&
Sampling design is an integral part of the data (olle(tion pro(ess as it is not feasible to
se(ure data from ea(h and ever unit of the entire population2 Simple random sampling
it=s used to (ondu(t the stud2
Simple random sample is a subset of individuals !a sample& (hosen from a larger set !a
population&2%a(h individual is (hosen randoml and entirel b (han(e 4su(h that ea(h
individual has the same probabilit of being (hosen at an stage during the sampling
pro(ess2
Sa"5/i& "et,o!
.onvenien(e sampling method is used in this pro/e(tL it refers to that fra(tion of
population being interviewed whi(h is sele(ted b (onvenien(e2
Sa"5/i& uit
Sampling unit spe(ifies the unit that is ta,en for the sample 2A sampling unit (onstitutes
those elements that are (onsidered available for sele(tion in some stage of the sampling
pro(ess2
2=) TYPES O. DATA COLLECTION
Pri"ar$ !ata
'B
"he primar data has been (olle(ted through personal interviews and questionnaires 2"he
questionnaires has been properl prepared in order to (over all the information required
for the stud 2In this pro/e(t the primar data has been obtained b intera(tion with the
offi(ials and staff in the division in the organisation and also obtained through the
questionnaires distributed to the emploees in different departments2
Se-o!ar$ !ata
Se(ondar data are the information (olle(ted indire(tl 2In this pro/e(t the se(ondar data
is (olle(ted through the annual reports of the (orporation from other re(ords available in
the organisation4 maga)ines and websites2
2=2 DATA ANALYSIS TOOLS AND TECHNI:UES USED
Statisti(al tools are used for anal)e data 2And per(entage analsis is used as the toolL
per(entages are used in ma,ing (omparison between two or more series of data2
.or"u/a'
Per(entage of respondentsM#o of respondents divided b total no of respondents and it is
multiplied b 'II2
Gra5,s
Graphi(al method was used in order to represent the fa(tor in various graphi(al methods
li,e pieJ(hart and bar diagram2
'C
CHAPTER ( > INDUSTRY PRO.ILE
'D
INDUSTRY PRO.ILE
O6ER6IE0
"he Indian Foundr industr produ(es appro> D Million M" of (astings
emploing estimated BII4III persons dire(tl G another '2B million indire(tl2
"he growth of foundr industr is ver important for in(lusive growth4 other engineering
se(tors G the overall Indian %(onom

Foundr industr is the basi( engineering industr4 the produ(t of whi(h is used
b almost all people2 @irtuall ea(h and ever industrial pro(ess needs (astings of one
tpe or the other2 All forms of transport do require to a ma/or e>tent the foundr industr
produ(tion2
Founding or (asting is the pro(ess of produ(ing metal Nallo into a prepared
mould and then allowing the metalNallo to (ool and solidif2 "he solidified pie(e of
metalNallo is ,nown as a (asting2
Founding or (asting is one of the oldest manufa(turing pro(esses4 whi(h dates
ba(, to appro>imatel AIII1.2 "he first foundr (enter (ame into e>isten(e in the das
of Shan Dnast in .hina2 A number of foundries using (ast iron as the stru(tural
material (ame into being after the industrial revolution2
"he Indian foundr is striving to rewrite its histor and emerge as automated
green industr2 India is (urrentl one among the 'I largest produ(ers of ferrous and nonJ
ferrous (astings and has over CBII foundries in the small4 medium and large 9s(ale
industries2
"he Indian Foundr Industr o((upies a spe(ial pla(e in shaping the (ountr=s
e(onom2 India is (urrentl among the 'I largest produ(ers of ferrous and nonJferrous
(astings and has over CBII foundries in the small4 medium4 and large s(ale se(tors2
Appro>imatel HIO are in the small s(ale2 India e>ports annuall above Rs2DIINJ (rores
worth of (astings to (ountries li,e USA4 U2*24 .anada4 German et(2
'F
"he ma/orit !nearl HBO& of the foundr units in India falls under the
(ategor of smal lJs(ale industr2 "he foundr industr is an important emploment
provider and provides dire(t emploment to about half a million people2 A pe(uliarit of
the foundr industr in India is its geographi(al (lustering2
"pi(all4 ea(h foundr (luster is ,nown for (atering to some spe(ifi( endJuse
mar,ets2 For e>ample4 the .oimbatore (luster is famous for pumpJsets (astings4 the
*olhapur and the 1elgaum (lusters for automotive (astings and the Ra/,ot (luster for
diesel engine (astings2
SIGNI.ICANCE O. .OUNDRY INDUSTRY
.ou!r$ I!ustr$ is Ma3or .ee!er to fo//o7i& se-tors:J
Automobiles G Auto .omponents
Railwas
Power Se(tor
"ra(tor Industr
%arth Moving Ma(hiner
Pumps4 .ompressors4 Pipes @alves G Pipe Fittings
%le(tri(alN"e>tileN.ementNAgro Ma(hiner
Ma(hine "ools G %ngineering Industries
Sanitar .astings
%ngineering %>ports
Appro> ;3O $utput of Foundr Industr goes to Auto Industries G 1alan(e to other
downstream %ngineering Se(tor2
Automotive Mission Plan !AMP& 3IICJ3I'C envisages A Fold Growth b 3I'C2 i2e2 from
P;A 1illion industr to P '33J'CI billion industr and emploing about 3B millions b
3I'C2 AMP 3IICJ'C will drive demand of .astings from Foundr Industr2
.orresponding Growth in Foundr Se(tor vital to sustain growth in Auto G other
%ngineering Se(tors2
Gra5, #e/o7 De5i-ts Se-tor 7ise Cosu"5tio of Casti&s i 5er-eta&e
'H

Gra5, #e/o7 De5i-ts T$5es of Meta/ Casti&s S,are i ?

Gra5, #e/o7 De5i-ts To5 Te Casti& Pro!u-i& Coutries
3I

THE INDIAN CASTING INDUSTRY
India ran,s Cth (ountr in the world for produ(ing an estimated C Million M" of
various grades of (astings2 "he various tpes of (astings whi(h are produ(ed are ferrous4
non ferrous4 Aluminum allo4 graded (ast iron4 du(tile iron4 steel et( for appli(ation in
automobiles4 railwas4 pumps (ompressors and valves4 diesel engines4 (ementNele(tri(alN
te>tile ma(hiner4 amongst others2 "he gre iron (astings have a ma/or share of DI
per(ent of the total (astings produ(ed2 "here are appro>imatel A4BII units engaged in
(astings4 out of whi(h FI per (ent (an be (lassified as smallJs(ale units and 'I per(ent
ea(h as medium and largeJs(ale units2
"he industr is a labor intensive one4 emploing about B4 II4 III people dire(tl
and an additional '4BI4III people indire(tl2 "he small units are mainl dependant on
manual labor2 -owever4 the medium and large units are semi or full me(hani)ed and
some of the large units are world (lass2
"he industr is organi)ed in (lusters in various regions li,e Agra4 1elgaum4
.hennai4 -owrah4 .oimbatore4 .hennai4 *olhapur4 +udhiana4 Pune and Ra/,ot2 %a(h
(luster has its own ni(he produ(ts for its user industries2
3'
THE PRODUCT MI@
"he industr is tring to fo(us on higher value added produ(ts to fa(e (ompetition
globall2 It ma be noted that C3 per (ent of the (asting produ(tion is (atered b .hina4
%uropean Union and US2 "he shortage of s(rap and pig iron in %U (ontinues to affe(t its
(ost of (astings4 for(ing them to loo, to .hina and India for (ost effe(tive (astings2 "he
produ(tion of (astings grew from 32DC million M" in HDJHF to D2DD million M" in 3IIDJ
IF2 "his is a ;II per (ent /ump in produ(tion (apa(it in a de(ade2 It was the growth in
the automobile industr that provided the ma/or thrust in the (astings industr2
COMPETITI6E AD6ANTAGE
India has a ma/or (ompetitive advantage over the (astings industr in the
developed .ountries2 -ere the total labor (ost is low (ompared to that of the US and %U2
-ere labor (ost a((ounts for '3J'B per (ent of the produ(t (ost2 "he Indian government
has en(ouraged te(hnolog transfer through a /oint venture !?@& with foreign (ompanies2
"he foundr industr has an edge over .hina as well 9 it is able to produ(e (omple>
ma(hine and pre(ision (astings as per international qualit standards2 "he (lusters in
1elgaum4 .oimbatore and -owrah are undergoing moderni)ation under the Industrial
Infrastru(ture up gradation s(heme
I4est"et
India would need appro>2 P ; 1illion in investment to meet the demand of
growing domesti( industr and strong e>port drive2 Following the e(onomi( reforms the
Government of India has redu(ed tariffs on imported (apital goods2 As a result4 the
annual average amount of FDI is reported to have in(reasedL but is still one tenth of the
annual FDI in .hina2 "he reforms en(ourage the privati)ation of industr4 enabling
foreign (ompanies to invest or enter into /oint ventures with Indian Foundries2 Several
International .orporate from USA4 %U and %ast Asian (ountries have in(reased overseas
foundr operations in India2 I2e2 @$+@$ foundries in .hennai and Su)u,i in -arana2
Sundaram .laton has /oined hands with .ummins2 -undai Motors4 Delphi2 Ford India4
"ata.ummins4 GM and Ford have (ontra(ts of foundr produ(ts for e>port with a value
of P AI Million2
Ra7 "ateria/s A Eer&$
Sin(e 3II;4 the steep in(reases in (ost of raw materials and energ have resulted
in the (losure of appro>2 BII units2 $verall4 India is e>porter of pig ironL but must import
s(rap metals and (o,e4 et(2 .ost re(over for material and energ is ver diffi(ult as most
(ontra(ts are long term (ontra(ts without an (lause for pri(e ad/ustment2 Moulding sand
is lo(all available G India has an advantage on this a((ount2 %nerg (ost tpi(all var
between '3'BO
33
La#our
India has ma/or (ompetitive advantage over the foundr industries in the
developed (ountries2 "he total labor (ost a((ount for '3'B O2 1ut availabilit of s,illed
labor be(omes an issueL bothering man industries in(luding the foundr industr2
Te-,o/o&$
"he Government of India !G$I& has en(ouraged te(hnolog transfer through a
?oint @enture !?@& with foreign (ompanies and the G$I has (ooperated with U#ID$ with
man foundr (lusters2 "he Indian foundr industr has an edge over .hina for
produ(ing (omple> ma(hined and pre(ision (astings as per international qualit
standards2 "he G$I also helps upgrade foundr (lusters2 "he (lusters in 1elgaum4
.oimbatore and -owrah are undergoing moderni)ation under the industrial infrastru(ture
up gradation s(heme2 More of su(h (lusters are li,el to follow2

3;
CHAPTER * > COMPANY PRO.ILE
3A
Auto,ast was established in the ear 'HF3 as a subsidiar of Steel Industrials
*erala +td2 !SI+*&4 a Govt2 of *erala Underta,ing for the manufa(ture of Gre iron and
Spheroidal graphite iron (astings2
Auto,ast has the following range of manufa(turing fa(ilities2
'2 Air impulse tpe high pressure moulding line with a bo> si)e of DBI > DBI >
AIIN;BI mm (apable of produ(ing FI moulds per hour2 "he line is full (omputer
(ontrolled and is supported b automati( (ore shooting ma(hines emploing
different sand sstems li,e (old bo>4 shell (ore et(2 Produ(t range varies from 'I ,g
to '3I ,g2
32 .onventional hand moulding line (apable of manufa(turing (astings ranging from
3II,g2 to AIII,g2 single pie(e weight2
;2 Ma(hine moulding fa(ilit having a mould bo> si)e of DHI > DHI > AIINAII mm
and ''HI > DHI > AIINAII mm (apable of manufa(turing (astings ranging from
;I,g2 to 'CI,g2
A2 +iquid metal is generated from 3 numbers of C M" mains frequen( indu(tion
furna(es and one ar( furna(e of B N D M" (apa(it2
Pattern shop at A*+ a(ts as a servi(e shop for pattern equipment used in produ(tion2
Auto,ast is full equipped with state of the art testing fa(ilities li,e
'2 0ell equipped wet analsis laborator2
32 "went si> (hannel4 1aird ma,e va(uum spe(trometer imported from U2S2A2
;2 Me(hani(al testing lab with CI" U"M4 1rinnel hardness "ester4 Ro(, well
hardness tester et(2
A2 Metallographi( fa(ilities2
B2 Ultrasoni( testing fa(ilities2
C2 Magneti( parti(le testing fa(ilities4 and
3B
D2 +iquid penetrant tests2
"he (ompan=s produ(ts at present (ater to the needs of following segments of Indian
and overseas industries2
'2 Automotive4
32 "ra(tor4
;2 1utterfl valve assembl4
A2 Agri(ultural4
B2 0ind mill energ and
C2 General engineering industries
MISSION
Produ(tion in large volume and (ost effe(tiveness in all segments
Produ(e te(hnologi(all superior produ(ts
A(hievement of (ustomer delight through ben(hmar,ing global pra(ti(e
.onsistent produ(tion through harmonious industrial relations
Strengthen suppl (hain management
6ISION
"o raise the (ompan as a leader of (asting industries in India
"he (ompan should be re(ogni)ed and respe(ted as a manufa(ture of the world
(lass produ(t serving (ustomers b suppling qualit (astings at right time
3C
SCOPE A .IELD O. APPLICATIONS
"his qualit management sstem (overs manufa(ture4 inspe(tion4 testing and
suppl of steel4 gre iron and nodular iron (astings for automotive4 tra(tor4 butterfl valve
wind mill energ and general engineering industries2
Auto,ast manufa(tures (astings to (ustomers= design onl2 +i,ewise4 all produ(ts
of Auto,ast (an be verified b subsequent monitoring and testing2 All a(tivities of
Auto,ast are (overed under the qualit management sstem to (ontinuall improve the
qualit of its produ(ts as well as to ensure (omplete (ustomer Satisfa(tion
LIST O. MA<OR PRODUCTS
S/=No Ite" Materia/ Cast= 0ei&,t A55/i-atio
'
Gear 1o> -sgN%ngine
-ousing
Gre Iron AI *g to ';I *g "ra(tor
3 -U1 Du(tile Iron 'III *g to ;;II *g 0ind Mill
; %>tender Du(tile Iron AII *g to CII *g 0ind Mill
A Main 1rg -sg Du(tile Iron 'BI *g to '3BI *g 0ind Mill
B 7aw "op Du(tile Iron DII *g to '3II *g 0ind Mill
C .law 1eam Du(tile Iron DI *g to ''I *g 0ind Mill
D 1ra,e Dis( Du(tile Iron BI *g to '3I *g 0ind Mill
F Gear Sta Du(tile Iron 'BI *g 0ind Mill
H 1ed G Frame Gre Iron 3II *g to ;BII *g Ma(hine "ool
'I @alve 1od Gre Iron Q3O #i ;II *g to BBII *g 1utterfl valve
'' @alve Dis( N @ane Du(tile Iron 3BI *g to BDBI *g 1utterfl valve
'3 Sphere Gre iron ;II *g to '3II *g 1all @alve
'; @alve 1od Gre Iron DII *g to 33II *g Gate @alve
'A 1od G -ead
Gre iron Q3O #i
QI2DBO .r
'II *g to ;;II *g @a(uum Pump
'B Dis(harge -ead Gre iron 'II *g to 'CI *g @erti(al Pump
'C Dome Gre Iron Q 'O.r AI *g to 'II *g Ash -andling
3D
'D Ash @essel Du(tile Iron 'DI *g to CII *g Ash -andling
ISO CERTI.ICATION
Auto,ast is an IS$ HII3: 3IIF (ertified (ompan2 It has got the (ertifi(ation in 'HHI2 IS$
HIII is a famil of standards for qualit management sstems2 IS$ HIII is maintained
b IS$4 the International $rgani)ation for Standardi)ation and is administrated b
a((reditation and (ertifi(ation bodies2 "he IS$ HII3: 3IIF agen( in Auto,ast is
#etherlands agen( *%MA2 "he agen( studies on various department and prepares a
manual on ea(h department2 "here is managing (ommittee on IS$ HII3 : 3IIF
(ertifi(ation pro(edure2 If there is an default or defe(t in the department4 the agen(
prepares a detailed (op of (hanges to ea(h department for modifi(ation2 "he Auto,ast
whi(h has e>port relationship with the foreign (ompanies4 the IS$ (ertifi(ation enables a
prompt impa(t on the fun(tioning pro(edure2 "he agen( also does internal audit in the
(ompan2 "he #@" is the Indian agen( whi(h does the (ertifi(ation pro(edures2 It is
granted b *%MA2
3F
RESPONSIBILITY AND AUTHORITY O.
E@ECUTI6ES
1+ MANAGING DIRECTOR
RESPONSIBILITY
$verall (ontrol of the (ompan
Resour(e planning
Growth and development of the (ompan
Ultimate responsibilit for produ(t qualit management sstem
.hairing of the (ompan poli( and a(hieving targetsNob/e(tives
AUTHORITY
"otal authorit for all tpe of transa(tion of the (ompan sub/e(t to approval b
the board of dire(tors
3& PRODUCTION MANAGER
RESPONSIBILITY
$verall responsibilit of engineering qualit (ontrol4 produ(tion and maintenan(e
(ontain (ost of produ(tion in line with the budgetL minimi)e nonJ(onformit in
produ(ts and pro(ess2 Shop planning to a(hieve target4 maintain shop floor
dis(ipline2
AUTHORITY
Approve pur(hase indents of raw materials G spares
Initiate dis(ipline pro(eeding against erring subordinates
Authori)e to send subordinates staff on tour for offi(ial purpose2
2+ MARKETING MANAGER
RESPONSIBILITY
$verall responsibilit of mar,eting a(tivities2
.onta(t review and mar,et development2
.oJordinate (ustomer (omplaints with emphasis on preventive a(tion2
AUTHORITY
.ontra(t finali)ation
Authori)ed to send subordinates staff on tour for offi(ial purpose2
3H
"o initiate dis(iplinar a(tion against erring subordinates2

(+ :UALITY CONTROL AND ENGINERING MANAGER
RESPONSIBILITY
Inspe(tion of in(oming materials Gpro(ess material li,e moulds4 (ores Gliquid
metal 2
.alibration of testing and laborator instruments
AUTHORITY
Final authorit to a((eptNre/e(t in(oming and pro(ess materials
Authori)ed to send subordinates staff on tour for offi(ial purpose
Authori)ed to stop Nrestart produ(tion Npro(ess in line with non (onformit 4of
pro(ess parameters as stipulated in pro(ess sheet
*+HEAD, HUMEN RESOURCE DE6ELOPMENT A
ADMINISTRATION
RESPONSIBILITY
0age administration and statutor (omplian(e under labor law2
Identifing training needs and organi)ing training programs
General administration and emploee welfare2
Adopt measures to see, emploee involvement in (ompan<s development
a(tivities
Up ,eeping of wor, environment and pressure vessels G lifting ta(,tes
AUTHORITY
Approve paments to emploees 4se(urit 4(anteen4 transport et( as per norms
Sales of usufru(ts
Authori)ed to send subordinate staff on tour for offi(ial purpose
"o initiate dis(iplinar a(tion against erring subordinates
;I
B+.INANCE MANAGER
RESPONSIBILITY
$verall (harge of the department
Preparation of budget annuall and enfor(ing finan(ial dis(ipline to wor, within
the budget
.osting of a(tivities and suggesting (ost (ontrol measures
AUTHORITY
"o represent Auto,ast in finan(ial transa(tion with finan(ial institution and other
agen(ies as authori)ed b managing dire(tor
"o re(ommend ne(essar training needs to subordinates staff
"o initiate ne(essar dis(ipline a(tion against erring subordinate staff
"o initiate ne(essar dis(ipline a(tion against erring subordinates staffs
C+MATERIALS MANAGER
RESPONSIBILITY
$verall (harge of melting produ(tion 4manpower (ontrol 4and (oJordinates with
other departments
.ost (ontrol and produ(tivit improvement
Monitoring and implementing adequate safet measures for mean and ma(hiner
AUTHORITY
"o re(ommend ne(essar training needs to subordinate staff
"o initiate ne(essar dis(iplinar a(tion against erring subordinate staff
;'
PRODUCTION
Auto,ast is ma,ing (asting to (ustomers design and produ(tion is (ontrolled in
two stages4 first stage being developing sample (asting followed b regular produ(tion
after getting approval from the (ustomer2
Sa"5/e -asti&
All the a(tivities of ta,ing out samples shall be (ontrolled b the Development
team under leadership of -ead4 %ngg until it is (leared for regular produ(tion2 In pro(ess
inspe(tion shall monitor ea(h a(tivit and re(ord observations2
1ased on wor, order from mar,eting dept24prepare the pro(ess sheet and draft qualit
plan along with method drawing and issue (opies of qualit planNpro(ess sheet to
(on(erned depts24 li,e Moulding4 Melting4 Rualit (ontrolNinspe(tion2
Stud the qualit planNpro(ess sheet of the item and arrange required fa(ilitiesNmaterials
at their respe(tive shop2
1ased on produ(tion plan from PP.4 draw pattern shop and start moulding
pro(ess a((ording to the guidelines provided in the pro(ess a((ording to the
guidelines provided in the pro(ess sheetNqualit plan and do(umented wor,
instru(tion of moulding dept2
After (ompletion of moulding pro(ess4 (lose the moulds2
.ast the mould with spe(ified metal under spe(ified pouring (onditions2
*no(, out the (asting after spe(ified holding time2
De(ore the (astings and transfer them to fettling shop2
Fettle the (astings2
Inspe(t the (asting visuall and re(ord the status2
.asting (leared after the visuall inspe(tion shall be mar,ed for dimensional
(onforman(e2
"est me(hani(al and metallurgi(al properties of representative test (oupons and
re(ord the status2
0hen all the (hara(teristi(s are (onforming to (ustomer requirements4 issue
dispat(h (learan(e for the (astings2
Dispat(h the (astings and see, (ustomer feedba(,2
Forward the feedba(, from the (ustomer to -ead4 %ngineering2
%valuate observations b (ustomer and observations b the development team
during the (ourse of development and update qualit planNpro(ess (ard2
;3
Issue final qualit plan and (learan(e for regular produ(tion2
Re&u/ar 5ro!u-tio=
After getting for regular produ(tion from %ngg4dept24 plan regular produ(tion and
issue (opies of planning sheet to (on(erned departments2
%nsure availabilit of update !latest revision& of pro(ess sheetNqualit plan at respe(tive
departments2
During regular produ(tion4 total responsibilit of (learing the (asting for dispat(h shall be
with -eads of inspe(tion and R.4 visual4 dimensional and #D" with the former and
metallurgi(al and me(hani(al with the latter2

STEPS IN6OL6ED IN MAKING A CASTING
'& Ma,e the Pattern out of 0ood4 Metal2
3& In (ase of sand (asting4 sele(t4 test and prepare the ne(essar sand mi>tures for
mould and .ore Ma,ing
;& 0ith the help of patterns prepare the Mould and ne(essar .ores2
A Mould is a (ontainer having a (avit of the shape to be (ast2
A .ore is a bod whi(h is emploed to produ(e a (avit in the (asting
A& Melt the Metal to be (ast2
B& Pour the molten metal into the mould and remove the (asting from the mould after
the metal solidifies2
C& .lean and finish the (asting2
D& "est and inspe(t the (asting2
F& Remove the defe(ts4 if an2
H& Relieve the (asting stresses b -eat "reatment
'I& Again inspe(t the (asting
''& "he (asting is read for shipping2
AD6ANTAGES O. METAL CASTING
.asting is one of the most versatile manufa(turing pro(esses2
.asting provides the greatest freedom of design in terms shape4 si)e and the
produ(t quantit
.asting imparts uniform dire(tional properties and better vibration damping
(apa(it to the (ast parts2
.asting produ(es ma(hine parts
;;
Shapes diffi(ult and une(onomi( to obtain otherwise ma be a(hieved through
(asting pro(ess2
A produ(t ma be (ast as one pie(e4 thereb eliminating the need of metal
/ointing pro(esses2
@er heav and bul, parts li,e those of power plants and mill housings4 whi(h
are otherwise diffi(ult to get fabri(ated ma be (ast2
Metals diffi(ult to be shaped b other manufa(turing pro(esses ma be (ast2
.astings (an be designed for equal distribution of loads and for minimum
stress (on(entration in order to a(hieve more strength and in(reased servi(e
life2
.asting pro(ess (an be me(hani)ed and usefull emploed for mass produ(tion
of (omponents2
APPLICATIONS O. METAL CASTING
"he growing demand of high pre(ision (astings and of intri(ate designs at
lower (osts has helped (onsiderabl in the development of Foundr Industr2 -ardl
there is an produ(t4 whi(h does not have one or more (asting (omponents2
A few appli(ations of founding or (asting are mentioned below:
'2 "ransportation vehi(les: .ast metal parts a((ount for more than HIO of
an automobile engine and for more than BIO of the total weight of a
tra(tor2
32 Ma(hine tool stru(tures2
;2 "urbine vanes2
A2 Power generators2
B2 Mill housings2
C2 Railwa (rossings2
D2 SuperJ(harger (asting
F2 Pump filter and valve2
H2 Paper mill sto(, brea,er parts2
'I2 Air(raft /et engine blades2
''2 Agri(ultural implements2
'32 Sanitar fittings2
';2 .ommuni(ation .onstru(tion and Atomi( %nerg Appli(ations2
'A2 0ind Mills2
;A
CHAPTER B' PRODUCT PRO.ILE
;B
PRODUCT PRO.ILE
Auto,ast +td is a foundr unit produ(ing iron (astings for a variet of industries2
"he iron (astings are made of (ast iron2 .ast iron is a general term that des(ribes iron4
(arbon4 sili(on allos whi(h are produ(ed b pouring the molten metal into sand N metal
moulds2 .ast iron is brittle and gre in (olor2 "he (arbon (ontent in (ast iron is more than
that in steel whi(h ma,es it less malleable2 1 varing the sili(on and (arbon (ontent at
allo4 several tpes of (ore iron (an be produ(ed ea(h with different properties and uses2
"he ma/or produ(t lines of Auto,ast are:
'2 Automotives (astings
.linder heads4 .linder blo(,s4 Drum -ousing et(2
32 Ma(hine (astings
Ma(hine tool (asting
;2 Pump (astings
@a(uum and Slurr pump (asting
A2 .astings for Pressure "ight Appli(ation
.entral valves4 pressure vessel (astings et(2
B2 0indmill .astings
1earing -ousings4 -ub4 %>tender4 et(2
Auto,ast produ(es (astings in gre iron and spheroidal graphi( iron or nodular (ast
iron2
Gre$ Cast Iro
Gre Iron (an be readil (ast into desired shapes b pouring into moulds2 So it is the
most (ommonl used tpe of (ast iron for the manufa(ture of (astings2 "he other
distinguishable (hara(teristi(s of Gre Iron are:
+owest melting point of all ferrous allos2
.arbon in Gre Iron is found in the form of graphite fla,es2
+ow (ost (ombined with hardness and rigidit2
-igh (ompressive strength2
-igh resistan(e to whether et(
;C
.hemi(al (omposition
Gre iron
.arbon O Sili(on O Manganese O Sulpher O Phosphorous O
32B 9 ;2DB '2I 9 32B I2A 9 '2I I2IC J I2'3 I2' 9 '2I
A55/i-atios
Ma(hine tool stru(tures2
Gas or water pipes for underground purposes2
.linder blo(,s and heads for internal (ombustion engines et(2
S5,erio!a/ Gra5,ite Iro
Spheriodal Graphite Iron or #odular .ast Iron is a higher grade of iron4 be(ause unli,e
stru(tures in gre iron4 the graphite in Spheriodal Graphite !SG& Iron is pre(ipitated as
spheroids2 "his is attained b adding some spheriodising agents4 whi(h (hanges the
solidifi(ation (hara(teristi(s and a((ount for notari)ation2
.hemi(al (omposition
S G iron
.arbon O Sili(on O Manganese O Sulpher O Phosphorous O
;23 9 A23 '2' 9 ;2B I2; 9 I2F I23 I2IF
CASTING

.ERROUS CASTINGS
SGNDU."I+% IR$# GR%7 IR$#
Similar to Steel 1rittle
Graphite in Spherodial shape %as to handle
+ow Manganese Rust free
-ardness
.ostl
"a,e more finishing time
Rust free
More elasti(
;D
CHAPTER C
ORGANISATIONAL STRUCTURE
;F
ORGANIZATION STRCTURE
$rgani)ational stru(ture spe(ifies the firm=s formal reporting relationships pro(edures4
(ontrols and authorit and de(isionJma,ing pro(esses2 Developing an organi)ational
stru(ture that effe(tivel supports the firm=s strateg is diffi(ult4 espe(iall be(ause of the
un(ertaint about (auseJeffe(t relationships in the global e(onomies rapidl (hanging and
dnami( (ompetitive environments2 0hen a stru(ture=s elements are properl aligned
with one another4 that stru(ture fa(ilitates effe(tive implementation of the fun(tion=s
strategies2 "hus4 organi)ational stru(ture is a (riti(al (omponent of effe(tive strateg
implementation pro(esses2
;H
ORGANIZATION CHART

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CHAPTER D ; DEPARTMENT
PRO.ILE
A'
DEPARTMENTS
Auto,ast limited has the following departments
-R and Administration Department
Mar,eting Department
Produ(tion Department
Rualit .ontrol G %ngineering Department
Materials Department
Finan(e Department

D=1 HR DEPARTMENT

-uman Resour(es is e>a(tl it sas: resour(es for humans 9 within the wor,pla(eS
Its main ob/e(tive is to meet the organi)ational needs of the (ompan it represents and the
needs of the people hired b that (ompan2 In short4 it is the hub of the organi)ation
serving as a liaison between all (on(erned2
"o ensure its su((ess4 a (ompan must establish a hierar(hal reporting sstem2
"he funnel of responsibilit is (riti(al to the effi(ien( of a smoothl operating business
entit in whi(h there is a (learl defined understanding of who is responsible for what2
"he provide (onsultation to a (ompanKs management team to identif what the
(ompanKs (ore business and (ulture is about4 and pro(eeds to plan and map the
(ompanKs organi)ational infrastru(ture to support those needs2
Personnel management is the spe(iali)ed bran(h of management that deals
with people who are not mere Ma(hines or .ommodities or .osts but who are as
human as an human beings are4 and who (onstitute the prin(ipal asset of the firm2
Personnel management is the part of total management of the organi)ation4
whi(h spe(ifi(all deals with the human resour(es in respe(t of their
'2 Pro(urement
A3
32 Development
;2 "heir motivation towards the attainment of the organi)ational ob/e(tives
"he su((ess of modern organi)ation alwas depends on the (ontribution made b
the emploees2 An organi)ation tends to be su((essful when emploees are satisfied and
produ(tive inspe(tion performing their tas,s2 "he a(tive fun(tion of labour fa(tor is
needed2
-R and Administration department is an inevitable part of ever organisation and
in this organi)ation also it is performing a number of fun(tions li,e re(ruitment4 sele(tion4
training4 pla(ement and development of staff4 /ob des(ription4 /ob evaluation4 merit rating
et(2 It devi(es methods of wage pament4 promotions4 transfers4 provides welfare
measures4 enters into (ontra(t for emploment4 handles labour problems and disputes4
,eep emploment re(ords and so on2
-RD and administration department is a spe(iali)ed bran(h whi(h deals with the
people2 "his department servi(es to the use of human resour(es in an effe(tive manner so
as to transform them for reali)ing the ob/e(tives of the organi)ation2
In Auto,ast -RDGA is a spe(iali)ed bran(h of management4 whi(h deals with
the people2 "his department strives to use human resour(es in an effe(tive manner so
as to transform them for reali)ing the ob/e(tives of the organi)ation2 It aims at relating
people at wor, with the a(tivities ne(essar to a(hieve goals2
MANPO0ER IN AUTOKAST
CATEGORY NO O. 0ORKERS
Manager F
Deput Manager A
Assistant Manager ''
%ngineer C
Assistant %ngineer 3'
Assistant $ffi(er ''
Permanent 0or,ers 'CI
TIME O..ICE
"he main fun(tions of time offi(e are attendan(e ,eeping and paroll preparation2
It (omes under the (ontrol of personnel department2
%mploees (an ta,e '3 (asual leave and 'B medi(al leave per ear2
'; holdas are allowed for the .ompan4 in(luding H Festivals and A #ational holdas2
A;
PUNCHING SYSTEM
Attendan(e and paroll are maintained using the pun(hing (ard sstem2 "he latest
(omputer te(hnolog is used in pun(hing sstem2 "he wor,er has to insert the (ard into
the sstem when he enters as well as leaves the (ompan2 If the wor,er omits inspe(tion
pun(hing the (ard4 he will not be given the wages for that da2
"he details of the wor,er=s attendan(e are entered into the (omputer everda
with the help of pun(hing sstem2 An ele(troni( wor,sheet is used for this purpose2
0ages are given to the wor,ers based on the verifi(ation of the pun(hing sstem as well
as the wor,sheet2
"he pun(hing (ard sstem gives onl the attendan(e of the wor,ers2 It gives the
information whether a wor,er was present or absent during a parti(ular da but not
whether he was wor,ing or not2 "herefore the time offi(e maintains individual attendan(e
register for ea(h se(tion of the produ(tion department2
In Auto,ast there are A shifts whi(h are (lassified A4 14 . and general shift2 "he duration
is F hours for ea(h shift2 "he timings are:
S,ift Ti"e
General H2IIam to B2II pm
A shift C2IIam to 32IIpm
1 shift 32IIpm to 'I2IIpm
. shift 'I2IIpm to C2IIam
RECRUITMENT
Re-ruit"et Pro-ess
It is an important fun(tion of -uman Resour(e and Administration department2
Re(ruitment is done b the (orporate personal and administration department as per the
delegation of powers issued from time to time2 All the permanent emploees are re(ruited
during the starting stage of .ompan2 Re(entl Auto,ast does not ma,e an permanent
re(ruitments2 #ow the ma,e onl temporar sele(tions2 Also apprenti(es are there to
meet the manpower2
Sour-e of Re-ruit"et
AA
"hrough %mploment %>(hange as per the provisions of the emploment
e>(hange !(ompulsor notifi(ation of va(an(ies&2
"hrough Publi( Servi(e .ommission in respe(t of posts e>(lusivel reserved for
P2S2.
Promotion of e>isting emploees from the lower s(ale who meet the pres(ribed
standard2
Dire(t re(ruitment from outside (andidate4 who meet the pres(ribed standards2
From I"I=s and RI .entre2
Mo!e of Re-ruit"et
'2 0or,men 9 @a(an(ies are notified in the emploment e>(hanges2 A part of the
va(an(ies are filled up that wa and the other4 whi(h is earmar,ed for those
who are promoted are filled through promotions2
32 %>e(utives and managerial staff J @a(an(ies are notified in emploment
e>(hanges4 newspapers and professional emploment e>(hanges2
;2 "rainees and apprenti(es 9 Re(ruitment is done under the provisions of the
Apprenti(e A(t 'HC'2
Re-ruit"et Pro-e!ure
Man power budgets : Information about the va(an(ies
Sele(tion .ommittee : Representatives from va(an(ies listed department4 from the
-uman Resour(e and Administration department and representatives from other
departments2 "he pro(edure also in(ludes4
Advertisement for open sele(tion
Registration and s(reening
Sele(tion4 InterviewNwaitJlisting
.andidate are (alled for interview
Appointment : It in(lude medi(al (he(,up4 verifi(ation report4 signing of appointment
order after approved b appointing authorit4 /oining time4 /oining formalities4 deputation2
TRAINING
AB
Advertisement
Registration G
S(reening
Interview
Appointment
Manpower
budgets
"raining is also essential for members of staff who have been wor,ing for the
organi)ation for a long time2 "his is espe(iall so in the wa,e of te(hnologi(al
advan(ements4 legal (hanges and (hanges in servi(e deliver2 It is important for an
$rgani)ation to ,eep up with industr trends otherwise it fa(es the danger of be(oming
obsoleteL espe(iall in the ba(,ground of in(reasing (ompetition2
In Auto,ast *erala State Produ(tivit .oun(il !*SP.& and #ational Institute of
Personal Management !#IPM& are usuall providing training to emploees2 It helps to
improve wor, (ulture2
T PER.ORMANCE APPRAes so far2 It is the poli( of the .ompan to
settle grievan(es at the lowest possible level so that grievan(es are not prolonged2
"he ob/e(t of the grievan(e pro(edure is to provide the wor,men of Auto,ast with
an eas and readil a((essible pro(edure and ma(hiner for the ventilation and
prompt re!ressa/ of t,eir !a to da grievan(es2
.urrent Issue
T +ong "erm Agreement !+"A& not performed for so man ears2 So that Salar
revision is not done so far2 Sin(e the 0or,ers in the (ompan have variable DA4
their pa revision is not done due to the non revisal of +"A2
S(ope
T .omplaints affe(ting an individual wor,man in respe(t of the following matters
will (onstitute grievan(es and will be sub/e(t to the pro(edure2
T Pament of wages
Regarding wage or pament !other than monthl salar&
+eave
InterJdepartment transfer
Promotion
Seniorit
0AGE SYSTEM
J T,e 7a&e sstem used in Auto,ast is the time wage sstem2 Pun(h
(ard method is used for time ,eeping2 "he net wages and salar
distributed (omes to about 3323B la,hs4 out of whi(h about ';2'; la,hs
as wages provided for the wor,men and the rest H2'' la,hs is provided
AC
for e>e(utives2 For overtime wor, there is no additional benefits4
single salar sstem is followed for wor,ers2
'& DIS.IP+I#AR7 A."I$#S
J If a wor,man is found guilt an of the following punishments ma
be awarded to him
'& .ensure or warning
3& with holding of in(rements 47it, or 7it,out -umulative effe(t or postponing of
an in(rement to an future date with (umulative effe(t or postponing of an in(rement
to an future date with or without (umulative effe(t2
;& Re(over from his pa of the whole or part of an pe(uniar loss (aused to the
(ompan b su(h mis(ondu(t4 sub/e(t to the provision of pament of wages a(t2
A& Imposition of fine4 up to 3Oof his salar in a month2
B& Reversion or demotion to a lower grade or post or time s(ale or to a lower stage in the
same time s(ale either permanentl or for a s5e-ifie! !uratio=
B+ Sus5esion for a period not e>(eeding A das at a time without pa or salar or on
su(h redu(ed pa Nsalar as mabe ordere!=
C+ Barri& of promotion
F& Dis(harge from servi(e4 (ompensation or noti(e
H& Dismissal
Suspension
Suspension imposed as wor,man:
'& As punishment for mis(ondu(t
3& %nding enquir for an alleged mis(ondu(t4 and
;& 0hen (riminal pro(eeding are pursue! #$ a -ourt of law4 if the management
deems it
ne(essar
D%PAR"M%#" .-AR" $F - R D
AD
C23 MAR*%"I#G D%PAR"M%#"
"he mar,eting department must a(t as a guide and lead the (ompanKs
other departments in developing4 produ(ing4 fulfilling4 and servi(ing produ(ts or servi(es
for their (ustomers2 .ommuni(ation is vital2 "he mar,eting department tpi(all has a
better understanding of the mar,et and (ustomer needs4 but should not a(t independentl
of produ(t development or (ustomer servi(e2 Mar,eting should be involved4 and there
should be a meeting of the "i!s, 7,ee4er dis(ussions are held regarding new
produ(t development or an (ustomerJrelated fun(tion of the (ompan2
Industrial mar,eting is a set of a(tivities dire(ted towards fa(ilitating and e>pediting
e>(hanges4 involving industrial produ(ts and (ustomers in industrial mar,ets2 Industrial
mar,ets (onsist of (ommer(ial manufa(turers4 government and other institutions2
Industrial mar,eting is !ifferet from mar,eting of (onsumer goods2 1ut the ultimate
aim remains the same e>(hange of goods for the satisfa(tion of human needs and wants2
Mar,eting in Auto,ast is not mu(h aggressive as in FM.G industries and
Auto,ast uses o/ their website as an advertising medium2 Auto,ast is a /obing
foundr i2e2 the produ(e items a((ording to (ustomer demands2 -en(e the don=t
have a fi>ed produ(t mi>2 It will var with variations in (ustomer demands2
AF
Appointment Appointment Appointment Appointment Appointment Appointment Appointment Appointment Appointment Appointment Appointment
Appointment Appointment
"he dut of mar,eting department shrin,s to new (usto"er i!etifi(ation and their
evaluation2 "he new (ustomers will be the firms in the same industr2 0hen those
firms are unable to meet their produ(tion requirements the will turn to other firms in
the same industr2 In su(h situations the mar,eting department has a (ru(ial role to
attra(t those firms into Auto,ast2
Mar,eting department re(eives enquir from the (ustomers2 "he enquiries i-/u!i&
t,e !ra7i&s, spe(ifi(ations and other details are send to the engineering
department2 After re(eiving the feasibilit stud report b the engineering department4
the mar,eting department goes for (osting and pri(ing a(tivities2 "he pri(ing
(ommittee (onsists of representatives from mar,eting4 engineering and finan(e
department and the managing Dire(tor2 Ruotation is given after the pri(e fi>ation and
negotiation is made if required b the mar,eting department2 $n re(eiving the order
from the (ustomer issues pur(hase order for raw materials and wor, order to
produ(tion planning and (ontrol 4engineering 4produ(tion and qualit (ontrol
departments2 After the produ(tion pro(ess4 the mar,eting department dispat(hes the
produ(t to the (ustomer2
MAR*%"I#G PR$.%SS
Determination of requirements2
Re(eipt of enquir and entering the details in the register2
Preliminar stud of the enquir for adequa( of information and obtaii& furt,er
details from (ustomer4 if required2
Forwarding the enquir to -ead 9 %ngineering for assessing produ(t requirements4
in(luding an implied4 statutor and regular requirements related to the produ(t and for
feasibilit stu! as 7e// as -ostE5atter -ost esti"atio2
Review of re8uiremets=
.easi#i/it$ stu!$ i4o/4i& -hief of Produ(tion2 "he stud group shall
ma,e sure that4
Produ(t requirements are defined
Requirements differing from those previousl e>pressed are resolved
"he $rgani)ation has the abilit to meet the defined requirements
Return the Feasibilit Report and .ost %stimation to Mar,eting2
Preparation of draft quotation and obtaining approval from MD2
#egotiation with the (ustomer4 obtaining Pur(hase $rderN.ontra(t4 verifi(ation of the
same with proposal after resolving differen(es if an with the (ustomer2
AH
Issue of 0or, $rder with relevant do(uments2
#egotiation with the (ustomer and finali)ation of (hanges in the (ontra(t if
an4 found ne(essar during (ourse of development N regular produ(tion2
Getting those amendments formall (onfirmed b the (ustomer and
(ommuni(ating the same to (on(erned departments2
In (ase of repeat order4 issue of wor, order shall be after as(ertaining (apabilit
of meeting deliver requirements2
MAR*%"I#G S"RA"%GI%S
Ma,ing highl sophisti(ated and modern fa(ilities for inspe(tion and
qualit (ontrol4 the firm has no diffi(ulties in (hallenges of /ob2 In this field it has
dependable supplies of qualit (astings and e(onomi( supplies2 "he (ompan follows the
guidan(e su(h as produ(tion of high qualit (astings4 provided inspe(tion to ensure
uniform and rigid qualit (ontrol4 the firm represents automated brea,through in Indian
foundr industr and grading to better international standards2
MAR*%"I#G MIU
"he primar dut of mar,eting department is to ta,e de(ision of produ(t mi>4
pri(e mi>4 and promotion mi> together ,nown as mar,eting mi>2 "he mar,eting
department of Auto,ast aims at improved (ustomer satisfa(tion through redu(ed re/e(tion
and (omplaints at (ustomer ends2 "hus the ultimatel aim at improvement in business
whi(h (an be a(hieved through large e>port volume as well as through the domesti(
(ustomers2
PR$DU." MIU
"he important features of industrial goods that should be ,ept in mind while
de(iding the produ(t mi> is that the have a derived demand4 limited number of buers4
greater s(ale of pur(hase4 (omple> nature and that the buers are full aware of the
produ(t the bu2
Auto,ast +td is equipped to produ(e a variet of (astings4 from the smallest to the
largest2 Sin(e the firm had been in(urring losses for some time now4 the most important
(onsideration is the proper produ(t sele(tion4 so as to redu(e the losses2 "he main fa(tors
ta,en into (onsideration while sele(ting a produ(t are:
BI
Pri(e 9 Pri(e is the single most important fa-tor -osi!ered while sele(ting a produ(t
Ruantit and .onsisten( of $rders 9 0hile bul, orders are re(eived4 due to
e(onom of mass produ(tion4 the (osts (an be redu(ed2 So for bul, orders4 the
primar (onsideration is the pri(e negotiation2 In the (ase of some produ(ts4
where (ustomer is well ,nown and has a wellJestablished business4 the (ompan
(an e>pe(t repeated orders2 In su(h (ases too4 pri(es are often negotiated2
Simpli(it of the Manufa(turing Pro(ess 9 "o generali)e4 the more (omple> the
produ(t be(omes4 the more will be the (ost of produ(tion2 So (astings4 whi(h has
(omple> stru(tures li,e (linder blo(,s have higher (ast of produ(tion4 and
simpler (astings li,e pipe (astings4 whi(h are less (omple>4 have less (ost of
produ(tion2 Giving due (onsideration to the above fa(tor the (ompan has almost
abandoned the produ(tion of thin walled (astings li,e (linder blo(,s for
automobiles2
PRI.% MIU
Pri(e is the e>(hange value pla(ed on the produ(t2 It is a ver important fa(tor4
whi(h affe(ts the profitabilit of the firm4 be(ause it relates dire(tl to the
generation of total revenue2
"here are various methods of pri(ing that (ould be followed2 In Auto,ast the pri(ing
method followed is the 5(ost plus pri(ing8 where a fi>ed per(entage of profit is added to
the (ost of produ(tion to arrive at the pri(e2 In this method4 the total (ost is (onsidered2 It
(onsist of manufa(turing (ost4 administration overheads and se//i& a! !istri#ution
overheads2 "o this a fi>ed per(entage of profit is added4 and thus the pri(e is fi>ed2
Usuall provisions are provided for all losses4 li,e melting losses4 (asting losses and
re/e(tions2
P+A.% MIU
It refers to the distribution (hannel adopted to pla(e the produ(ts before the (ustomer2
"hough there are a variet of distribution (hannels4 industrial goods usuall have a
shorter distribution (hannel2
In Auto,ast about HBO of the distribution is done through the dire(t (hannels2
Dire-t -,ae/ represent a distribution (hannel in whi(h the (ompan dire(tl
distributes the produ(ts to the (ustomers2 "his method (an be (onvenientl followed
be(ause the (ustomers are less in number4 and (an be given individual attention2
"he rest BO is done through agen(ies for e>ports4 a Madras agen( sour(es
orders for Auto,ast2 1esides that4 an agen( in Pune4 Sividha enterprises4 performs
B'
liaison fun(tions in 0est India2 ?a#a/5ur a&e- is one another agen( in #orth India
for Auto,ast2
PR$M$"I$# MIU
Promotion is the pro(ess of (ommuni(ating with (ustomers2 For mar,eting
purposes4 (ommuni(ation of produ(ts and servi(es (ontributes to the persuasion
pro(ess to en(ourage (onsumers to avail themselves of whatever is on offer2
Auto,ast mainl done their promotional a(tivities through various e>hibitions
(ondu(ted at International Foundr 1angalore2
+$.A"I#G .US"$M%RS
'2 Auto,ast does not advertise in an medias2 "hough it has an attra(tive
bro(hure4 designed b the leading advertising agen( U+*A4 with the
attra(tive (aption4 5If ou (an design it4 we (an (ast it84 it has never been used
for (ommer(ial advertising2 Sin(e the firm does not advertise4 sour(ing of
(ustomers is a ma/or dut of the mar,eting department in Auto,ast2 Usuall it
is done
From %>perien(e 9 Almost all the managers and e>e(utives in Auto,ast are those
who have had previous e>perien(e in foundries2 So from their prior e>perien(e4
the are in a position to ,now the people who need parti(ular (astings2
32 $rgani)ations li,e %%P. 9 %ngineering %>port Promotion .oun(il !%%P.& is a
government organi)ation promoting our engineering goods abroad2 "he
(ondu(t trade fairs and provide bro(hures4 whi(h (ontain spe(ifi(ations of
industries and the fa(ilities available2 Auto,ast is in(luded in %%P.=s bro(hure2
Media 9 .ustomers4 who are in need of the (astings4 usuall advertise their
enquires4 tenders et( in newspapers2
+iaison Agents
%U%.U"I$# $F "-% .$#"RA."S
Mere sour(ing of the (ustomers is not eou&,= In fa(t4 it is the first step from
whi(h the length pro(ess of gathering and e>e(ution of (ontra(ts for produ(tion and
suppl of (astings2
#ormall e>e(ution of (ontra(ts pro(eeds through different steps2 "he are:
Step ' 9 Sour(ing the .ustomers
Step 3 9 .onta(ting the Prospe(tive .ustomers
Step ; 9 Re(eiving %nquiries from Interested .ustomers
Step A 9 Prospe(ts of Feasibilit of Produ(tion is %nquired
Step B 9 If found Feasible4 Ruotations are Sent
B3
Step C 9 .ustomer Rea(tion
Step D 9 Re(eiving Pur(hase $rder
Step F 9 Preparing Internal 0or, $rder
Step H 9 Follow up of the Produ(tion
Step 'I 9 Shipment
Step '' 9 .olle(tion of mone and further e>tension of orders
PRI.I#G S"RA"%GI%S
.omple>it of (astings
Pro(ess of Produ(tio
Material Spe(ifi(ation
@olume of .asting
Spe(ial (onditions !"esting J Radiograph4 Ultra Soni( et(&
.$MP+AI#" -A#D+I#G
Register all (omplaints from (ustomers allotting a number with date and time
of re(eipt and a(,nowledge within a da2
Stud the (omplaint to see whether the (omplaint is of te(hni(al or (ommer(ial
nature2 If the nature of (omplaint is not (lear4 see, (larifi(ation2
.omplaints of (ommer(ial nature shall be settled within a period of D3 hrs
from the re(eipt of (omplaint in (onsultation with the MDNFinan(ial .hief2
.omplaints of te(hni(al nature shall be dire(ted to PM with a (op to MRs
$ffi(e within 3A hrs of re(eipt2
Plant Manager shall analsis the nature of (omplaint and dire(t it to (on(erned
-$D li,e4
.omplaints of dimensional deviations to %ngineering and Is5e-tio=
Due to failure of material propert to R.2
Improper inspe(tion pro(edure4 to inspe(tion2
Dela in deliver and damages o((urred during transportation handling4 pa(,ing et( to
Dispat(h se(tion !PP.NMar,eting&2
B;
Department -eads shall analsis the problem and report their observations li,e
.ause of the non (onformit
Suggested disposition date
.orre(tive a-tio 5/a
Pre4etive a(tion plan4 all with a target date
PM shall approve the a(tion plan proposed b (on(erned -$D and return it to
Mar,eting through MR=s $ffi(e2
Inform the (ustomer about the proposed disposition and due date2
Intera(t with the (ustomer to assure that the (omplaint has been addressed and
disposed of to their satisfa(tion and (lose the (omplaint2
Update the .omplaint +og at stages of progress and send a monthl summar
to MR for presenting in the MRM
.orre(tive a(tion Report shall be dis(ussed along with (ustomer (omplaints in
MRM as one of its main agenda2
MAR*%" S-AR% $F MA?$R PR$DU."S
%M1%D %>(el2.hart2F Vs
MA?$R .US"$M%RS
Sl #o .US"$M%R S%."$R '*am(oPower tiller3Ma(awbwer
be,aAsh handling;United .onveor .orporationAsh handlingAPioneer 0in(on0ind
millBRelian(e %nerg0ind millCFourees %ngg@alveDFlowserve@alveF*a,ati
*arsha,@a(uum pumpH+G" Units-eav engineering'IA(e DesignersMa(hine
tool''"riveni %ngineering-eav dut gear bo>'3Shriram %PC0i! "i//
E@PORTS
Auto,ast has been e>porting its produ(ts to Ameri(a and Saudi Arabia4 sin(e 'HFH2
#ow appro>imatel 'IO of the total annual produ(tion is e>ported2 "he (astings4
whi(h are e>ported4 are all GI (astings2
BA
Foreign (ustomers are:
#ational Pump .ompan4 USA2
?Jline Pump .ompan4 USA2
Saudi #ational Pump .ompan4 Riadh2
"he most important benefits of e>ports are that the (ompan gets a higher
pri(e for its produ(ts when e>ported and that the paments are made in (ash2
MA?$R .$MP%"I"$RS
"he ma/or (ompetitors of Auto,ast +imited are the following:
'2 +M0 foundr4 .oimbatore
32 Simple> (astings4 1hilai
;2 Southern allo foundries4 .hennai
.-AR" $F MAR*%"I#G D%PAR"M%#"
BB
SKILLED
LABOUR
SKILLED
LABOUR
SKILLED
LABOUR
SKILLED
LABOUR
SKILLED
LABOUR
SKILLED
LABOUR
SKILLED
LABOUR
C2; PR$DU."I$# D%PAR"MENT
Pro!u-tio !enotes the (onversion of raw materials to semiJfinished or finished
produ(ts with the help of (ertain produ(tion pro(esses2 "he main aim of an
produ-tio s$ste" is to produ(e e(onomi(all the goods and servi(es
required b the (ustomer2
Auto,ast +td is a foundr unit produ(ing iron (astings for a variet of industries2
"he iron (astings are made of (ast iron2 .ast iron is a general term that des(ribes iron4
(arbon4 sili(on allos whi(h are produ(ed b pouring the molten metal into sand N metal
moulds2 .ast iron is brittle and gre in (olour2 "he (arbon (ontent in (ast iron is more
than that in steel whi(h ma,es it less(ted to PM with a (op to MRs $ffi(e within 3A hrs
of re(eipt2
Plant Manager shall analsis the nature of (omplaint and dire(t it to (on(erned -$D li,e4
.omplaints of dimensional deviations to %ngineering and Inspe(tion2
Due to failure of material propert to R.2
Improper inspe(tion pro(edure4 to inspe(tion2
Dela in deliver and damages o((urred during transportation handling4 pa(,ing
et( to Dispat(h se(tion !PP.NMar,eting&2
Department -eads shall analsis the problem and report their observations li,e
.ause of the non (onformit
Suggested disposition date
.orre(tive a(tion plan
Preventive a(tion plan4 all with a target date
PM shall approve the a(tion plan proposed b (on(erned -$D and return it to Mar,eting
through MR=s $ffi(e2
Inform the (ustomer about the proposed disposition and due date2
Intera(t with the (ustomer to assure that the (omplaint has been addressed and disposed
of to their satisfa(tion and (lose the (omplaint2
BC
Update the .omplaint +og at stages of progress and send a monthl summar to MR for
presenting in the MRM
.orre(tive a(tion Report shall be dis(ussed along with (ustomer (omplaints in MRM as
one of its main agenda2
MARKET SHARE O. MA<OR PRODUCTS
MA<OR CUSTOMERS
'& S/ No CUSTOMER SECTOR '*am(oPower tiller3Ma(awbwer
be,aAsh handling;United .onveor .orporationAsh handlingAPioneer
0in(on0ind millBRelian(e %nerg0ind millCFourees
%ngg@alveDFlowserve@alveF*a,ati *arsha,@a(uum pumpH+G" Units-eav
engineering'IA(e DesignersMa(hine tool''"riveni %ngineering-eav dut gear
bo>'3Shriram %P.0ind mill
BD
E@PORTS
Auto,ast has been e>porting its produ(ts to Ameri(a and Saudi Arabia4 sin(e
'HFH2 #ow appro>imatel 'IO of the total annual produ(tion is e>ported2 "he
(astings4 whi(h are e>ported4 are all GI (astings2
Foreign (ustomers are:
#ational Pump .ompan4 USA2
?Jline Pump .ompan4 USA2
Saudi #ational Pump .ompan4 Riadh2
"he most important benefits of e>ports are that the (ompan gets a higher pri(e
for its produ(ts when e>ported and that the paments are made in (ash2
MA<OR COMPETITORS
"he ma/or (ompetitors of Auto,ast +imited are the following:
'2 +M0 foundr4 .oimbatore
32 Simple> (astings4 1hilai
;2 Southern allo foundries4 .hennai
CHART O. MARKETING DEPARTMENT
BF
MANAGING DIRECTOR
DEPUTY MANAGER
%MARKETING+
ASSISTANT MANAGER
SKILLED
LABOURS
D=2 PRODUCTION DEPARTMENT
Produ(tion denotes the (onversion of raw materials to semiJfinished or finished
produ(ts with the help of (ertain produ(tion pro(esses2 "he main aim of an
produ(tion sstem is to produ(e e(onomi(all the goods and servi(es required b
the (ustomer2
Auto,ast +td is a foundr unit produ(ing iron (astings for a variet of
industries2 "he iron (astings are made of (ast iron2 .ast iron is a general term that
des(ribes iron4 (arbon4 sili(on allos whi(h are produ(ed b pouring the molten
metal into sand N metal moulds2 .ast iron is brittle and gre in (olour2 "he (arbon
(ontent in (ast iron is more than that in steel whi(h ma,es it less malleable2 1
varing the sili(on and (arbon (ontent at allo4 several tpes of (ore iron (an be
produ(ed ea(h with different properties and uses2

PRODUCTS O. AUTOKAST
"he (ompan=s produ(ts at present (ater to the needs of following
segments of Indian and overseas industries
'2 Automotive
32 "ra(tor
;2 1utterfl valve assembl
A2 Agri(ulture
B2 0ind mill energ and
C2 General engineering industries
DEPARTMENTS
"he manufa(turing department of Auto,ast limited is divided into four
divisions 2"he are4
'2 Melting
32 .onventional line
;2 -igh pressure line
A2 Fettling
1= MELTING
1efore pouring into the mould4 the metal to be (ast has to be in the molten or
liquid state2 "he raw material melting pro(ess is done in the melting department2
For the preparation of liquid metal the raw materials li,e .R.A!(old rolled
(ontinuousl annealed&s(rap and -MI!heav melting &s(rap are brought to the
indu(tion furna(e2 "he s(rap is (harged to the furna(e with the help of ele(tro
magnet hoo,ed in %$" (ranes4 the furna(e (an withstand a (apa(it of C" with
holding atta(hment and with a (hange over (ontrol sstem2 Furna(e is heated to
BH
about 'ABI degree .elsius!in(luding the loss due to transportation of liquid metal
from the furna(e to the pouring moulds&2the slag is s,immed off from the molten
metal b adding (oagulant2 "he liquid metal is tested for its grades in (omparison
with the standards !eg: different grades of IS 3'I for (ast iron&2 "he samples are
tested at ea(h stage of melting2 "he e>traNe>(ess (hemi(als (omponents are
addedNremoved to a(hieve the spe(ifi(ation2 "emperature of the liquid metal is
ad/usted b the ele(tri(al settings of the furna(e and measured with measuring
instrument!prometer&and is re(orded in the log sheet2 Finall the molten metal is
tapped into (lean pre heated ladle and required quantit of ino(ulants is added to
the stream for the purpose of homogeneous stru(ture of metal (astings2 +iquid
metal is (arried in this ladle and is poured into the previousl prepared moulds for
the testing of final (hemistr ladle sample is ta,en2
"he other melting (omponents are foundr returns4 pig iron4
(o,e!both petroleum and shell&4Ferro sili(on allos4 ferromanganese4 ni(,el
4(opper4 aluminum4 molbdenum4 ferrotitanium et(2
Re-or!s Maitaie!
Registers:J
+ining details
+adle details
Formats:J
+og sheet
.harts
Metallurgi(al (ontrol for -P +ine
Metallurgi(al (ontrol for .onventional +ine
Allo addition
)= CON6ENTIONAL LINE
"his is the semi automated division of the manufa(turing department2 "he main
raw material used for mould ma,ing is sili(a sand2 "his sili(a sand is treated with
sodium sili(ate4 dried and mi>ed with flour dust and is filled into the pattern bo>2
.arbon dio>ide gas is passed through the sand for strengthening !.$3
pro(ess&2then the (ore assembl is fi>ed2 "he moulds are painted with spirited
paint for further finish2 "he metal pouring path is fi>ed and the liquid metal from
the ladle is poured through this2
After a proper setting time the produ(t is separated from the moulds and is
dispat(hed from the se(tion for finishing2
Re-or!s Maitaie!
Registers:J
CI
Mould shop planning
.ore shop planning
.losing
Dail produ(tion
.onsumption of materials
Mould bo> maintenan(e
*no(, out
Formats:J
Dail produ(tion report
Pattern inspe(tion
*no(, out and de(oring
.he(, points for (losing
2= HIGH PRESSURE LINE
-igh pressure line is full automated2 Green sand is the material used for high
pressure molding at first the molding ma(hine is inspe(ted and the good wor,ing
(ondition is ensured2 "he molding ma(hine is operated at C to D ,gN(m
3
2at first the
sand mi>!sili(a sand mi>ed with 1entonite and Menta(oal&2is made available to
the ma(hine in the pattern bo>2 "he sand mi> is thoroughl rammed in the bo> to
the required (ompa(tness b appling pressure2 "he (ore is pla(ed for (avit
formation2 "he metal is poured b the ladle fa(ilit2
.asting identifi(ation mar,s su(h as Sl #o24 month and ear is pun(hed in
the spe(ified area mar,ed in the pattern and details re(orded in the register2 After
a dwelling time of four to five hours the moulds are ,no(,ed out2 "he return sand
shall be (olle(ted in an overhead hopper b means of (onveor belt and bu(,et
elevator2 .asting is sent to the de(oding shop for further pro(ess2 "he molding
bo> are (leaned4 inspe(ted and returned to mould bo> ard2 All the mould bo>es
shall be identified b its si)e and serial number2
Re-or!s Maitaie!
Registers:J
Sand propert
Produ(tion details
.ore produ(tion
.ore shop (onsumption
Sto(, position of (ores
Pouring reports
Mould bo> details
Formats:J
Dail produ(tion planning
Dail produ(tion report
Dail (ore produ(tion report
(= .ETTLING
C'
Fettling is the pro(ess b whi(h unwanted parts of the (asting are (ut off4 (leaned
and finished 2this in(ludes removal of gates 4risers from (asting et( 2"he (astings
are send to the shot blasting ma(hine from whi(h iron shots are blasted at high
velo(it and proper finishing is established2
Re-or!s Maitaie!
Registers:J
.astings for fettling
.astings to sub (ontra(ts
Painting details
Re/e(tion details
Formats:J
Produ(tion report
Finished produ(t return note
PRODUCTION PROCESS
C3
Metal
B&Melting
B&-andlin
g molten
metal
3&Sand
Additives
'&Pattern
Ma,ing
;&.ore
ma,ing
and
ba,ing
Sand
3&Sand
mi>ing and
preparation
A&Moulding
A&Mould
assembling and
handling
C&Pouring D&Sha,ing out F&Fettling G Finishing H&-eat "reatment 'I&Inspe(tion G "esting
STAGE 1 > MOULDING SAND
A mould material is one4 out of whi(h the mould is made2 A mould material
should be su(h that the mould (avit retains its shape till the molten metal has
solidified2 Sand is the prin(ipal moulding material in the foundr shop where it is
used for all tpes of (astings2 "he most important (hara(teristi(s of sand are its
refra(tor nature4 (hemi(al resistivit4 high degree of permeabilit and fle>ibilit2
"hese properties var from sand to sand and onl those sands (hara(teri)ed b the
foregoing features are (onsidered for moulding wor,2
In Auto,ast Sili(a sand is mainl used for moulding2
Sour(es of Sili(a sand :J
J River beds
J Sea
C;
J +a,es
J Desert
Properties of Moulding Sands :J
Flow abilit
Green Strength
Dr Strength
-ot Strength
Permeabilit
Refra(toriness
Adhesiveness
.ollapsibilit
Fineness
1en(h +ife
.oeffi(ient of %>pansion
Durabilit
MOULDING SAND INGREDIANTS
MATERIALS USED AS ADDITI6ES TO SAND
"wo tpes of additives used with sands in A*+ are:
CA
MOULDING
.$#@%#"I$#A+
M$U+DI#G
MA.-I#%
-P M$U+DI#G
+I#%
.$3 Sili(a Sand Green Sand
Fa(ing Sand
WSili(a Sand
!'IIO& Q
Sodium Sili(ate
!A2B to BO& Q
Iron $>ide
!I2BO& Q
7ellow De>trin
!I2BO& Q 0ater
!I2BO&X
1a(,ing Sand
WSili(a Sand
!'IIO& Q
Sodium Sili(ate
!A2B& Q 7ellow
De>trin
!I23BO& Q
0ater !I2BO&X
Fa(ing Sand
WSili(a Sand
!3IO& Q Return
Sand !FIO& Q
1entonate Q
.oal Dust Q
0aterX
1a(,ing Sand
WSili(a Sand
!3IO& Q Return
Sand !FIO& Q
0aterX
Redu(ing agents: "hese are used to improve surfa(e finish of the (astings2 .oal
dust and pit(h are the most (ommon redu(ing agents2 .oal dust suppresses the
formation of sili(ates or iron o>ides due to the rea(tion of metal and sand and also
redu(es metal penetration2
1inders: "he primar purpose of binders is to influen(e the bonding properties of
sand2 De>trin is the (ommon organi( tpe of green binder used in A*+2 De>trin
in(reases air setting and (ollapsibilit2 It prevents sand from dring rapidl2
MOULDING SAND PREPARATION
%ven the best sele(ted sands and binders would not produ(e good (astings4 until
the are effi(ientl and properl mi>ed and prepared2 "he qualit of moulding
sand depends upon the manner in whi(h it is prepared2 An operation (onne(ted
with sand preparation is ,nown as Sand "empering whi(h is essentiall an
operation b whi(h adequate amount of moisture is added to moulding sand to
ma,e it wor,able2 Sand preparation means mi>ing the moulding sand ingredients4
su(h as sand4 binder4 moisture and other additives2 Mi>ing is (arried in Auto,ast
b me(hani(al mi>ers (alled Muller2 A Muller ,neads4 shears4 sli(es through and
stirs the sand b means of revolving wheels or rollers2 Sand (onditioning (onsists
of preparing the mould sand so that it be(omes suitable for moulding pro(ess2
STAGE ) > CORE SAND AND CORE MAKING
A (ore ma be defined as an pro/e(tion into the mould and made up of (ore sand2
A (ore forms internal or e>ternal surfa(es of a (asting2 .ore sand is a suitable
sand mi>ture emploed for ma,ing (ores2 .ores are made separatel4 are ba,ed
and are suitabl pla(ed and positioned in the mould (avit2 .ore ma be defined
as that portion of the mould4 whi(h forms the hollow interior of the (asting or a
hole through the (asting2 .ores must have suffi(ient hardness4 strength in both dr
and green states4 permeabilit4 (ollapsibilit4 high temperature resistan(e and
should produ(e onl minimum amount of gas when in (onta(t with molten metal2
Properties of .ore Sand :J
Adequate Green Strength
-igh Dr Strength
.ore hardness
Adequate Permeabilit
-igh Refra(toriness
-igh .ollapsibilit
Smoothness
Good Friabilit
1en(h +ife
Able to resist the effe(ts of molten metal
Generate minimum amount of gases during the pouring of the (asting2
CB
STEPS IN6OL6ED IN CORE MAKING
.ore bo> is usuall pla(ed on wor,Jben(h4 it is filled with alread mi>ed and
prepared (ore sand4 is rammed b hand and the e>tra sand is removed from the
(ore bo>2
0ea, (ores ma be reinfor(ed with steel wires to strengthen them2
.ore bo> is inverted over the (ore plate and this transfers the (ore from the (ore
bo> to (ore plate whi(h is then ba,ed in the oven2
CORE SAND INGREDIANTS
CC
CORE
.$#@%#"I$#A+
M$U+DI#G
MA.-I#%
-P M$U+DI#G
+I#%
#o 1a,e .ore
WResin4 .atalst4
-ardenerX
3 Part Sstem
WResin Q
.atalstX
; Part Sstem
WResin Q
.atalst Q
-ardenerX
+ow setting Fast setting
Pepset .old 1o>
Sstem WAmine
Gas4 Resin4
.atalstX
.$3 Sili(ate .ore
.$3
Sili(ate
.ore
Pepset -ot 1o>
Sstem
WShell
SandX
STAGE 2 ; MELTING
1efore pouring into the mould4 the metal to be (ast has to be in the molten or
liquid state2 A furna(e is used to melt the metal2 A furna(e (ontains a high
temperature )one or region surrounded b a refra(tor wall stru(ture whi(h
withstands high temperature and being insulating minimi)es heat losses to the
surroundings2 Metal to be remelted is pla(ed in the high temperature region of the
furna(e2 S(rap iron4 whi(h is the most important raw material4 is melted in furna(e
into molten iron2 In Auto,ast Indu(tion furna(e is used to melt metals2 Prometer
is used to (al(ulate the temperature2
STAGE ( > POURING
It is the pro(ess b whi(h the molten metal is poured into the preJprepared sand
moulds2 Pouring is a (ompli(ated pro(ess4 in whi(h man things are to be noted2
"he metal should be poured at the right temperature2 If it is too hot it will produ(e
a te(hni(al defe(t (alled blowholes in (astings4 and if it is too (old due to
premature solidifi(ation4 proper filling will not be attained2 Pouring temperature is
ver important and should be spe(ified with the (asting method4 the tapping
temperature and mould sequen(e are determined a((ordingl2 -igher temperature
are required for (astings with high surfa(e area to volume ratio and short free)ing
time4 in order to fill the mould satisfa(toril2 +ower pouring temperature are
preferred where heav4 (ompa(t (astings are to be produ(ed2
P$URI#G %RUIPM%#"
Pouring +adles : +adles are used to (arr molten metal from the furna(e to the
moulding bo>es2
+adle handle
"rolle
Rails
.ranes
-and wheels
"ilting levers
STAGE * > KNOCK OUT AND DECORING
CD
After the molten metal has been poured into the mould4 it is permitted to (ool and
solidif2 0hen the (asting has solidified4 it is removed from the moulding bo>2
"his operation is (alled *no(, $ut2
A (asting ma be removed or separated from the sand in the following was:J
Dump the mould assembl upside down on the ben(h or ground2 It will
disintegrate the sand of the moulding bo>2
1rea, the sand around the (asting b stri,ing against the sand with the metal rod
or even the ba(, of a rammer2
.astings (an be separated from sand b me(hani(al sha,e out also2
STAGE B > .ETTLING
Fettling is the name given to (over all those operations whi(h help giving the
(asting a good appearan(e after the same has been sha,en out of the sand mould2
Fettling is the pro(ess b whi(h unwanted parts of the (astings are (ut off4 (leaned
and finished2
Fettling in(ludes:
Removal of (ores from the (asting
Removal of adhering sand and o>ide s(ale from the (asting surfa(e
Removal of gates4 risers4 runners et( from the (asting
Removal of fins and other unwanted pro/e(tions from the (astings
STAGE C > SHOT BLASTING
%ven after fettling4 there ma be minute sand parti(les atta(hed to the (astings2
"hese are removed b shot blasting2 Shot blasting is the pro(ess b whi(h (ast
iron shots are blown to the surfa(e of the (astings to remove the adhering sand2
CF
DEPARTMENT CHART
CH
MANAGING DIRECTOR
MANAGER PRODUCTION
ASST=
MANAGER ;
MELTING
ASST=
MANAGER
> CON6
MLDG
ASST=
MANAGER ;
.ETTLING
ASST=
MANAGER ;
HPL
ENGINEER
ASST=
ENGINEER
ENGINEER
ASST=
ENGINEER
ASST=
ENGINEER
ASST=
ENGINEER
SKILLED
LABOUR
SKILLED
LABOUR
SKILLED
LABOUR
SKILLED
LABOUR
D=( :UALITY CONTROL DEPARTMENT
"he (on(ept of high qualit in (astings is defined as the absen(e of
signifi(ant defe(ts in ea(h pie(es2 "he fa(t that the properties of metals have been
sub/e(t to s(atter has been with metallurgists for so long that the problem is hardl
noti(ed2 In fa(t a number of qualit assuran(e sstems have developed to allow
for the ta,ing of a se(ond sample test bar if the first fails une>pe(tedl2
Rualit is the essen(e of modern e(onomi( pro(ess2 "he word qualit refers to the
degree of e>(ellen(e of a produ(t2 Modern age is the %ra of qualit2 "he
(ompetition toda is (utJthroat and ever produ(er tries to improve the qualit of
produ(ts to lure the (ustomers to him2 For improving qualit4 Rualit .ontrol is a
must2 Rualit (ontrol is the sstemati( (ontrol of those variables4 whi(h affe(t the
e>(ellen(e of the ultimate produ(t2 I# Auto,ast there is a fullJfledged qualit
(ontrol and inspe(tion department2
LAB
In Auto,ast A +abs are fun(tioning2
Sand +ab
Me(hani(al +ab
.hemi(al +ab
Spe(tro +ab
"he lab is equipped for the dete(tion and measurement of the elements li,e
Sili(on4 Manganese4 Phosphorus4 Sulphur et(2 It has various equipments for
testing the properties and (hara(teristi(s of moulding sand2
SAND LAB
"he need for sstemati( evaluation of the wor,ing qualities of moulding sands has
led to the development of a wide range of sand (ontrol tests2 Sand (ontrol tests are
performed on the sand whi(h has been prepared and is read to be transferred to
the moulding se(tion2 Sand tests indi(ate the moulding sand performan(e and help
the foundr men in (ontrolling the moulding sand properties through the (ontrol
of (omposition2
@arious sand (ontrol tests (ondu(ted in Auto,ast are:
Infra Red Speed Moisture "est
"his test is used for (he(,ing the moisture (ontent is sands2 0ater is one of the
most important fa(tors whi(h (ontrols properties of moulding sands2 +ow
moisture (ontent in the moulding sands does not develop strength properties2 -igh
DI
moisture (ontent de(reases permeabilit and adds to other problems asso(iated
with moulding operations2 "he moisture is determined b an instrument ,nown as
5Infra Red Moisture "ester82 Spe(imen is weighed and pla(ed on the apparatus2
"he moisture per(entage reading will be )ero2 "hen it is allowed to heat up to a
temperature of ''IJdegree .elsius2 Moisture per(entage reading is again ta,en2
"his gives the moisture (ontent in the spe(imen2
Sand Strength Ma(hine
"he strength of a foundr moulding sand is determined b (ompression4 "ensile
and Shear tests2 "he most (ommonl used test is that of (ompression strength2
Strength testers are used to estimate the (ompressive4 tensile and shear strengths
of sand2 "he sand sample as prepared b a standard sand rammer is pla(ed in a
holder and the same tester ma be used for testing shear and tensile strength2
Permeabilit "est
Permeabilit is that propert of moulding sand whi(h permits the es(ape of steam
and other gases generated in the mould during hot metal pouring2 Permeabilit is
tested with an apparatus ,nown as a <Permeabilit Meter=2 "his has an
arrangement for allowing a (ontrolled amount of air to pass through a sand
sample2 Permeabilit is e>pressed in terms of the permeabilit number4 whi(h is
defined as the volume of air that will pass per minute through a sand sample of
'sq2 (m in (ross se(tion and '(m high at a pressure of 'gNsq2 (m2 "hus
permeabilit number M @2-NA2P2"4 where

@ is the volume of air in ((4
-4 the height of sample in (m4
A the (ross se(tional area of sample in sq2 (m and
P4 the pressure of air in gNsq2 (m4
"4 the time in minutes2
Sieve Analsis
"his test is used to (lassif Sili(a sand a((ording to different grain si)e2 "he
apparatus required for determining grain fineness (onsistsof a number of standard
sieves mounted one above the other4 on a power driven sha,er2 "he sha,er
vibrates the sieves and the sand pla(ed on the top sieve gets s(reened and (olle(ts
on different sieves depending upon the various of grains present in the moulding
sand2 "here are eleven standard sieves mounted one above the other and under the
bottom most sieve is pla(ed on a pan2 "he top sieve is the (oarsest and the bottom
most sieve is the finest of all the sieves2 "he grain si)e of sand is e>pressed b a
number (alled <grain fineness number=2 A given grain fineness number
(orresponds to a standard sieve of 3FImm diameter whi(h has the identi(al
number of meshes in it2
Sand Rammer
D'
Sin(e permeabilit is the propert of rammed sand4 a standard si)ed sand
spe(imen is first rammed b a Spe(imen Rammer2 A standard spe(imen is made
with Split Spe(imen "ube2
.la .ontent "est
In the (la (ontent test4 BIgms of sand is mi>ed with A3B(( of water and 3B(( of
standard #a$- solution in a /ar4 whi(h is then (overed and sealed2 "he (la
(ontent testing apparatus has the provision for tightl holding the /ar in a frame
and rotating the whole frame at about CIrpm2 After an hour of rotation the /ar is
removed and unsealed and the sand adhering to the (over and sides is washed into
the (ontainer2 "he /ar is then filled with water to a predetermined mar,2 After the
sand has settled water is removed from the (ontainer2 .la is dissolved in water
and gets removed along with the same2 "o the sand left in the (ontainer4 more
water is added up to the mar, and is on(e again siphoned off after allowing the
sand to settle for 'I minutes2 "he pro(ess is repeated till water over the settled
sand is (lean and then the settled sand is dried2 "he (la (ontent (an be
determined from the differen(e in weights of the initial and final samples2
MECHANICAL LAB
Representative test bars poured along with (asting identified b heat numbers
pun(hed on the strips imbedded in it shall be tested for its me(hani(al properties2
"he pouring of the test bars shall be witnessed b shift in (harge of laborator2
"wo bars out of the total poured shall be ma(hined to the spe(ified dimensions
and one shall be tested in the lab of Auto,ast2 In (ase the test values do not
(onform to the spe(ifi(ation4 two more bars shall be tested and if onl both of
these bars (onform4 the (asting represented b this test shall be (onsidered as
qualit passed2
1rinnel -ardness "ester : For (he(,ing the hardness of the (asting
1end "est : For (he(,ing welding qualit
Impa(t "esting Ma(hine
Universal "esting Ma(hine
#on Destru(tive "ests
J Ultra Soni( "est
J Magneti( Parti(le "est
J Die Penetrant "est
J Radiographi( "est
CHEMICAL LAB
0%" Analsis is done in this lab2 It is the .hemi(al analsis of iron and steel b
(onventional method2 In this test4 the (ontent analsis of .arbon4 Manganese4
Sili(on4 Phosphorous4 Sulphur4 (hromium4 #i(,el et( are (ondu(ted2
SPECTRO LAB
D3
Analsis of (hemi(al (ombination of metals b spe(trometer is based on the
prin(iple of dire(t reading atomi( emission2 Atoms of ea(h element (an be
energi)ed to emit radiant energ !light& and ever element has its own
(hara(teristi( wavelength2 "he emitted light is diffra(ted over a high resolution
grating or prism and made fall on an arra of photo multiplier tubes2 "he PM"s
(onvert the light energ into ele(tri(al energ4 whi(h is proportional to the
(on(entration of the element present in the spe(imen2 "he (omputer (onverts the
measured energ into (on(entration mode4 whi(h is displaed on the monitor as
per(entage of elements2
Representative spe(imens for evaluating the mi(rostru(ture of the (asting made
shall be drawn from ever heat of SG iron and of Gre iron as per (ontra(tual
requirement2 "pe and si)e of graphite fla,es and the matri> stru(ture shall be
e>amined and re(orded for Gre iron spe(imens2 Per(entages nodularit4 (ount of
nodule per standard area and matri> stru(ture shall be e>amined and re(orded for
SG iron spe(imens2
:UALITY CONTROL
Depending on the requirement of testing G measuring instruments indents
for pro(urement shall be raised b (on(erned departments under intimation to R.
dept2 $n arrival of the instrument4 it shall be inspe(ted4 verified for (alibration4
(alibrate if ne(essar4 label with identifi(ation number G due date for ne>t
(alibration where ever required4 and (lear it for issue to user dept2
A master list of all inspe(tion4 measuring and test equipments shall be
maintained and all these equipments shall be identified b a (odeNserial number2
"he frequen( of (alibration required for the instrument shall be
determined and a s(hedule prepared2 0hen (alibration (an be done in house4
ensure that (alibration is done as per s(hedule against masters having tra(eabilit
to national standards and maintain re(ords for su(h (alibration2 0hen outside
agen(ies are engaged for (alibration4 ensure that su(h agen(ies do the (alibration
against masters having tra(eabilit to nationalN international standards2
.ertifi(ates of su(h (alibration shall be maintained as re(ord2 %nsure that users
are trained to handle the instrument2 Store them in su(h a wa that a((ura( and
fitness for use are maintained2 If and when Inspe(tion4 measuring and test
equipments are found out of (alibration4 the immediate previous test re(ords shall
be anal)ed4 verified4 do(umented and ne(essar (orre(tive a(tion shall be
initiated2 If ne(essar the produ(t will be re(alled2
INSPECTION
"he /ob of inspe(tion department is to interpret the spe(ifi(ation properl4 inspe(t
whether or not the /ob (onfirms to those spe(ifi(ation and (onve the information
D;
obtained to the (on(erned department for ne(essar (orre(tion pro(ess2 In A*+4 a
four stage inspe(tion pro(edure is followed
1la(, .asting Inspe(tion
J Inspe(ting (astings without removing sand
J If defe(ts found4 then segregation
After Shot 1lasting
J #on (onformit Salvaging
J #on .onformit Re/e(tion
3& In Pro(ess Inspe(tion
J Dire(t to #.
;& After Finishing
J 0ith paint Y Dire(t to #.
9 0ithout paint Y Dire(t to #.
T$5es of Is5e-tio
'& @isual Inspe(tion
3& Dimensional Inspe(tion
9 As per .ustomer drawing
In Dimensional Inspe(tion the deviations noti(ed will be send to the (on(erned Produ(t
Development "eam
Dimensional Inspe(tion done to :
J Sample Inspe(tion
J Random Inspe(tion
.learan(e Report will be send to the Produ(tion4 Mar,eting4 +ab4 PP. Departments
Re/e(tion Report will be send to the Produ(tion4 Rualit .ontrol4 PP. Departments
:UALITY CONTROL PROCESS
DA
Requ
ireme
nt
.u
sto
me
r
.ust
omer
Sati
sfa(t
ion
.ontinual Improvement of RMS
Rualit .ontrol
Mar,eting %ngineering
Produ(tion
of .asting
Deliver
Pur(hasing G
$utsour(ing
Suppliers
Storage
Measurement Analsis
G Improvements
Resour(e Management
Management Responsibilit
Re-or!s Maitaie!
Registers:J
Details of Measuring equipments
Manufa(turing and #. details
.asting Inspe(tion details
Sub(ontra(t Inspe(tion 9 Fettling
Final Inspe(tion after ma(hining
Dispat(h details
.ustomer details
Returnable gate pass
Formats:J
Shot blasting Inspe(tion Report
.asting Dimensional Inspe(tion Report
DB
Maintenan(e G
.alibration
Defe(t Analsis Report
Dail #. Report
.he(, list for inspe(tion (learan(e
Ma(hining inspe(tion report
Inspe(tion (learan(e report for dispat(h
.he(, list for e>port (learan(e
DEPARTMENT CHART
DC
MANAGING DIRECTOR
MANAGER %:C A ENGG+
INSPECTION
D=* MATERIALS DEPARTMENT
Materials department (on(erned with pur(hasing of raw materials needed for the
produ(tion pro(ess2 %ver manufa(turing organi)ation will have a pur(hase department
and performs a variet of fun(tions starting from pur(hase requisition to the pur(hase of
raw materials2
Pur(hase and stores together forms the materials se(tion of materials and sub(ontra(t
department
PURCHASE DEPARTMENT
$btain pur(hase indents of all raw materials4 (onsumable and spares from user
departments2 Indents for offi(e equipments4 stationer and printing items shall be raised
DD
ASSISTANT MANAGER
TECHNICAL ASSISTANT
SKILLED LABOUR
b Administration department2 All indents shall be dul approved b Plant Manager2
Details shall be entered in a register2 @erifi(ation of indents for (ompletion in respe(t of
spe(ifi(ations and other details and ambiguities if an4 are (larified2
After sele(tion of the vendor4 pur(hase se(tion prepare a pur(hase proposal and
put up to the tender (ommittee2 "he (ommittee (onsists of representatives from finan(e
and pur(hase departments and plant manager and MD 2After the approval b the tender
(ommittee4 pur(hase order is prepared and registered2 Pur(hase order up to a value of Rs
'I la,h is reviewed and released2 "he reviewing authorit of pur(hase order ensures all
the relevant data in the pur(hase order2 Finall the original (op of the pur(hase is sent to
the supplier2
PROCESS
PARAMETERS .OR SELECTING A SUPPLIER
Spe(ifi(ations of material
Pri(e negotiation
Deliver time
LOCATING SUPPLIERS
"hrough Mail4 Phone4 Advertisements
E@ISTING SUPPLIERS
DF
"hese are the some of the e>isting registered suppliers
'& S(rap
- .ali(ut steel
- *erala Metal4 "hrissur
- Ambal "raders4 .oimbatore
- @i/aa "raders4 $ttappalam
3& Sodium sili(ate
- *iran Global .hemi(als +td
- Minar .hemi(als
;& .$3 Gas
- Paulos G Mathen4 %rna,ulam
- A,shaa Gas4 %rna,ulam
A& 7ellow De>trin
- Rualit "raders
STORES DEPARTMENT
Store is a part of Materials Department2 It=s main fun(tion is to store items2 Raw
materials4 other items related to produ(tion and spares et( shall be labeled using tags
after (learan(e from Inspe(tion Department2 "he tag shall (ontain material (ode
number4 material des(ription4 unit of a((ount4 part number if an GR@ referen(e et(2
Storage pro(edure for raw material depends on the volume si)e and quantit2 Spare
parts shall be stored equipment wise2 Rualit of stored material shall be assessed
annuall to dete(t an deterioration in qualit2 1la(, (astings after first stage
inspe(tion (learan(e4 handed over to Fetting dept2b PP.4 shall be sta(,ed item wise
near the shot blasting ma(hine2 After shot blasting4 inspe(tion (leared (asting shall be
sta(,ed at designated area2 .astings mar,ed for salvage shall be shifted to area
demar,ed for salvaging operations2 After salvaging operations4 these (astings shall be
offered for inspe(tion and shall be shifted to designated areas as per the status2 Fettled
(astings after inspe(tion (learan(e4 read for dispat(h shall be shifted to designated
area and preserved there (arefull till dispat(h2 .astings meant for painting and
ma(hiner operations shall be shifted to respe(tive areas2 After painting (astings shall
be preserved (arefull at the areas demar,ed for su(h (astings2 Ma(hined (astings4
(leared b inspe(tion4 shall be sub/e(ted to painting NgreasingNrust preventive (oating
as per requirement and sta(,ed with proper (overings to prote(t from dust and rust2
.UNCTIONS
Re(eption of materials
-ouse *eeping
IssueNDisposal
Main thing that is (on(erned with this department is quantit
DH
PROCESS
'2 0hen a material is re(eived4 it is weighed and the re(eipt is entered in the da boo,2
32 #e>t step is to prepare GR@ !goods re(eived note&
;2 "he material is send to the qualit (ontrol department for (he(,ing and inspe(tion
A2 If the material satisfies the required spe(ifi(ations and qualit standards4 it is put to
sto(, and otherwise it is re/e(ted2
B2 Finall prepare material wise bin (ards !sto(, (ards&
!At first the (ompan prepared the bin (ards manuall4 bt4 now it is done b the
softwareJ "all %RP H&
Re(eipt in and dispat(h from stores is (ontrolled through do(umented sstem2
Sto(, Statement is given to PP.
Indent stores Issue #ote !Departments have to given to stores for re(eiving
FI
materials&
Z
1in .ard !Re(eipt4 IssueNDisposal&
Stores Return #ote !For e>(ess materials from the (on(erned departments&
Materia/s Store!
M S S(raps
Ferro Allos
Additives G Flu>es
Refra(tories G Ramming Masses
Fuels G Gases
Abrasives= G Grinding 0heels
%le(tri(al Items
+oose "ools
+ab .hemi(als G %quipments
Produ(tion .onsumables
Ma(hiner Spares
Instruments G Gauges
0elding G 1ra)ing Materials
Fasteners G -ardware Items
1earings
Pulles G @ 1elts
.hains4 Spro,ets4 0ire Ropes G Slings
Paints G Pipe Fittings
Mis(ellaneous Stores
.apitali)ed Stores
Prote(tive G Safet Applian(es
Stationar Items
.ement G Stru(tural Steels
Pattern G Pattern %quipments
Spares for -P +ines
F'
DEPARTMENT CHART
F3
MANAGING DIRECTOR
MANAGER %MATERIALS+
ENGINEER %MATERIALS+
ASST ENGINEER
%STORES+
ASST O..ICER
%MATERIALS+
SKILLED SKILLED
D=B .INANCE DEPARTMENT
"he part of an $rgani)ation that manages its mone2 "he business fun(tions of a Finan(e
Department tpi(all in(lude planning4 organi)ing4 auditing4 a((ounting for and
(ontrolling its (ompan=s finan(es2 "he Finan(e Department also usuall produ(es the
.ompan=s finan(ial statements2
Finan(e is defined as the provision of mone at the time when it is wanted2 Finan(e
department in Auto,ast is (on(erned with the maintenan(e of a((ounts and preparation of
finan(ial statements2 "he a((ounts of the (ompan are maintained a((ording to the
(ompan a(t of 'HBC regarding in(ome and e>penditure2 It is finali)ed during the end of
the finan(ial ear and the annual reports are all under due proper audit2 "he ear begins
on '
st
April and ends on ;'
st
Mar(h2
"he finan(e department ,eeps the transa(tion of the sale of (astings4 pur(hase of
(ast materials 4pament of salaries and wages et(2 Details regarding over time pament4
leave surrender4 bonus are also maintained b the finan(e department2
.UNCTIONS
Maitea-e of A--outs
A((ounts in A*+ are maintained as per the requirements of the .ompanies A(t 'HBC2
"he (ompan maintains the detailed a((ount of its assets G liabilities and in(omes G
e>penditures2 At the end of the finan(ial ear a((ounts are finali)ed and annual
a((ounts are prepared2 "he are properl audited2
"ransa(tions
F;
"he main transa(tions in the (ompan are sale of (astings4 pur(hase of raw materials and
other materials4 pament of salaries and wages4 various statutor and other paments et(2
'2 Pur(hases 9 A boo, is maintained at the stores for pur(hases2 An material
brought to the (ompan is routed through the stores2 "he a((ounts department
maintains a parallel re(ord for the same4 i2e2 a pur(hases daboo, through the
.omputer Sstem2
32 Sales 9 0henever a sale is effe(ted4 the sales or mar,eting department prepares
invoi(es4 (entral sales ta>4 gate pass et( and dispat(h (astings2 "he transa(tions
are (onveed to the a((ounts department through networ,4 where the sales
daboo, is maintained2
;2 0ages and Salaries 9 %mploees paments are made b the department and
-R Department prepare the detailed pa rolls for monthl wages4 salaries4
overtime paments4 leave surrender salar4 bonus et(2
All other transa(tions are re(orded and (arried out through other boo,s of entries vi)2
(ash boo,4 ban, boo, and /ournals2
PRICING METHOD
"here are various methods of pri(ing that (ould be followed2 In Auto,ast the
pri(ing method followed is the 5(ost plus pri(ing8 where a fi>ed per(entage of profit is
added to the (ost of produ(tion to arrive at the pri(e2 In this method4 the total (ost is
(onsidered2 It (onsist of manufa(turing (ost4 administration overheads and selling and
distribution overheads2 "o this a fi>ed per(entage of profit is added4 and thus the pri(e
is fi>ed2 Usuall provisions are provided for all losses4 li,e melting losses4 (asting
losses and re/e(tions2
BUDGETING
Bu!&et Pre5aratio
Annual 1udget of the (ompan is prepared b Finan(e Department in (onsultation
with the higher management2 .ir(ulars are issued months ahead for the (olle(tion of
required data from the other departments2 Past data and future pro/e(tions are (olle(ted
from all the departments4 the are verified for a((ura( and (onsisten( and draft
budgets are prepared2 1ased on the further dis(ussions with the MDN-$Ds budget is
prepared2 "here is a budget for the (ompan as a whole and for ea(h department2 As
the finan(ial resour(es of the (ompan are ver mu(h limited the budget is again
trimmed and brought down to the bare minimum si)e2 "he budget (onsists of e>pe(ted
e>penses and anti(ipated in(omes for the (oming finan(ial ear2
"he different (omponents of the budgets are:
FA
"he Sales 1udget
"he produ(tion 1udget
"he Revenue 1udget
"he .apital 1udget and
"he Manpower 1udget2
"he 1udget is approved b the 1oard of Dire(tors of the (ompan before the
(ommen(ement of the finan(ial ear2
I"5/e"etatio of t,e Bu!&et
Finan(e Department is the wat(hdog of the budget2 It s(ruitinises the implementation
of the annual budget and its monthl4 quarterl4 and half earl targets2
DEPARTMENT CHART
FB
MANAGING DIRECTOR
MANAGER %.INANCE+
ASSISTANT MANAGER
%INCOME TA@+
ASSISTANT O..ICER
%SER6ICE TA@+
ASSISTANT
%PURCHASE+
ASSISTANT
%CASH+
ASSISTANT
%BANK+

CHAPTER F > S0OT ANALYSIS
FC
S0OT ANALYSIS
Identifi(ation of the threats and opportunities in the environment and strength
and wea,ness of the firm are the (ornerstone of business poli( formulationL it is these
fa(tors that determine the (ourse of a(tion to ensure the survival or growth of the firm2
"he environment might present opportunities but a (ompan might not have the
strength to e>ploit all opportunities2 Similarl sometimes a firm will not have the
strength to meet the environment threats2
STRENGTHS
'2 -ave sophisti(ated ma(hiner4 fa(ilities and equipment
32 Availabilit of good qualit Sili(a sand
;2 #earness to seaport infrastru(ture2
A2 @ersatilit in produ(tion pro(ess 9 abilit to produ(e a wide range of produ(ts2
B2 "here is no problem of power failure2 Auto,ast has got 3A hours power suppl
C2 0ell established (ustomer base4 (ustomer loalt and satisfa(tion2
D2 "ailor made produ(ts 9 made to order to suit requirements2
F2 Rualified and well trained emploees2
H2 Installed (apa(it to produ(e large volumeJ brea, even at BIO (apa(it2
'I2 Good potential for e>port2
''2 Government ownership
0EAKNESSES
'2 +ong development time for new produ(ts2
32 -igh fi>ed overheads2
;2 Insuffi(ient fettlingNma(hining fa(ilit2
FD
A2 Situated awa from ma/or (ustomers2
B2 +ow (orporate image2
C2 +ow managerial (apa(it2
D2 Finan(ial (onstraints2
F2 -eav burden of past liabilities2
H2 Absen(e of (ost (ontrol me(hanism2
'I2 Redu(ed manpower2
''2 #ature of the industr in general and low demand2
OPPORTUNITY
'2 "he new /oint venture with Railwas will open a wide opportunit for future
growth of the (ompan2
32 "here is high potential for e>port to %urope and USA due to better qualit of
produ(ts2
;2 Redu(tion in input (ost is possible2
A2 +ess (ompetition for windmill (astings2
B2 .omposite foundr 9 (an produ(e B,g in si)e to BIII,gL GI and SGI (astings for
different appli(ations2
THREATS
'2 General re(ession in the mar,et2
32 Survival of the (ompan depends on government poli( regarding revival2
;2 Ma/or investment required to pro/e(t health finan(ial position2
A2 Global (ompetition2
B2 More bargaining power of (ustomers and suppliers2
C2 Politi(al intervention in the (ompan pro(eedings2
Ma/or strategies to (ounter the threats and wea,nesses in(lude the following:
'2 A(hieving more e>port sales2
32 Identif and develop domesti( mar,et2
;2 Aggressive sales and promotion a(tivities2
A2 .on(entration of high value items2
B2 Good (ost (ontrol me(hanism2
FF
CHAPTER 1O > .INDINGS AND
SUGGESTIONS
FH
.INDINGS AND SUGGESTIONS
Auto,ast +td manufa(tures all tpes of ferrous (astings under the same roof2
Auto,ast is a modern industrial (asting unit with IS$ HII3 (ertifi(ation2 "he (ompan
has an optimum (apa(it of 'FIII tons per annum and (overs an area of 3'BII sq2
meters2 "he (ompan (an manufa(ture ferrous (astings of all grades and si)es ranging
from B,g to FIII,g2
.INDINGS
Auto,ast +td has the potential for produ(ing good qualit .astings2
It owns all sorts modern testing equipments2
"he lo(ation of (ompan is advantageous while (onsidering the availabilit of
Sili(a sand whi(h is a ma/or raw material4 but when (onsidering the ma/or
.ustomers and other raw materials the problem of transportation arises2
"he .ompan has lot of s,illed wor,ers4 but the influen(e of trade unions
wea,ens the Management2
Re(ruitment is not often done in the .ompan2 #ow the ma,e onl temporar
sele(tions whi(h results in low (ommitment of emploees towards $rgani)ation2
Promotional a(tivities for their produ(ts are not (ondu(ted effi(ientl2
"he .ompan is in loss and it has a heav burden of past liabilities2
"he (ompan lost ma/or portion of its equipments due to ineffi(ient maintenan(e2
"he .ompan provides less motivational fa(tors2
Auto,ast does not provide mu(h safet measures for their wor,ers2
In the earl stages Auto,ast have the fa(ilit for ma,ing the Fa(tor environment
(lean and dust free using the Dust .olle(tor Ma(hine2 1ut now it=s not wor,ing
and no measures ta,en so far for ma,ing it in wor,ing (ondition2
+a(, of Professionalism in almost all areas2
"here is no .ost .ontrol "e(hniques adopted2
HI
Some of the newl pur(hased ma(hineries for Steel Plant is not et start
fun(tioning and it stas ba(, as dead mone2
"here are several areas of opportunities to ma>imi)e its profit2 1ut the politi(al
influen(e on Auto,ast is a barrier of its development2
Auto,ast does not ta,e the advantage of newest I" "e(hnolog advan(ements2 It
sti(,s on to the (onventional methods2
+ow (apa(it utili)ation2
+a(, of proper training to %mploees2
-igh operating e>penses2
"he Management ma not able to ta,e de(isions effe(tivel4 be(ause of the
limited (apabilit to withstand politi(al pressure2
"he (ompan is not tring to e>pand its mar,et2
SUGGESTIONS
.ompan should fo(us on giving more motivations to %mploees2 At present
.ompan la(,s motivational a(tivities2 1 introdu(ing Parti(ipative Management
the morale of the %mploees (an be in(reased2
Introdu(e the new advan(ements in I" "e(hnolog to the .ompan2 Usage of
modern software su(h as Magma will help in Produ(tion b redu(ing re/e(tion
rates2 0ith (asting simulation tools we (an simulate and visuali)e4 on the
(omputer s(reen4 the entire pro(ess of (asting the part4 in(luding pouring4
solidifi(ation and shrin,age formation2 Using this information4 we (an fineJtune
our design to produ(e the best (asting possible4 at the lowest (ost2 #ow .ompan
uses trial and error method for Pattern drawing2 Also introdu(e SAP based
"e(hnolog to the $rgani)ation2
Give more importan(e to RGD Department2 Find out methods for redu(ing the
operating e>penses2 Re(ruit more e>perien(ed people to RGD2 At present there is
a la(, of manpower2 0ith the help of RGD department the (ompan will be able
to diversif its produ(t line and find alternative uses for its e>isting ma(hiner2
Implement .ost .ontrol te(hniques aiming at redu(ing (osts to be more
(ompetitive2 %stablishment of a (osting department will help the (ompan to
anal)e the (ost stru(ture and find out the loopholes2
In(rease the (apa(it utili)ation2 "he present produ(tion of the (ompan is less
than its total (apa(it2 If the (ompan utili)es the (apa(it at its best4 it (an
generate profits2
Give importan(e to .ustomers2 A (onsumer analsis will help to tra(e out the
reasons4 whi(h ma,es them turn to Auto,ast2 "his will help to ,now the strengths
and wea,nesses of the firm2 So a (onsumer analsis will help the (ompan to
H'
understand the (onsumer more and (ater to their needs more su((essfull2
.ontinuous and health (lient relations should be maintained
Deliver proper maintenan(e to the e>isting ma(hineries2 Shut down maintenan(e
is not done so far2 It=s alwas better to give Preventive maintenan(e rather than
waiting for the ma(hiner to brea,down2
Provide some safet methods to the wor,ers for ensuring prote(tion to their life2
.ompan offi(ials and government authorities should (olle(tivel intera(t and
evolve plans for implementing the de(isions for revamping the firm to potential
areas2 %ffort for over(oming the politi(al bias is required2
Ma,e more sales reali)ation in the domesti( mar,et2 Generating more sales in the
mar,et (an redu(e (ost burden of the (ompan and thereb in(rease the profit2
As the (ompan is owned b government4 the should ta,e initiatives to settle the
loans4 whi(h are alread overdue and prepare the ground for the (ompan to
obtain wor,ing (apital support2
CHAPTER 11 > CONCLUSION
H3
CONCLUSION
$rgani)ation Stud in Auto,ast +imited4 .herthala helped me in several areas li,e
understanding about the organi)ation4 understanding its wor, (ulture4 diffi(ulties in
maintaining of the business et(2 An organi)ation stud is essential for all studies2 "he
main ob/e(tive of this stud was to understand the da to da fun(tioning of an
organi)ation2 Purpose of this stud is to understand how the theoreti(al ,nowledge (an be
applied to the pra(ti(al situations and e>amine an organi)ation=s fun(tions and identif its
oppor t uni t i es N pr obl ems and al s o s ugges t (or r e(t i ve meas ur es 2 "hi s
s t ud i s al s o ver ne(essar to gain (onfiden(e and be(ome aware of the
me(hanism of an organi)ation2
Auto,ast is a modern industrial (asting unit with IS$ HII3 (ertifi(ation2 "he unit is
lo(ated at S # Puram near .herthala2 "he (ompan has an optimum (apa(it of 'FIII
tonnes per annum and (overs an area of 3'BII sq2 meters2 Auto,ast is the largest foundr
in the publi( se(tor in South India2 Most of its (ustomers are lo(ated outside *erala2 "he
(ompan e>ports (astings to USA and %urope also2 In spite of its past liabilities Auto,ast
is striving to turnaround2 %ven though it is a publi( se(tor (ompan it does not en/o an
privilege or patronage from publi( bodies2 It is (ompeting with the private se(tor in the
open mar,et2
"he (ompan has spe(iali)ed in the manufa(ture of (astings required for windmills2
0indmills form nonJ(onventional energ sour(e and therefore the fun(tioning of this
(ompan (ontributes towards a priorit se(tor of the e(onom2
"he organi)ation stud gave me a (han(e to understand the internal fun(tioning of a
manufa(turing (ompan in the engineering industr2
H;
BIBLIOGRAPHY
HA
RE.ERENCE
Annual report of Auto,ast limited
Rualit manual of Auto,ast limited
SamanvaamJA publi(ation b Auto,ast re(reation (lub
www2auto,astltd2(om
www2indianfoundr2(om
Personnel management L %dwin 1 Flippo
$rgani)ational 1ehavior L * Aswathappa
Mar,eting ManagementL Philip *otler 2
HB