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EXECUTIVE SUMMARY :

AIRTECH saw its beginning in the year 1980 in Dharwad with a vision of team
of qualified engineers who came together to serve the technical needs of the market. Thus
they established a manufacturing unit at Dharwad that began its manufacture with
CONCENTRIC COVENTRY CHUCKS as its first product. The energizing power of the
promoters saw new chucks and tools for work-holding being added regularly to the range.

AIRTECH is a private company that is involved in the production of power chucks,


rotary cylinders, custom built chucks and turret lath tooling.

At the start AIRTECH registered as small concern for manufacturing of concentric


Coventry chucks. Later the Company is registered under the Company’s Act 1956 as
AIRTECH PVT LTD, with the initial investment of Rs. 5, 00,000/-

Beginning in 1980 with the manufacturing of concentric chucks, Airtech has


grown as one of the leading manufacturer of chucks. In fact, they provide total work-
holding solutions.

Through constant interaction with customers and continues product innovation


over a span of two decades, the employees have added to the company’s range of
standard products.

This encompassed practically every work holding need. They have also helped in gain of
technical competence that provided cost effective customized solutions to some of the
most complex work holding environment. They have also developed a range of matching
cylinders.

They have specially designed their chucks, cylinders and work holding solutions for
Indian working condition to easily match some of the best known global manufacturers.
The industries who have opted for their products accepted the fact of reliability.

To ensure a consistently superior product, Airtech adopts a system of continuous


checks and inspections right from raw- materials to finished products. The company’s

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trained work force are satisfied and proud of Airtech’s reputation for the quality, thus
they also keep an eagle eye during the production.

In AIRTECH, there are 8 departments. The Planning and purchase department


gets orders from various suppliers as well as from perspective customers. After seeing to
its terms, conditions and cost aspects the department issues acceptance order. But for
specialized tool where some parts cannot be manufactured the company outsources the
activities. After it comes from the outsourced agency, the department is responsible for
execution of purchase orders once accepted.

The stores department carry out the activity of storing the raw materials as and when it
arrives. When the raw-materials is received from suppliers the sum is tallied with the
delivery challen / invoice / cash memos / credit memos placing slips etc.

The quality assurance department checks the quality of the raw materials, semi finished
product and finished product. It verifies the quality at each and every stage right from the
purchase till the delivery of the product.

The production plant is big and clean in which workers can work out of dust and foul
without any problem. In this department all the products of different dimensions are
produced and for specific batch members specific dimension products are said to be
produced.

The marketing department regularly improvise in their designs, cut the costs to keep their
customers satisfied.

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INTRODUCTION TO STUDY

The main purpose of conducting this study is to fulfill the BBA degree apart from our
curriculum activity in the name of In-Plant training program in an Organization.

More importantly to conduct this study is to get practical knowledge at work place and
utilize our theoretical aspects in the practical problems. It is important to utilize day-to-day
knowledge for the problems that a raised in the organizations and give the decision ideas by
analyzing the problems.

1. To complete the project work as part of our curriculum activity.

2. To get work experience in practical environment with real work persons

and develop sense of confidence of conducting work.

3. To identify the problems in the organization and analyze the problems and

give solutions.

4. To bring the close attachment between the entrepreneurs, managements

and educational institutions to make the students to face the challenging

job in future.

5. To develop the student’s individuals by making them to carryout the study

works in units and prepare them to make the suggestions to develop the

unit.

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INDIAN MACHINE TOOL INDUSTRY

Indian economy has been generating growth and outcome since many years.2008-
09 was yet another landmark year for the Indian economy and the industry, generating a
great deal of optimistic growth and promising outcome. The year was marked by 6.2%
GDP growth-earning the accolade of being one amongst the fastest growing countries in
the world.

Surge in demand was rampant across Indian industries, especially in the


engineering and the manufacturing sector. Key aspect about manufacturing industry’s
performance was its efforts to achieve excellence in quality, technology, design and
innovation. The country also posted optimistic results in agriculture and in the service
stream.

For the Indian machine tool industry, 2008 was the year of smooth sailing, with
increased business opportunities, as a result of the demand surge from the Indian and
overseas markets. Metal working machine tool output of the Indian industry worth Rs
16,797 million, registered a growth of 34% in Jan-Dec 2008. Much of the growth in
India’s metal working machine tools came about because of enhanced requirements from
the automotive sector, the auto ancillary industry, defense, railways and small-scale
industry units.

With growth and business optimism on the swell in the Indian economy and the
industry, the year 2008 is expected to result in continuing heightened orders for the home
machine tool industry.

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METAL-CUTTING AND METAL-FORMING MACHINE TOOLS:

Metal cutting segment continue to account for 68% of the total output of the
machine tools in India. In 2008, metal cutting machine tool output worth Rs 14,780
million, led a growth of 32.8%.

Turning centre’s recorded the largest production in the industry during Jan-Dec
06, with a share of 30% in the total machine tool output. Turning centre’s together with
machining centre’s and grinding centre’s, accounted for nearly 3 quarters of the total
metal cutting produce and about 2/3rd of the total metal working output in the year 06.

Indian manufactures in the metal forming segment, on the other hand, registered a
growth of 41.7%, with an output valuing Rs 2,016 million. Press manufacturers witnessed
largest volume of business in this segment, with a 60% share in metal forming machine
tools.

CNC & CONVENTIONAL MACHINE TOOLS:

In keeping with the focus of the Indian industry towards enabling manufacturing
excellence, CNC machine tools comprised bulk of the manufacture from the Indian
stable. This segment had over 69% share on the total metal working metal tool output in
2007.

CNC machine tool segment in India clocked a growth of 32% with a turnover of
Rs.11,598 million.

CNC turning centers together with machining and grinding centre’s held a share
of as high as 81% in the total CNC machine tool produce and 56% share in the metal
working output in 2007. These three segments have been leading for over half a decade.

Conventional machine tool manufacturer likewise registered high growth of


38.3% to an output valuing Rs. 5,198 million.

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WORLD-CLASS WORK HOLDING SOLUTIONS

Specially designed for Indian working conditions, our Chucks, Cylinders and Work
holding solutions easily match some of the best known global manufacturers.

EXPORT SCENARIO:

Focus of Indian manufacturers to expand its potential to other frontiers resulted in


tapping new opportunities in overseas markets. As a result, exports increased by 45% in
2007-2008 .The exports by Indian industry in Jan-Dec 2007 were 286 machine tools of
worth Rs. 746 million.

Indian manufacturers exported 36 countries, including to prominent ones such as


Italy, Canada, Germany and United states. Highlight of the machine tool exports in 07-08
was the performance in the CNC segment. CNC machines not only registered a growth of
60% over in the past year, but also increased its share in total Indian machine tools
exported to 62%. Machining centers followed by turning centers, electro-discharge
machines and witnessed highest export orders. Together these three machine segments
accounted for nearly two-thirds of the total exports in 2007.

IMPORT TREND:

The Indian market and a capacity-constrained Indian machine tool industry


resulted in a zoom-phase for importers. Machine tool imports by 31% to register a total
value of Rs. 37,936 million. With this hike, imports captured 70% of the Indian market
share.

Bulk of the imports comprised metal-cutting machine tools witnessed a 22%


increase in growth over the previous years. And within this segment, machining centers,
turning centers and grinding centers formed the large chunk of imports. These three
machine categories captured 40% of the total machine tool imports into the country in
2008.

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FIGURES OF INDIAN MACHINE TOOL INDUSTRY:

[Values in Rs.million]

YEAR PRODUCTION EXPORTS

2004 4,817 485

2005 5,178 478

2006 10,111 491

2007 12,556 516

2008 16,796 746

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PERFORMANCE OF USER INDUSTRIES:

Persistence in growth prospects of the Indian economy was evident in


most sectors of the industry, in particular amongst the major users of machine tools. A
consistent enhancement in performance was observed in most segments of the Indian
automobile, Capital goods, Consumer durable and intermediate goods’ sectors in fiscal
year 2007-2008.

AUTOMOTIVE SECTOR:

Indian automotive industry continued with its momentum of steadfast


performance in output, clocking a growth of 13.6% during 2007-2008. Growth was
skewed with most key segments in the auto sector witnessing high turnover and a few
moderate growth in the previous year. Commercial vehicles segment witnessed a high
growth of 32% in the wake of a increased demand in the Indian market. High growth was
witnessed in both the segments. Production of light commercial vehicles jumped by
31.4% , i.e, 2,25,734 units. Heavy and medium commercial vehicles – the segment that
constitutes 60% of the total commercial vehicle industry in the country, had a better
growth of 34.2%. even the high performing passenger car segment sustained the
momentum of high growth. Passenger car and multi-utility vehicle manufacturers, with
an output of 1.55 million passenger cars, registered a growth of 18% in 2007-2008.
Moderate results came in from the two-wheeler auto segment, with a production of 8.4
million motorcycles, scooters and mopeds – aggregating a growth of 11% . riding on the
demand surge from all across the country, motorcycles segment recorded a high growth
of 17.5%. share of motorcycles increased to 84% of the total two – wheeler industry in
India.

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CAPITAL GOODS SECTOR:

Indian capital goods industry was clearly the success story of the Indian
industry’s performance in 2007-2008. And a major contributory to the high
manufacturing growth.

High growth was evidenced in all the segments of the capital goods
industry. Segments such as diesel engines, earth moving and construction equipment,
industrial furnace, pumps, transformers, textile machinery and tractors had a high growth
ranging between 15% to 32% during April 2007- March 2008.

CONSUMER DURABLE SECTOR:

Again in the auto sector, it was a see-saw performance in the country’s


consumer durable industry. Although on the whole it was eighth successive year of good
of moderate growth. Continuous process of mergers and alliances as well as introduction
of new brands kept up the tempo of demand in this sector. Air conditioners, microwaves,
video recorders and electric fans recorded a high growth to the tune of 20%, 25% 20%,
22% respectively. While manufacturers of refrigerators, washing machines and colour
televisions managed to stay afloat by recording a marginal growth ranging between 8.0%
- 12.0% in 2007-2008.

INTERMEDIATE GOODS SECTOR:

The intermediate goods industry sustained a major development on an


aggregate. Prominent users of machine tools in this sector – the auto components, ball
and roller bearings had a promising output; while the electronic components had a
marginal turnover in the year ended 31 March 2008. The automotive component industry
witnessed high growth of 25.0% in 2007-2008 in the wake of increased exports orders.

Conquering the world with their world-class capabilities, Ball and roller
bearing segment performed well to post 15.1% growth in the same corresponding year.
Electronic components’ industry had moderate demand for their products leading to a
10% growth in 2007-2008.

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COMPANY PROFILE :

Name : Airtech private ltd.

Location : NH-4 highway, Dharwad.

Banker : State bank of India.

Certification : Registered under Company’s Act 1956.

Auditor : Basavaraj Balageri.

Year of incorporation : 1980.

Constitution : Private ltd company, governed by Board of Directors.

FOUNDERS OF THE COMPANY:

 Mr. Lajpat Rai Sukhija.

 Mr. M.B Suhindra Rao.

 Mr. D Dhume.

 Mr. P G K Murthy.

 Late. N Sukravala.

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DIRECTORS OF THE COMPANY:

 Mr. Lajpat Rai Sukhija CHAIMAN AND MANAGING DIRECTOR.

 Mr. M D Dhume.

 Mr. S A Phalnikar.

 Mr. Vishvanath Swamy.

 Mr. P G K Murthy.

 Mr. Anil Madan.

 Mrs. Renu Anil Madan.

 Mr. Rohit Seth.

 Mrs. Sapna Rohit Seth.

 Mr. Vikrant Saigal.

 Mrs. Lopa V Saigal.

NATURE OF THE BUSINESS:

Manufacturing:

Airtech manufactures chucks and cylinders that are manufactured according to the
specification prescribed by the customers in order to meet the customer satisfaction and
requirements.

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MISSION:

 Build an organization that installs in every employee a sense of


dedication, true camaraderie and a feeling of one family.

 Make working in Airtech a passion rather than a duty.

 To be a social responsible and environment friendly organization.

VISION:

 To design, develop and manufacture high precision work holding


solutions.

 To create quality standards that will be bench marking in work


holdings.

 To build the brand image that would be preferred by choice not by


persuation.

QUALITY POLICY:

 Constant interaction with the customers.

 Expert engineers for expert work.

 Leading manufacturers of chucks.

 Provision for work holding solution.

 Customer contribution and care.

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GUIDING PRINCIPLES:

1).Innovation continuously to excel in designing and manufacturing.

2). Develop products required by the market.

3). Manufacture products of high quality.

4). Respond promptly on customers needs.

5). Deliver supplies on time.

6). Treat each other with trust and respect to build a team.

7). Develop people by training and delegation.

8). Adopt process oriented thinking, continuous improvements etc

LOCATION:

Airtech pvt ltd is situated in Narendra village just 5 kilometers away from
Dharwad city right beside the national highway. Hence it is very convenient for them to
transport their goods.

TRANSPORTATION:

APL usually transports the goods through roads since it is more


convenient . If the customers are located nearby such as Hubli-Dharwad and Belgaum
they use their jeep (private vehicle). And for other customers who are far they either og
with currier, traveler or transporter.

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COMPETITORS INFORMATION:

AIRTECH is one of the major leading company in India. Even though it


faces huge competition from various companies it always try to maintain its reputation.
Some of the competitive companies are:-

 GMT (Guindy Machine Tools), Chennai.

 Scientific Engineering Corporation (SECO), Gurgaon Punjab.

 Chennai Clamping Devices.

 Jaws manufacturing, Pune.

APL offers not only standard work holding solutions but also total solutions in
work holding. That is why the APL customers are spanning various sectors like Auto
components manufacturers, ordinance factories, railways and machine tool
manufacturers.

These are competitive in cost margin. This can be manageable by APL. Through
its quality and the service it is eligible to compete with other companies.

They even face the competition from various international companies, hence
competitors can be classified as Indian and foreign competitors. Details of them are as
follows.

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INDIAN COMPETITORS:

Guindy Machine Tools Ltd, Chennai (GMT):

GMT was the first company which started its manufacturing power chucks in
India in the year 1950 with technical know how from BERG,Germany. They are still
leading the market with 44% market share. OEM prefers their chucks because of;

1). Superior quality products.

2). Marketing set up is sound.

3). They have various sales and service staff/ office in Delhi, Mumbai, Chennai,
Bangalore and many more cities.

Their prices are 10%-15% more than APL but 20%-30% lower than imported
chucks.

Their production capacity is high hence it helps them to meet the market demand
fast.

Scientific Engineering Corporation (SECO)- Punjab:

This company is manufacturer of scroll operated manual chucks since 1950. It


started manufacturing power chucks and cylinders since 1995-1998.

Quality is inferior but price wise, it is making dent into end user sector. OEM’s
are not giving preference to its products. It has dealers and stockiest in almost all the
industrial towns.

It is coming up very fast and may be an eye sore of GMT and APL in very near
future.

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Chennai Clamping Devices (CCD), Chennai:

This company is in a way of GMT. They were dealers for GMT for quite a long
time. Somewhere in 2002, some design and shop floor personnel of GMT resigned and
joined this company and started manufacturing power chucks and cylinders.

They do not have good manufacturing setup. They are in marketing especially in
Chennai and Pune. In their anxiety to come up fast and secure second place, they are
picking up design, shop floor, sales and service people from APL and GMT. Their
quality is not up to the mark but yet is able to sell and recondition good numbers of
chucks.

Jaws Manufacturing, Pune:

This company is basically chuck spare part manufacturer. It started reconditioning


GMT, APL and imported chucks. Now they are manufacturing jaws brand power chucks
and cylinders. It also manufactures precise manual chucks. They sell most of their
products through dealers. But it is very famous in Pune and surrounding areas.

MNC’s COMPETITORS:

1). ROHM, Germany.

2). SMW- Auto block.

3). Kitagawa, Japan.

4). ITW USA & India (Hydrabad).

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INFRASTRUCTURE FACILITIES:

The plant is 60 acres which provides good and sufficient facilities to employees
such as:

1). Good ventilation.

2). Polycentric control and good electrical facility.

3). Rest room for workers.

4). Canteen facility.

5). Wide parking area.

6). Transportation facility.

7). Free medical facility.

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PRODUCT PROFILE:

AIRTECH pvt ltd manufactures 3 kinds of products. They are:

1. Chucks.

2. Cylinders.

3. Chuck jaws.

CHUCKS:

It is defined as rotating work holding device. It is one of the important accessory


components in the lathe, grinding, milling machines etc. the wedge design of the chucks
has a self locking features that prevent the accidents and it does not loose its gripping
power even at cutting loads with high repeatability. It is fitted to the spindle for holding
the jobs of different shapes and sizes.

CHUCKS are specified by:

1). Type of chucks : APL manufactures manual and power chucks.

2). No of jaws : It manufactures 2 to 3 jaw chucks.

3). Maximum diameter : APL manufactures chucks with a diameter ranging from 130mm
to 1000mm.

4). Open centre diameter.

5). Maximum gripping force.

6). Maximum speed.

APL has also designed chucks operating at 6000 rpm. It produces standard as well
as specialized chucks.

Standard chucks are manufactured to hold standard jobs whereas specialized


chucks are manufactured according to specification of the customers.

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CYLINDERS:

Cylinders are used for operating power operated chucks. These cylinders activate
the chucks via the draw bar passing through the spindle bore and should provide the
correct operating force to match the chuck.

Some cylinders are specially designed for high speed CNC bar and chucking
lathes. They are also used in fingure chucks, clap applications and special chucks.

CHUCK JAWS:

APL manufactures standard, soft, hard and special chuck jaws. All soft jaws are
made of high carbon steel. The hard revisable jaws are made up of case hardened steel.
Special jaws are offered according to their customers satisfaction or to suit customer
requirements.

SOME OF THE PRODUCT CATEGORIES ARE:

Product Category: Diaphragm Chucks.

Airtech pvt ltd introduce diaphragm chucks [sd & scd] that utilise inherent
strength of spring action of steel to achieve chucking pressures on jobs. There are no
sliding parts, due to which high degree of reliability and long service life is assured and
are most used on internal grinding machines where high degree of concentricity accuracy
is required. Sd models need power sources, ie, rotating hydraulic or pneumatic cylinders
mounted on the rear side of the machine spindles. Scd model is self- contained where
cylinders are inbuilt with the chucks.

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Product category : Pull Grip Chuck

Airtech offers pull grip chuck that works on principle of master jaw collects. Its
interchangeable jaw inserts exert radial force as well as axial pull, thus drawing the job
against the face of the chuck. The jaw guides are of cylindrical shape with perfect lapping
fit in the body. Design wise, the chuck is very stable and maintains accuracy for a very
long time. Its stable design its jaw guides having perfect fit in the body its absolutely
negligible back lash - all these factors permit the chuck to operate at very high speeds
without any appreciable loss of grip due to centrifugal forces. The large jaw stroke and
easy insertion and removal of jaw inserts make the chuck versatile. This chuck is useful
only for external gripping. Short cut piece bar work on medium or small batch size is
most suited to this chuck. Gear balk turning, bearing race turning where floor to four
times is in seconds, are ideal jobs for this chuck.

Product category : Retractable Jaw Chucks

Airtech manufactures retractable jaw chucks. These chucks are specially manufactured
for machining cylindrical jobs that are required to be machined over the whole length in
one operation. Centre-drilled and faced components are held in between centers. A built-
in face driver placed in the chuck drives the work. The jaws grip the component to
provide additional driving force during heavy machining. When the tool approaches near
to the end of the component, jaws open and retract for the tool to complete the machining
of the gripped portion. The driving force during the jaw-retracted position is transmitted
through face driver and hence, is less. Gripping and retraction is performed with the help
of hydraulic cylinder placed on the rear side of machine spindle.

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Product category : Indexing Chucks

Airtech has introduced hand indexing chucks with power clamping. It is suitable for
machining jobs at 90°c or 180°c or 120°c or any other angle in one clamping. When
the job is clamped, the operator has only to pull and push a lever to index for next
operation. The job need not be declamped for indexing. The chuck is ideal for machining
automobile transmission cross, hydraulic fittings and valve bodies. The jaw pads are
manufactured to suit the shape of the component.

Product category : Power Chucks

Airtech pvt. Ltd supplies eccentric chucks. These chucks are used to hold work pieces in
between centers having eccentricity or irregularity. These power chucks provide
complete solution to all chucking problems where the jaw movement has to be
compensated for the above stated work piece. A centering insert with spring loaded
centre is fitted as standard equipment. It is possible to adjust the centering inserts. To run
concentric by set screws, these chucks are actuated by air cylinder model hc and hch. The
chucks are manufactured from steel and all wearing parts like taper wedges are hardened
and ground; has interchangeable centering inserts with spring loaded centre and the base
jaws are well lubricated.

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Product category : Hydraulic cylinders

Airtech manufactures high speed light weight aluminum alloy hydraulic cylinders in
compact design which reduces the weight on the machine spindle and maintains
outstanding stability during high - speed operation. These hydraulic cylinders are ideal
for high speed cnc chucking lathes while its high quality cylinder seals and accurately
controlled finish helps to avoid daily inspection adjustments. The oil supply system in the
distributor housing of these hydraulic cylinders allows little oil leak out ensuring
continuous lubrication of the bearings and avoid heat generation. These cylinders are
applicable to perform with oil pressure from 3 kgs per cm² to 40 kgs per cm². The
company also supply cylinders with non - return valves.

Product category : Industrial components & devices

Airtech manufactures btt series electromechanical tool turrets. The company supplies
these tool turrets equipped with three-piece coupling facilitating the tool disc to be
indexed without lifting. These turrets are built to deliver high accuracy, fast tool change
and high rigidity and provide quality, productivity and profitability of cnc lathe. The
company also offers turrets with centre height of 63 mm, 80 mm and 100 mm.

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Product category : Jaw chucks

Airtech provides 2+2+2 jaw chucks for holding large diameter thin walled components,
aluminium components of turbines and couplings, precision railway wheels and large size
gear blanks of earth moving equipment. Usually the sizes of these chucks are above 500
diameter for mounting on vertical lathes. The company provides chucks up to 250
diameter on special order. The inter-linked jaws revolve around each other.

Product category : Collet Chucks

Airtech pvt limited offers range of chucks-from manual chucks to power chucks and total
solutions. These are suitable to accommodate components of ranging in 3-80 mm
diameter. It extends to over a 1000 standard and custom designed workholding tools.
Pccdlr/pccdla dead length collet chucks are available with standard cylindrical recess
mountings and with short taper mountings, pneumatic or hydraulically operated.

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PRODUCTS

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PRODUCTS MODEL DIMENSIONS

Hollow Chuck WH 130,165,200,250,380,450,530,610.

Closed Centre Power WC 110,125,160,200,250,305,400,530,610.


Chuck

Ultra High Speed WHCB 165,200,250,315,400,500.


Power Operated
Hollow Chuck

Eccentric CC 160,200,250,315,400.
Compensating Power
Chuck

Quick Change Jaw QCJ 160,200,250,315,400,500.


Power Chuck

Ball Fulcrum Power BFC 160,200,250,300,380,450,500.


Chuck

Power Operated PCC 25,40,60,80.


Collet Chuck

Front Operated FOCC 40,60.


Power Collet Chuck

Stationary Power PSC 165,200,250,315.


Chuck

Diaphragm Chuck SD/SCD 160,200,250.

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AREA OF OPERATION:

Area of operation is at national level covering all zones i.e, North, South, East ,
West. They purchase raw materials (rough forged steel) from Mumbai and KGF.

CUSTOMERS:

APL has enough customers classified as under:

OEM (Original Equipment Manufacturer)

1). Laxmi Machine Works, Coimbatore.

2). ACE designers, Bangalore.

3). Jyoti Machines, Rajkot.

4). HHT, Bangalore.

Public and Private Company’s:

1). Bajaj Auto, Aurangabad.

2). Telco, Dharwad & Pune.

3). BHEL, Bangalore.

4). HAL, Bangalore.

The customers are finding value in the products due to

1. High uptime of the equipments

2. Easy and quick availability of genuine Parts

3. Excellent post installation Service support

4. Low life cycle ownership and operating cost of the equipments.

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ORGANISATION CHART

Managing
Director

Planning Stores Quality Productio- Marketing Finance Admin Design &


and Dept. Assurance n Dept Dept. Dept. and HR Developm-
purchase ent

Stores Manager. Manager Manager Manager


P&P Incharge Manager
incharge
Engineer Asst. Asst. Asst.
Asst. P& Manager Manager Manager Asst.
P Manager
incharge
Superviso- Superviso- Executive Accountant
r r Designer
Designer
Worker. Operators Represent
-atives
Sales
Manager Helpers

Productio-
n
Manager

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1). PLANNING AND PURCHASE DEPARTMENT:

Headed by: Mr. Rajendra Prasad.

Planning department:

The company gets orders from various suppliers as well as from perspective
customers. After seeing to its terms, conditions and cost aspects the department issues
acceptance order. But for specialized tool where some parts cannot be manufactured the
company outsources the activities. After it comes from the outsourced agency, the
department is responsible for execution of purchase orders once accepted.

DEPARTMENT CHART:

P&P incharge

Assistant P&P incharge

Designer

Sales Manager

Production Manager

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ROLES AND RESPONSIBILITIES:

P&P incharge:

He is the head of the P&P department who plans regarding


the purchase of raw-materials or components from the respective suppliers. He plans
from where and at minimum cost how to purchase the materials. He also plans what kind
of raw materials are to be purchased.

Assistant P&P incharge:

He is a person assisting the P&P incharge head in planning and purchasing the
components or raw materials. He carries the activities of P&P incharge in his absence and
guides the employees to carry out their tasks.

Designer:

After the P&P incharge head plans the assistant of purchase and planning
incharge is responsible to assist the designer the kind of chucks and cylinders to be
designsed and the designer develops the drawing for the production manager.

Sales Manager:

Once the drawing of the design is complete the responsibility of the sales
manager begins. He is responsible to check the diagram of the respective model to be
produced so as the sales work is carried out easily.

Production Manager:

His responsibility is to give the developed design to the supervisor of the shop
floor to produce the prescribed product.

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PROCESS:

Customer Representative

Product Specification

Status of raw- materials

Production Outsourcing

The persons called as CUSTOMER REPRESENTATIVES are allotted at each


zones who are responsible in knowing the customer needs and collect the necessary
information and give it to the company. The customers give their product specification to
the representatives. These representatives present the specifications to the purchase
manager. Then the purchase manager asks the stores manager to check the status of the
raw materials. He makes the list of the stocks to be purchased for production process.

Once the raw materials are bought into the company the stores manager stores the
materials and provide the shop floor workers to carry out the production. If the
production is not possible from the company workers like for the specialized products
then the process is outsourced.

Here at AIRTECH pvt ltd, the raw-materials are classified into 4 categories. They are:

RAW-MATERIALS:

The raw-materials consists of basic raw materials which is raw in nature like
carbon steel and alloy steel etc

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.

COMPONENTS:

These are the sub parts which are required as a part in the final product like
screws, nut bolts etc. They are also required in components like carbon steel and alloy
steel screws.

CONSUMABLE:

These are inputs consumed while carrying out production such as oil, lubricants etc.

PACKING MATERIALS:

The materials used for final packing of the products. Purchase department obtains
raw-materials for standard products by care a month before but for special products it
follows just in time techniques.

SUPPLIERS:

APL gets supplies from:

1). Hitech forge, Bangalore.

2). Rukmani forge, Mumbai.

3). Sona steels, Mumbai.

FUNCTIONS OF THE DEPARTMENT:

1). Selecting the suppliers at minimum cost.

2). Ordering of the product in time with all necessary specifications.

3). Giving quotations to the tenders and negotiation.

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2) STORES DEPARTMENT:

Headed by: Mr. B S Sangapur.

Objective:

To establish a proper system for receipts, storage and issue of materials.

Scope:

The procedure is applicable to both the main stores and the finished stores.

Process:

When the raw-materials is received from suppliers the sum is tallied with the
delivery challen / invoice / cash memos / credit memos placing slips etc.

In the absence of pay orders or any other document from the sub contractor, the
material is flown in only after the purchase department authorizes by issuing
interdepartmental note. The details of materials received is I entered in inward register.
Then after the completion of inward inspection the materials both accepted and rejected
comes at the stores, and with the material receipt the accepted material is stored at the
desired place.

Whenever the stock reaches the Re-order level main store raises the purchase
request to the purchase department.

FUNCTIONS OF THE DEPARTMENT:

1). They check the stocks and gives orders whenever required.

2). They check inward registers at regular intervals.

3). Maintaining the status of the stocks properly.

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3). QUALITY ASSURANCE DEPARTMENT:

Headed by: Mr. Maqbool.

Objective:

To check the standards of the quality of the prescribed products and maintain the
same at every stage of process of production.

Quality Control Authority:

Manager

Engineer

Supervisor

Workers

ROLES AND RESPONSIBILITIES:

Manager:

The manager is the head of the department and he takes care of the activities
performed by the employees. He keeps the activities carried in track and takes care of the
quality of the products manufactured. If the quality is assured by the manager then only
the products will go to the engineers.

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Engineer:

He is the person who checks the accuracy of the design, that is, its length, width
etc of the product.

Supervisor:

He is responsible in delegating the shop floor workers to reproduce the product


incase if the quality differs from standard suggested quality and get the work done again.

Workers:

These are the shop floor workers who physically work with the CNC and LATHE
machines and check the quality of the product.

FUNCTIONS:

1) To check the design or the drawings according to the prescribed diagram as


quality and reliability are the hall mark of APL products.

2) It adopts continuous check and inspection right from raw-materials to finished


product stage.

3) In case the product is outsourced, the department checks the quality and the
product is rejected if it is not satisfying the needs.

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4). PRODUCTION DEPARTMENT:

Headed by: Mr. M A Dixit.

The production plant is big and clean in which workers can work out of dust and
foul without any problem. The production process is done on shift basis. There are 2
shifts of 8 hours each.

I – 8:30 am to 5:00 pm

II – 5:00 pm to 1:30 am.

PRODUCTION HIERARCHY:

Production Manager

Production Assistant

Supervisors

Operators

Helpers

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ROLES AND RESPONSIBILITIES:

Production Manager:

He is the HOD of the department who guides the workers in production according
to the needs of the customers.

Production Assistant:

He is a person who assist production manager in looking after production


department and takes care of the department on behalf of the manager either in his
absence or if he is busy with other work.

Supervisor:

He supervises the work of the workers and check whether the work is going on
properly and takes care that raw-materials are provided as and when required.

Operators:

The persons who operates the machines manually or non-manually. These people
are given training by the department and they perform the work according to the direction
of the supervisors advice.

Helpers:

These people help the operators in putting oil or Greece to the products or
providing necessary accessories.

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SHOP FLOOR:

Different sections are made in the shop floor. There are 4 rows namely:

1). Milling Operations.

2). Turning Operations.

3). Grinding Operations.

4). Grinding Operations.

There are two seperate grinding operations in the shop floor because some
products which are to be grinded in large pieces are done in one grinding operation and
the products which are to be grinded finely are grinded in another grinding operations.

There is an inspection department at the back in the shop floor. Drawing is the
language for the inspection department. They have to confirm whether the shop floor
workers’ working is limited to certain constraints.

In production department all the products of different dimensions are produced


and for specific batch members specific dimension products are said to be produced.

The shop floor workers are 100 – 150 in number and basically work either
manually or on CNC machines. They produce the jaws and the teeth of the jaws should
be 1/60. To measure the specific dimension of the chucks or cylinders they use an
instrument called micrometer screwgauge and so on.

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PRODUCTION FLOW CHART:

Raw materials

Bar cutting-
forging-casting

Machining

Turning Milling Drilling HT Grinding Inspection

Stage inspection

Assembly

Inspection Testing and Marketing Stores


Evaluation

Packing

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PRODUCTION PROCESS CHART:

TURNING PROCESS

MILLING PROCESS

DRILLING PROCESS

HEAT TREATEMENT

INSPECTION

SERRATION

CLEANING

ETCHING

ASSEMBLY

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TESTING

PACKING AND DISPATCH

PRODUCTION PROCESS:

1). Turning:

This is the first department in which the work operation is held in a lathe machine
and rotated, while the cutting tool removes the metal from the work piece.

2). Milling:

In this process a hole is produced at the work piece before forcing a rotating cutter
known as drill bit.

3). Heat treatment:

It’s the process of heating and cooling of metal or alloys in order to obtain certain
desired properties such as hardness, toughness and strength.

4). Grinding:

It refers to wearing away by friction of the material. It is accomplished by forcing


a war piece against a rotating wheel made of abrasive material.

PROCESS IN GRINDING:

Phase Grinding

Surface Grinding

Slot Grinding

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External Grinding

Internal Grinding

5). Inspection:

The components are then sent for inspection where tolerance and size of each
component is checked. When approved these are sent to the serration process.

6). Serration:

It is the process where the teeth on the hard surface jaws form firm grip. The
serration can be used to move the jaws to hold war pieces of different sizes.

7). Cleaning:

Components are thoroughly cleaned with oil, which prevents from rusting before
it is taken to further process.

8).Etching Process:

For each and every product a number is given, the trade mark of APL is printed
on the product.

9). Assembly:

The process of joining different components or parts produced during the


production process in order to complete a single finished product.

10). Testing:

The finished assembled products are tested for maximum speed and gripping
force and maximum diameter it can hold.

11). Packing:

The packing of the products is done in a wooden box and thermocol to reach the
product safe to the destination.

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5). MARKETING DEPARTMENT:

It plays an important role in an organization. It carries out its activities as follows:

Marketing Manager

Asst. Marketing Manager Customer Care Manager

Marketing Executive Service engineer

Representative Dealer

ROLES AND RESPONSIBILITIES:

1). Marketing Manager:

He manages marketing and sales activities of the organization.

2). Asst. Marketing Manager:

He assists the head of the department and takes the orders from the customers. He
also assures them the time of delivery of the goods according to their needs.

3). Customer Care Manager:

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The responsibility of this person is to see the complaints of the customers and try
to solve their problems. He replaces the product or send the person to the place of the
customers and solve their problem if caused any damage.

4). Service engineers:

These person render the service to customers who have problems in product sent
by company

5). Marketing Executive:

These are also known as sales engineers. These people are part of the company
who takes the responsibility of marketing the products to the customers and discuss with
them about the prices.

6). Representatives:

Representatives work on behalf of the company who go out to talk with the
customers and know their needs. They are given some quotations and given price limit to
take orders from the customers.

7). Dealers:

They are in different places who find out the needs of the customers, take orders
and give it to the company.

PROCESS OF SELLING :

The representatives all over the regions i.e North, East, West and South are
appointed. They collect the quotations and give the details to the company.

The marketing department regularly improvise in their designs, cut the costs to
keep their customers satisfied. They also have the strategy to attract the customers by
participating in the International level Exhibition, which is conducted for every 2 years in

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Bangalore. Thus the marketing manager as and when he participates in the exhibition, he
makes new customers

FUNCTIONS OF THE DEPARTMENT:

1). Controlling information flow between head office and dealers / representatives.

2). Sales representatives should send sales report every week to main office.

3). To satisfy customers.

4). Orders form and Sales form is issued and send to head office.

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6). FINANCE DEPARTMENT :

Headed by : Mr. A.S. Desai

In this department a personnel should have enough qualification and skills


regarding maintenance of transaction of transaction of firm and prepare the balance sheet.

Principle :

Minimum expenses and maximum profit .

DEPARTMENTAL CHART :

Finance Manager

Asst. Finance Manager

Accountant

ROLES AND RESPONSIBILITIES :

1). Finance manager:

He manages the overall view of the accounts section. He checks the Final
accounts and Annual report prepaid by Assistant Finance Manager.

2). Asst Finance Manager:

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He prepares the Annual report of the respective year and assist Finance Manager
in carrying out the activities. He also takes incharge in his absence.

3). Accountant:

He maintains all the books of accounts separately in respective books i.e cash
book, journal, ledger , purchase book ,sales book etc

INVENTORY MANAGEMENT:

Inventory management also play a key role in Finance department. The Finance
manager will try investing less in the inventory because for him it is an idle investment,
where as production manager will emphasis to acquire more and more inventories as he
does not want any interruption in production due to shortage of inventory. The purpose of
inventory management is to keep the stocks such that neither there is over stocking nor
under-stocking. The over stocking will mean a reduction of liquidity and targeting of
other production process. Under-stocking on the other hand will result in stoppage of
work. The investment in inventory should be kept at reasonable limits.

OBJECTIVES OF INVENTORY MANAGEMENT:

The main objective of inventory management means that the materials and the
spares should be available in the adequate quantity, so that the work is not disrupted. The
investment in inventories should not remain idle and minimum working capital should be
locked in it.

The following are the objectives of inventory management:

1). To maintain investments in inventory at the optimum level as required by the


operation and the sales activities.

2). To avoid both over stocking and under stocking of inventory.

3). To keep materials cost under control so that they contribute in reducing cost of
production and overall costs.

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4). To eliminate duplication in ordering or replenishing stocks. This is possible with the
help of centralizing purchase.

5). Minimize losses through deterioration, pilferage, wastage and damages.

FUNCTIONS :

1). Preparation of cash transaction, vouchers, day book etc.

2). Distribution of salary and wages.

3). Preparing monthly operational data which includes production , sales, raw materials
and income expenditure.

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7 ) ADMINISRATION AND HR DEPARTMENT:

Headed by : Mr Purohit.

Objective :

To identify the training needs of employees and organizational needs.

Procedure :

The forms of recording training needs is forwarded to respective HOD’s by


training department. They decide regarding the person to be trained and type of training
required. After getting the forms back this department process the forms and plan the
work to be carried out.

Recruitment and selection:

In APL there is scope for internal source of recruitment like present permanent
employees, present temporary, so as to motivate them and gain advantage of minimum
cost of selection.

For external source, the management will go for district employment exchange
where job profile of required employees will be handed over to employment exchange.

Different types of trainings:

1). In-house training program :

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HOD of the department organizes the in house training program as per the
training program is finalized. He announces the date of the training program and
nominations are finalized in consultant with respective HOD faculties maybe from in-
house or outside agencies.

2). External departments :

As ongoing activity, in charge of department keeps close relation with


professional instate to receive various training programs for the group of employees after
attaining external program. Deputed employees gives the presentation to the groups
decided in consultation with the respective HOD, the administration coordinates the
activities and maintain the record of presentation.

3). Off the job training:

External training for the skill development is due to the change in the work
process, if a employee or group of employees have to acquiring a special skill then HOD
initiates the activity and workout on the external training schedule.

4). On the job training:

Due to internal transfer if job profile of employee is likely to change then the
HOD organizes the job training .

5). Induction training to new entries:

The HOD decides and initiates induction training to new employees after the
names of employees are prescribed by the concerned departmental heads.

1). Strategy:

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This is an ideal route that the organization has chosen for its future growth, a plan
an organization has formulated to gain the competitive advantage.

2). System:

The company has the unique integrated systems in all the departments. The
execution of order is followed by all the levels of management. This includes formal and
informal procedure including the innovation system, compensation system, management
information system and capital allocation system which governs everyday’s activities.

3). Style:

The leadership approach of top management and the organization’s overall


operating approach, guides the employees to present themselves to outside world ,
suppliers and client. The decision making is participative in nature where all the middle
level and lower level management is allowed to suggest their ideas in the decision
making process.

4). Staff :

The organization‘s human resource refers to how people are trained, developed,
specialized, integrated, motivated and how their career is managed.

The APL has effective staff o participative in nature with positive attitude towards
organizational goals and also performing efficiently with effective results.

5). Skill:

The distinctive capabilities always resides within the employees in the


organization. This is what the company does its best. APL’s process of training the
employees is on the job training. Whereas off the job training is theoretical in nature and
provides overall design of the job. The company is equipped with skilled faculty to train
the employees.

Skills include:

1). Communication skills

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2). Presentation skills

3). Listening skills

4). Technical skills and

5). Managerial skills

FUNCTIONS OF THE DEPARTMENT :

1. Follow factory rules act for providing safety.

2. Recruitment, selection, placement and induction of candidates.

3. Planning on wage and salary of the employees.

4. Providing all the basic facilities including safety, PF, ESI etc.

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8). DESIGN AND DEVELOPMENT DEPARTMENT:

Headed by : Mr A C Kulkarni.

Objective :

To design the products (Chucks, work holding solutions) as per specifications


provided by customers.

Procedure:

After receiving the purchase orders from customers, marketing department will
send the orders to planning and purchase department. They check the availability of raw
materials. Once it passes this stage it will go to design and development department
where the designers develop the drawings according to the needs of the customers.

Softwares used for designing :

1. AUTO CAD

2. MECHANICAL DESKTOPS

Flow chart :

1 Design and development manager

Asst.D&D manager

Designers

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ROLES AND RESPONSIBLITIES:

1. D&D manager :

He is the HOD of design and development department. He checks whether


proper design is made by the designers.

2. Asst. D&D manager:

He assists the HOD in carrying out the activities. He guides the designers
and help them in designing.

3. Designers :

These are the key persons (Engineers) who design and give the drawings
to the production manager.

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Strengths:

1). APL has very good image since they produce chucks as per prescribed specification
by customers.

2). It has the goodwill in the domestic market.

3). Quality of the products are one of the strengths of APL.

4). They are highly concerned about Research and developmental activities which plays
vital role in new product development and design.

5). Since from its inception APL has not faced any problems regarding stick lockouts,
which indicates cordial relationship between management and workers.

Weakness:

1).They have to work within the scope of Companies act .

Opportunities:

1). Company can expand its business to large extent since they are planning for capturing
market demand and reliable quality etc.

2). They enjoy benefit of labour in dharwad since there are many ITI diploma colleges
from where students are hired.

3). Since it is situated besides highway they can solve the distribution problem.

4). As company is going for ISO certification, this may help the company enter into
global market.

Threat :

1). More than 300 chuck manufacturing companies are present in industry that creates
stiff competition.

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CONCLUSION

At AIRTECH quality is never an after thought. With the philosophy of getting


everything “Right First Time” ingrained at every level of organization, they have worked
hard to attain quality at all levels. A sophisticated metrology center equipped with latest
facilities like Co-ordinate Measuring Machine, Hardness testers etc help them overcome
any kind of errors.

They always try their best to ensure that no products leaves the plant unless it is
thoroughly tested and certified by a team of quality specialists because they know that
these work holdings work under severe and exacting conditions.

I had a great experience in this company . I got a good priviledge and scope to do
my in plant study in AIRTECH PVT LTD where all the employees and the workers of
the company were kind enough to help me in my study.

I did learn how to prepare a questionnaire with the guidance of my HR manager


and my internal guide.

Thus I would conclude that my in plant training was a satisfactory and successful
one.

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BIBLIOGRAPHY:

1). Company’s prospectus.

2) G. C. Berry- Marketing Research

3) Employees

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