CHAPTER 1

INTRODUCTION

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1.1 INTRODUCTION TO ORGANIZATIONAL STUDY

To help the students to have an overall understanding about the organization and various functions of management. M.G University in their curriculum for the degree of Master of Business Administration insist an organisation study for the purpose of acquiring in depth knowledge about the organisation. With the permission and consent from the company management and other department coordinator I got an opportunity to undertake an Organization Study in one of the top glass manufacturing companies in India, Excel Glasses Limited Alappuzha district. Excel Glasses Limited was incorporated on 01-02-1970 in the joint sector promoted with Kerala State Industries Development Corporation as co-promoter with the main object of manufacture and sales of glass bottles. Presently the company is controlled and manager by the Bombay turnover of over 400 Crore. Excel glass limited has an integrated plan that combines sand beneficiation units, automated batch plant, microprocessor controlled regenerative furnace and state of the art glass forming machine. Manned by a team of experts dedicated to meet exacting specification, customer are assured of consistent quality in every product. The company operates a 210 tons/day glass melting furnace with five glass forming lines. Excel Glasses manufacture flint glass bottles and jars mainly for the liquor, food and pharmaceutical industry. based PARIJAT group. The group has an animal Pathirappally in

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1.2 AIMS AND OBJECTIVES OF THE STUDY

To learn and understand the vision and goal of the organization. To have a general idea about the company, it History, Management,
Present position and Future prospects.

To study the functioning of the organization and its different

departments.

To get an awareness about the roles and responsibilities carried out by

companies key personnel.

To familiarise with internal and external environment and competition

facing the company.

To familiarise with working environment of an organisation. To relate theories and concepts into practice.

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1.3 METHODOLOGY OF THE STUDY

The Organization Study was in Excel Glasses Limited, Alappuzha. The company manufacturing white flint glass bottles and jars Methodology is the way and design of conducting the study. An important aspect of the methodology is the data collection. PRIMARY DATA The primary data collected was through observation. Different departments its roles and functions were observed and noted. The other important method of primary data was unstructured interviews . Workers, Managers, Supervisors, of various departments were interviewed to collect information and opinions.

SECONDARY DATA Secondary data are those which are already collected by some other person for the purpose and published. So an investigator is said to make use of the data already compiled by some other person. The secondary data sources use were Company Annual Report Company Records Websites etc.

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1.4 SCOPE OF THE STUDY

The study aims at providing a first-hand experience in organization effectiveness. It also provides assistance in developing the analytical skills of person with respect to business management.

The students shall encounter practical situation which require immediate troubleshooting and fast and prudent solution thereby students can relate numerous concept and theories into practice.

By permitting this type of study the industry academic tie up is strengthened which is beneficial to students academicians, managers and organization as a whole.

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1.5 LIMITATIONS

A Major limitation of this study was the lack of the time to undertake as in depth and analysis. The workers are busy with their work and had little time available for an interview or conversation. Secrecy nature of business operation prohibit the collection of certain information. The managers time availability for discussion were limited and frequently interrupted due to official commitment. Due to the huge sounds and temperature of the machineries information from the workers is difficult collecting the

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CHAPTER 2

PROFILE

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2.1 GLASS INDUSTRY- OVERVIEW

Glass is an amorphous (non-crystalline) solid material. Glasses are typically brittle and optically transparent. The most familiar type of glass, used for centuries in windows and drinking vessels, is soda-lime glass, composed of about 75% silica (SiO2) plus Na2O, CaO, and several minor additives. Often, the term glass is used in a restricted sense to refer to this specific use. In science, however, the term glass is usually defined in a much wider sense, including every solid that possesses a non-crystalline (i.e., amorphous) structure and that exhibits a glass transition when heated towards the liquid state. In this wider sense, glasses can be made of quite different classes of materials: metallic alloys, ionic melts, aqueous solutions, molecular liquids, and polymers. For many applications (bottles, eyewear) polymer glasses (acrylic glass, polycarbonate, polyethylene terephthalate) are a lighter alternative to traditional silica glasses.

History of glass The history of creating glass can be traced back to 3500 BCE in Mesopotamia. The term glass developed in the late Roman Empire. It was in the Roman glassmaking center at Trier, now in modern Germany, that the late-Latin term glesum originated, probably from a Germanic word for a transparent, lustrous substance

Ingredients of Glass

Quartz sand (silica) is the main raw material in commercial glass production While fused quartz (primarily composed of SiO2) is used for some special applications, it is not very common due to its high glass transition temperature of over 1200 C (2192 F).Normally, other substances are added to simplify processing. One is sodium carbonate (Na2CO3), which lowers the glass transition temperature. However, the soda makes the glass water soluble, which is usually undesirable, so lime (calcium oxide [CaO], generally obtained from limestone), some magnesium oxide (MgO) and aluminium oxide (Al2O3) are added to provide for a better chemical durability. The resulting glass contains about 70
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to 74% silica by weight and is called a soda-lime glass. Soda-lime glasses account for about 90% of manufactured glass. Most common glass has other ingredients added to change its properties. Lead glass or flint glass is more 'brilliant' because the increased refractive index causes noticeably more specular reflection and increased optical dispersion. Adding barium also increases the refractive index. Thorium oxide gives glass a high refractive index and low dispersion and was formerly used in producing high-quality lenses, but due to its radioactivity has been replaced by lanthanum oxide in modern eye glasses.[citation needed] Iron can be incorporated into glass to absorb infrared energy, for example in heat absorbing filters for movie projectors, while cerium(IV) oxide can be used for glass that absorbs UV wavelengths. Fused silica glass, vitreous silica glass: silica (SiO2). Has very low thermal expansion, is very hard and resists high temperatures (10001500 C). It is also the most resistant against weathering (alkali ions leaching out of the glass, while staining it). It is used for high temperature applications such as furnace tubes, melting crucibles, etc. Soda-lime-silica glass, window glass: silica 72% + sodium oxide (Na2O) 14.2% + magnesia (MgO) 2.5% + lime (CaO) 10.0% + alumina (Al2O3) 0.6%. Is transparent, easily formed and most suitable for window glass. It has a high thermal expansion and poor resistance to heat (500600 C). Used for windows, containers, light bulbs, tableware. Sodium borosilicate glass, Pyrex: silica 81% + boric oxide (B2O3) 12% + soda (Na2O) 4.5% + alumina (Al2O3) 2.0%. Stands heat expansion much better than window glass. Used for chemical glassware, cooking glass, car head lamps, etc. Borosilicate glasses (e.g. Pyrex) have as main constituents silica and boron oxide. They have fairly low coefficients of thermal expansion (7740 Pyrex CTE is 3.25106/C as compared to about 9106/C for a typical soda-lime glass), making them more dimensionally stable. The lower CTE also makes them less subject to stress caused by thermal expansion, thus less vulnerable to cracking from thermal shock. They are commonly used for reagent bottles, optical components and household cookware. Lead-oxide glass, crystal glass: silica 59% + soda (Na2O) 2.0% + lead oxide (PbO) 25% + potassium oxide (K2O) 12% + alumina 0.4% + zinc oxide (ZnO) 1.5%. Has a high refractive index, making the look of glassware more brilliant (crystal glass). It also has a

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high elasticity, making glassware 'ring'. It is also more workable in the factory, but cannot stand heating very well. Aluminosilicate glass: silica 57% + alumina 16% + boric oxide (B2O3) 4.0% + barium oxide (BaO) 6.0% + magnesia 7.0% + lime 10%. Extensively used for fiberglass, used for making glass-reinforced plastics (boats, fishing rods, etc.). Also for halogen bulb glass. Oxide glass: alumina 90% + germanium oxide (GeO2) 10%. Extremely clear glass, used for fiber-optic wave guides in communication networks. Light loses only 5% of its intensity through 1km of glass fiber. Another common glass ingredient is "cullet" (recycled glass). The recycled glass saves on raw materials and energy; however, impurities in the cullet can lead to product and equipment failure. Fining agents such as sodium sulfate, sodium chloride, or antimony oxide may be added to reduce the number of air bubbles in the glass mixture. Glass batch calculation is the method by which the correct raw material mixture is determined to achieve the desired glass composition

Glass industry in India

Glass industry in India remind in the form of a cottage industry till the beginning of the 20th century. first glass plant in India was set up in august 1908by freedom fighter Lok Manaya Balagangadar Tilak at Tallegaomn near pune. The plant was financed by collecting one paisa per month from the masses and was named as PAISA FUND GLASS WORKS.

Glass Industry in India has made a steady progress since then particularly after the Indian independence. Glass industry is also a classical example of co-existence of smaller and the large size plants. Many a delicate, decorative and utilitarian glass products are

manufactured by the labor intensive mouth blown process.

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All India Glass Manufacturers' Federation:

The All India Glass Manufacturers' Federation was founded in 1944. The Federation is made up five Regional Associations viz., Western India Glass manufacturers' Associations Mumbai, Easter India Glass Manufacturers' Association Kolkata, U.P. Glass Manufacturers' Syndicate Firozabad, Northern India Glass Manufacturers' Associations Bahadur Garh (Haryana) and South India Glass Manufacturers' Association Chennai. The Federation was incorporated under the Companies Act, 1956 (No. 1 of 1956) as a Limited Company on 25.06.1970. The main aims & objects of the Federation are : a) To encourage, promote and develop the manufacture of glass articles of all kinds and to safeguard and protect the interests of glass industry and glassware business in India

b) To form a common link amongst Glass Manufactures' in India and thus develop a spirit of mutual help and co-operation with one another

c) To promote the study and research in Glass Technology

d) To consider all matters relating to the manufacture and marketing of glass articles in India and the question of export and import thereof

e) To devise ways and means for securing necessary supply of raw materials required for the manufacture of glass articles at comparatively lower prices and thus to decrease the cost of production and increase the national wealth

f) To collect necessary information and data and propagate it for the benefit it for the benefit of Glass Industry and trade in India

g) To make representations whenever necessary to the Union Govt. or any unit of the Union of India for the removal of difficulties that might hamper the trade of glass articles or for grant of special facilities for the glass industry

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h) To draw Government or public attention to the difficulties in the way of Glass Industry and to solve other problems confronting it and to solicit their help and support through concerted action

i) To organize a united front on behalf of all glass manufacturers and thus strive to gain all those advantages which may not be possible through individual effort.

Major Competitors:
Ace Glass AGL Association Glass Industries Hindustan National glass Mohan Braveries And Distilleries Limited The New Indian Glass Work Limited United Glass Bottle Mfg Co.LTD

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2.2 COMPANY PROFILE

Excel Glasses Limited was incorporated on 01-02-1970 in the joint sector promoted with Kerala State Industries Development Corporation as co-promoter with the main object of manufacture and sales of glass bottles. The company is situated at outskirts of Alappuzha city at Udayanagar, Pathirapally. Presently the company is controlled and manager by the Bombay based PARIJAT group. The group has an animal turnover of over 400 crores ,Kopran Chemicals Ltd, Oriental Containers Ltd, are some of the other major companies in the group. The company is one of the premier soda lime glass container manufacturers, were manufacturing concerns in India and its works nestle in the back water lagoons of

midtown Alleppey on NH.47,55 .Km south of Cochin in Kerala. The business operations are mostly concentrated in the southern states of India and recent years in Sri Lanka across the Indian ocean. The present management in 1984 acquired financial and management interests of the company and then onwards Excel glasses has been vibrant and the production facilities were being slowly but steadily modernised and apdated . The company got ISO 9002 certification in June,1999 and has been re-certified for ISO 9001(2000 series) in November 2002 which renewed on 26.4.2002.due to furnace breakdown, plant was closed for about 3-4 years and restarted a few months back. Now Excel glass trying hard to gain it sold market position . The companys sale offices are located at Karnataka and Tamil Nadu. The companys factory is located at Kerala. The companys business operations are mostly concentrated in southern states of India and in recent years in Sri Lanka. The companys head office situated in Bombay and the branch office situated in Pathirapally, Alappuzha district. The company operates a 210 tons/day glass melting furnace with five glass forming lines. Excel Glasses manufacture flint glass bottles and jars mainly for the liquor, food and pharmaceutical industry.
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Excel glass limited has an integrated plan that combines sand beneficiation units, automated batch plant, micro processor controlled regenerative furnace and state of the art glass forming machine. Manned by a team of experts dedicated to meet exacting specification, customer are assured of consistent quality in every product. PROPOSAL FOR FUTURE Adding one more bottle making machine to utilise the full capacity of the furnace keeping the viability of the unit. We have the basic infrastructure to add one more glass-melting furnace of smaller capacity with 2/3 forming lines to produce green/amber bottles.

VISION AND MISSION :

Ensure product design fully meets customer requirement. To manufacture quality product, deliver in time at acceptance price to the customer. To be cost effective and a profitable organisation. To upgrade technology with continuous improvement of productivity and customer focus. To continuous train and upgrade skill of the employees

Historic background of the company

EXCEL GLASSES LIMITED was incorporated in the year 1970 as a joint sector unit by excel production and Kerala state Industrial development corporation limited (KSIDC) to set up a plant for the of 12000 TPA of glass bottles at Pathirapally, Alleppey in Kerala. The company commenced commercial production in 1974. However the company was not performing satisfactorily till 1984.

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In august 1984, the management of the company was acquired by Somani group The institutions provided reschedulement of term loans and other reliefs to receive the company. Subsequent to change in management, a balancing scheme was implemented to increase the capacity of glass bottles from 12000 TPA to 19710 TPA . In 1986, the company undertook a modernisation scheme aimed at reduction in cost of

production , improvement of quality and increase in capacity 23000 TPA. The company has been continually upgrading its manufacturing facilities through modernisation and Absorption of improved technology The company is now a part of Parijat enterprises The Company makes bottles of customized shape and sizes from 10ml to 1000ml in volume. The company mainly caters to the liquor, food and beverages, pharmaceutical and cosmetic Industries. The company has currently undertaken an expansion project at Alleppey for the manufacture of glass bottles with a furnace capacity of 170 TPD. production from the plant commenced from march 27,1995 with commissioning of the new furnace and first of its five forming lines. the company has since commissioned the remaining 4 forming lines the company is yet to install the decorating machines and decorating lehr for printing of soft drink bottles and lowerators for conveying finished bottles. The company will be one of the few producers of small wares/vials in the south.

BOARD OF DIRECTIORS: Mr.G.D.Mantri Chairman Mr. Prashant Somani -Managing Director Mr. Ramesh Prabhu Independent Non Executive Director Mr. Gopal Das Munti - Independent Non Executive Director Mr. Vishnu Narayan Khanna - Independent Non Executive Director Mr. R.D.Prabhu Member Mr. V.N.Khana Member

BANKERS:
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State Bank of Travancore. The South Indian Bank Ltd. UCO Bank.

AUDITORS: M/s Joseph & Nampiathiri Chartered Accountants, Alappuzha (Kerala). Registered Office & Works: Udayanagar, Pathirapally, Allapuzha 688 521 (Kerala), Tel. : (0477) 2258671 5 Fax. ((0477) 2258670 Web Address : excelglasses.com Email Address : mail@excelglasses.com Corporate Office Parijat House, 1st Floor, 1076 Dr. E. Moses Road, Worli, Mumbai 400 018 (Maharashtra) Tel. : (022) 24933050/24920611 Fax.(022) 24937743 Email Address : eglmumbai@hathway.com

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2.3 PRODUCTS OF THE COMPANY

The company produces different types of white flint glass bottles ranging from 180-1500 ml capacity required for the industries like liquor , pharmaceuticals, food beverage , toiletries etc.

The company manufactures about 150 types of bottles .some of these are given below : SI NO: 1 Bottle 180 ml BERMUDA RUM 2 3 180 ml CLR 180 ml CARDINAL 4 5 180 ml MIDAS 180 ml MORPHUES 6 180 ml SHIVA ROUND
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Weight

164 gm 163 gm

165 gm 160 gm

163 gm

180 ml STANDARD

163 gm

180 ml NO.1 BRANDY

162 gm

9 10

180 ml OAB 375 ml BRANDY

163 gm 240 gm

11 12 13

375 ml CAMUS 375 ml CLR 375 ml LBGS (NM)

210 gm 230 gm 280 gm

14

375 ml MONITOR

280 gm

15 16

750 ml DSW 750 ml HONEY BEE

500 gm 610 gm

17 18

750 ml MGM 750 ml NO.1.MCD.BRA

450 gm 500 gm

19

180 ml MWR FAMILY SHA

450 gm

20 21

200 ml juice 720 ml GHERKINS

175 gm 210 gm

22 23

200 ml PEPSI 200 ml COCACOLA

210 gm 210 gm

24

250 ml GM JAM JAR

175 gm

25

200 ml KOTTAKAL

160 gm

26

200 ml DETOL

210 gm
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CHAPTER 3

FUNCTIONAL DEPARTMENTS

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FUNCTIONAL DEPARTMENTS AT EXCEL GLASSES LIMITED:

PRODUCTION DEPARTMENT MARKETING DEPARTMENT PERSONNEL AND ADMINISTRATION DEPARTMENT PURCHASE DEPARTMENT GLASS DEPARTMENT QUALITY ASSURANCE DEPARTMENT GENERAL MAINTENANCE DEPARTMENT WORKSHOP DEPARTMENT FINANCE DEPARTMENT PACKING DEPARTMENT STORE DEPARTMENT INSTRUMENTATION DEPARTMENT

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3.1 PRODUCTION DEPARTMENT

Production involves the step by step conversion of one form of materials into another though chemical and mechanical processing to create or enhance the utility of the products. Production is performed by a group of persons who are responsible for producing goods .

The major raw materials used for production are Silica sand, Soda ash, Lime stone, Dolomite, Feld Spar and decolouring and refining chemicals such as sodium nitrate, Sodium Sulphate, Arsenic trioxide, Selenium, cobalt oxide and cullet(broken glass piece) . Major fuels used for the production are furnace oil, LPG, Diesel

Production department is divided into five sub functional departments are there. They are: Production and planning Departments Purchasing Department Store Department Design and Technical Department Works Department

Glass manufacturing process

Step 1: Glass Melting The furnace melt cullet, silica sand, soda ash, lime stone and other raw materials together. Molten glass usually ranges in temperature between 2300 and 2800 F. A furnace control room houses the computer which monitors and controls furnace temperature, pressure and fuels levels Step2: Container forming The refiner distributes the molten glass to the fore hearth, which bring the temperature of the molten glass to a uniform level. A shearing and distribution system cut molten glass from the fore hearth into uniform gobs and sends them to an IS forming machine that
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forces the molten gobs into the mold shape. The glass temperature drops further in the forming machines to below 2100 F. Formed glass containers leave the machine, crossing a cooling plate where they are cooled rapidly to below 900 F. The glass has now passed from liquid to solid form. Step3: Container Conditioning The formed container are loaded to an Annealing Lehr, where their temperature is brought back up close to the melting point then reduce gradually to 470 F for this an Annealing Lehr process containers are passed through different zones. Pass through each zones then temperature is gradually reduces with the help of fans, burner, Evacuation flap and waste air blower Step4: Surface Treatment The temperature of the containers is reduced to between 225 and 275 F. Cold end sprays then apply to an exterior coating to the bottles to increase line mobility and reduce abrasions to maintain the inherent strength of the container. Step5: Automatic Inspection The fast cooling section then brings container temperature down to about 100 F cool enough to touch by hand. The manufactured container then pass thought a series of instruments that physically and optically test the containers. recycled back to the furnace directly. Step6: Product handling and packaging A case packer then packs the containers in corrugated cases for shipment. The cases are then send to the case palletizer where they are stacked in pre arranged pattern to increase stability for shipment. A stapper fit plastic band around the stacked boxes for added stability and finally the strength wrap unit covers the stacked boxes with the plastic wraps Rejected containers are

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Simply the production process can be described as follows: 1. The raw materials, duly processed wherever necessary, are weighed and mixed in the desired proportion in a batch mixer. The mixed batch together with cullet from the broken and rejected bottles are conveyed and stored in a hopper, avoiding segregation during transport.

2. The batch sometimes after adding small percentage of moisture is automatically fed into melting end into the melting end of the furnace. An automatic level controller is provided to regulate the charging so as to maintain glass level in the furnace within a narrow specified limit.

3.The furnace is heated with furnace oil atomised by compressed air much of the waste heat being recovered in the form of pre-heated secondary air passing alternately through the regenerators.

4.The molten glass passes through a throat at the bottom to the working zone and from there into the feeders where a set of burners are so arranged as to condition the glass to the temperature required for the production of a particular weight of bottle. 5. From the feeder by a number of delicate mechanisms the glass gobs of required weight are delivered to the bottle forming machines at the required speed. 6.The bottle are automatically formed in the machine through a number of operations and are conveyed over a cross conveyer into the Annealing Lehr by means of a push barstacker.

7.The bottle are Annealed in a continuous belt type electrical\ fired Lehr from a temperature of 500\550 to the room temperature. 8. Each of the bottle is then inspected and quality control test are performed on the bottles at frequent intervals. The bottles are then packed as per clients specification and send to the bonded ware houses.
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9.Its to be noted that for each type of the bottle a set of mould with various part have to be fabricated by the glass plant,maintaining very orderof accuracy and out of a special type of casting. 10. However large supply of compressed air at specified pressure is required for driving the machine and for various blowing processes. Compressed air is also required for the furnace and feeder if it is oil fired. 11. Large centrifugal fans provide air for cooling the furnace, machines and moulds.

Raw Materials & Machines Used In Production

Raw materials: Abundant quality of superior quality low iron silica sand is available from on mines located close to the plant. The sand is processed in our sand beneficiation plant using wet ssieves, spirals and hydro- cyclones to remove heavy minerals and other impurities. Other minerals like calcite, dolomite and Feldspar are procured in processed condition and final sieving and Demagnetising is done at our premises. Soda ash, Sodium nitrate, sodium sulphate along with other minor chemicals of internationally acceptable quality is either imported or locally procured. Presently company use 40% cullet , which is washed , crushed, and demagnetised at the plant to a high level of purity in our cullet treatment plant. BATCH PLANT: Using state of the art load cells, batching controllers, weight indicators and PLCs, interfaced with a range of feeders, hoppers, conveyors and a TEKA/MILLER TZ 1875 pan mixer, the batching process is automated to achieve consistent accuracy in precise proportioning and mixing of raw materials. The batch plant can handle batching for 300 T/day glass with 30% cullet Inside and outside cullet are stored in separate silos and added to the batch conveyors. Plant rejection cullet return system is automatic and crushed cullet is fed in to silos.
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Furnace : The 75 sq meter end fired two pass vertical regenerative furnace with forced draft chimney was designed by KTG (UK). It incorporate microprocessor controlled temperature level and pressure control as well as automatic fuel/air reversal system. Heavy fuel in the furnace and highspeed diesel is used as fuel in working end. The working end has 3 zones with separate automatic temperature controls . Fore hearths: Five fore-hearths all L.P.G fired or Owens Illinois design condition the glass to the feeders. Two of the larger fore-hearths-K36x24^1 and K30x 24 have 3zone auto heating/cooling system with try level thermo couples at rear, middle and conditioning sections in addition to three other single point thermocouples ensuring a high degree of thermal homogeneity. The other three small fore-hearths KW26x20x2 nos and KU 16x14 have 3 zone with radiometric temperature controls. The LPG/air mixes through zero governors and inspirators. Glass forming machines There are 5 IS machines giving a high degree of flexibility to produce large range bottles and jars to cater to large as well as small orders. all machines are equipped with veriflow cooling mechanisms for improved glass distribution and speeds. The configurations are as follows. IS 10 DG 41/4 centre:Electronically synchronised, mechanically timed machine with cc takeouts and inverts, silent chain conveyors and power super wide stacker. The annealing lehr is 2.4 m wide electrically heated and re circulated type with five-zone automatic temperature control. Cold end is equipped with single liner and illuminated dual line inspection stations .This machine generally produces large volume requirements. Feeder is Emhart type 503 which can condition glass up to 85 T/day . S 10 DG 5Centre (fully electronic ):Page | 26

Feeder is Emhart 81 deep which can condition the glass up to 85 T/day .Cold end has long single liners and dual line inspection stations. IS 6 DG 5Centre Mechanically synchronised and timed machine with CC inverts and take out producing large sized bottles on D.G smaller orders. Annealing lehr is 1.8 M wide re circulating type .Feeder is BHF type 144 deep capable of handling 60 T/ day. IS 6 DG4 1 4 Centre

Mechanically synchronised and timed machine with CC inverts producing smaller bottles on blow and blow on double job in short runs.

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3.2 MARKETING DEPARTMENT

Marketing may be defined as the performance of business activities that direct the flow of goods from producer to customer or user. The goal of marketing department is to attract customer by delivering satisfaction and for managing customer relationship in ways that benefit the organisation and its stake holders.In kerala the only glass manufacturing company is Excel glass limited. Pricing method of the company depend on the market condition . It fluctutates withvariation of business environment. To penetrate market and to create new customer the market will be adjusted. Distribution is also a function of marketing department.

MARKETING DEPARTMENT CHART:

GM

Marketing manager

Marketing Executives

Marketing Executives

Company main marketing office is housed in its factory premises for the smooth planning and execution of the production and delivery of bottle in time. The company has also marketing offices at Chennai and Bangalore.

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Procedures for carrying out various activities pertaining to the Marketing Department: This procedure covers the following activities: Enquiry Handling Order review and Acceptance Review and acceptance of order Amendments Storage of Finished product Despatch Activities Handling of customer complaints

Enquiry Handling:

Enquiry is received from the prospective customer fo the products in the existing product range. The enquiry for the new production in the existing product specification etc. Are also received from the existing customer.

Based on the review and analysis of technical capability the enquiry is either accepted or rejected. The same is intimated to the customer. Whenever the enquiry is accepted the details of the same are recorded in Enquiry file for products in the existing product range necessary techno-commercial details are submitted to the client in the form of quotation enquiries for new bottle are received along with the drawing or sample bottle. Then marketing department studied this enquiry with the help of the other department and and the take the discussion. After calculating the manufacturing cost necessary commercial details are submitted to the client in the form of a quotation. The status of the enquiry is updated in the Enquiry File periodically.

Order Review and Acceptance:

The order received from the customer is received to ensure that Excel Glasses has the capability to meet the customer requirement with respect to product
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specification Quality and Delivery. After ensuring the capability of meeting the customer requirement the order is accepted and filed in the order file.

The order details are entered in the computer and the order is registered. An order Acceptance letter is sent to the customer and a copy of the same letter is attached with the order letter if any. Then collect the cost sheet for this product. When the conformation is get the communicate to the Production department in the form of a Montly Production Programme . if any change to that order required communication are send to the Production department. The order execution status is updated in the order / despatch register on weekly basis.

Review and Acceptance of Order Amendment:

Amendment to an accepted order may be made either by the customer or by Excel Glassesfor any of the following :

Quality Specification Price

The amendment is created by the company or customer is send to the other party and then return is given through both letter/ verbal means . Details of the Amendment are incorporated in the computer. The amendment details are intimated to the Production Department in writing. If it affects the production planning of the current month.

Storage and Finished Product:

The packed products ready for despatch is stored in finished goods godown. The bottle of different specification are stored at designated are to avoid any mix-up proper indentification is provided at the finished good godownto locate different type of bottles easily. The stock of the finished goods is maintained in the finished Goods Stores Ledger.
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Every year actual physical stock of finished goods is verified by statuatory auditors in coordination with Account Department and is registered in physical stock verification report.

Despatch Activities:

The Despatch section of the Marketing Department as per the despatch instruction makes deliveries ona daily basis from the Marketing Department. Based on the despatch commitments made to the customer despatch instruction note is prepared by the Marketing Department and forwarded to the despatch section on the previous day for the next day despatch. Marketing Department prepare a Despatch advice and forwarded it to the despatch section updates the despatch instruction.

Note and plan the despatch activities accordingly{A sales Invoice Delivery Chelan and Gate pass} is prepared and hand over to the concerned personnel as despatch documents. The despatch status is updated in the order/despatch register. In case of a request for any change in delivery by the customer it shall be entered in the register.

Handling of customer complaint: The compliant received from the customer are filed in the customer compliant file and then recorded in the customer compliant register. Transfer this compliant to the Quality Assuraance Departments and the department analysis the compliant and then if correctness is needed then correct it .The customer compliant Register is updated with the details of the settlement of the compliant. A summary report of the customer complaints is prepared and submitted in the Management Review Meeting for the discussion . The customer support office are situated at Bangalore , Chennai and Mumbai. MAJOR CUSTOMERS: Reckkit Benkiser( India) Ltd
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Hindustan Lever Limited Arya Vaidya Sala, Kottakal Mc Dowell & Co Limited Radico United Breweries Ltd

RECORDS MAINTAINED IN THE MARKETING DEPARTMENT:

Enquiry status register Quotation Cash sale advice Despatch advice and instrumentation note Sales invoice Delivery chelan Gate pass Order acceptance Order file Customer compliant file

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3.3 PERSONNEL AND ADMINISTRATION DEPARTMENT Human Resource Management is the part of the management which concerned with people at work and with their relationship with an enterprise. Actually it is a bridge between employees and Management. This department is mainly concerned with problem regarding the development of staff and labors force of the organization. HRM tries to achieve the organsational goal through respect for human personality and the well being of the individual .The company is having an Employee strength of 521 it consist of 81 officers and 440 staff and also company have workers according to the contract basis nearly to 350.

Departmental chart

DGM( PERSONNEL AND ADMINISTRATION)

HRM ( PERSONNEL AND ADMINISTRATION)

INDUSTIRAL RELATION MANAGER

INFORMATION SYSTEM MANAGER

ASSISTANT HRM(PERSONNEL AND ADMINISTRATION) PEONS

TIME OFFICE

SECURITY

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PERSONNEL DIVISION Duties and Responsibilities: Recruitment and Selection procedure Transfers and promotions Training and development Maintaining employee records

ADMINISTRATION DEPARTMENT Duties and Responsibilities: General administration Maintaining office discipline Guest relation Maintaining staff welfare activities

RECRUITMENT AND SELECTION PROCEDURE:

The personnel department does it. There is no fixed policy as such. Both external and internal sources are used for the recruitment. For the post of the top manager company fills the position through employment exchange and by giving advertisement in newspaper. The company also fills the vacancies of employee through promotion and transfer. Selection is based on personal interviews. New workers will get to know about the work by being involved in the work with their supervisors or first grade worker. For first one month new workers give the training period then to six month probationary period and the analysis about the worker and then appointed as the permanent worker.

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 TRANSFER AND PROMOTIONS:

Transfer from one department to another can be possible in two ways.It can be on the basis of request, company decided to transfer and also according to the educational basis Demotion and punishment transfer is also there. Demotion is a punishment transfer cutting several grades and also at the same time reduce the salary. Seniority is only basis for promotion. TRAINING AND DEVOLPMENT:

Training is compulsory for all employees since company emphasis on quality. Survival of the fitness this attitude is implemented in the mind of employees through trainings. It improves the performance of personnels Concerned head of the department identifies training needed staff. Training is conducted internally and externally depending on the needs of employees and facilities available. Training helps to equip the employees to face the challenges in the modern world. Development programs are meat for the managers. Company is taking initiatives to send their various devolpment programs, seminars etc MAINTAINING OFFICE DISCIPILINE: Company maintaining the discipline with the help of the punching system and rules and regulations of the company ie, company gave some instruction to their employee. The employee will not obey then it will affected the salary. Then employee are forced to obey the rules and regulation through this company can maintain the discipline. COMPONENTS OF BASIC PAY Basic pay, various dearness allowances, percentage dearness allowances, permanent allowances, annual increments, allowances as per wage board awardand holiday wages.

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BASIC PAY: The main component of the basic pay is gross pay. The management depending on the employees position, experience and merit fixes it. In Excel Glasses different basis is for different grade as per the agreement.

WAGE AND SALARYNADMINISTRATION: Wages are decided or various jobs on the basis of bilateral agreement between representatives of Glass manufacturers association and trade union representatives.The salary of the management is decided as per the KSR( Kerala State Rule).

DEDUCTIONS

STATUTORY DEDUCTION: It includes provident fund, employee state insurance, professional tax and income tax

NON STATUTORY DEDUCTION: It include co-operative society, advance recovery, welfare fund and life insurance premium.

NET PAY Net pay= Gross earnings Deductions =Amount which the employee receives

LEAVE PATTERN Fourteen days of sick leave is allowed to all. Twelve days of casual leave for the staff and eight for the non staff .Eighteen days of the privileged leave are allowed for the
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non staff workers and thirty days for the officers. Even after the employees take all leave he can have medical re imbursement of 20% of the bill. The maximum limit is 4000.

SAFETY POLICY The company gives great importance to safety of the employees and provide safety and health working environment. The safety policy shows the concern for the employees by the management.

SAFETY POLICY OF EXCEL GLASSSES LIMITED:

Excel Glasses is commited to provide possible safe and health working environment for the protecting and well being of the employees and general public by means of safe health system of works. Safety and health of the employees are prime concern of the organisation. Company constantly endeavour to impart integrated safety training to each and every one in the organisation. Accident can be avoided if proper care is taken by all concerned in the organization. Each and every one in the work of Excel Glasses no matter in what capacity he or she may function must accept responsibility for safety. The organization commitment to promote safety of employee shall not end where ends laws. WORKING TIME The factory is running in three shift a day giving one day off in a week. Shift 1 7 am to 3pm Shift 2 3pm to 11 midnight Shift 3 11midnight to 7 am
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 OFFICE TIME Office time of Excel Glasses is from 10.00 am to 05.00 pm on all working days from from Monday to Saturday .

CANTEEN FACILITIES A fair price canteen is operating at the premises. TRADE UNIONS

Now five trade unions are functioning in the company with harmony CITU INTUC BMS AITUC UTUC Trade union maintains a good relation with the labors and the Management. If an employee has some grievance he/ she inform the trade union and through them compliant will go to the personnel department

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3.4 Purchase Department

This department is concerned with the purchase of both indigenous and imported material. This department also performs the procurement of indigenous engineering spares, general engineering and other miscellaneous items other than raw material. This department is mainly concerned with purchase of indigenous goods, imported items and vendor selection. Indents from the engineering stores and purchase requests from other departments are available online in computer to purchase department. Vendor selection is mainly based on materials quality and delivery promptness. This section describe the method of evaluation and selection of subcontractors prior to approval for procuring the various items and o define the procedure for carrying out activities related to purchase of materials. Structure of the department Structure of the purchase department
PURCHASE MANAGER

ASSISTANT MANAGER PURCHASE

ENGINER PURCHASE

Clerical Staffs

Steno typist

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Functions of the department Selection of new subcontractors Performance monitoring of subcontractors Purchase specification Purchasing

Selection of new subcontractors All the major subcontractors who have supplied the products to the companies satisfaction till 01.12.1998 are included in the Approved List of Subcontractor. A new subcontractor is identified by the enquiries done either by us or by the subcontractor. If the subcontractor falls under the category of mineral supplier the details of the subcontractor is recorded in the Subcontractor Evaluation Form. If required, the capability of subcontractor to meet our requirements is assessed by our representative at his premises. Based on the assessment result, if found eligible, either product is found acceptable, the details are recorded in the Subcontractor Evaluation Form and forwarded to HOD (PUR) for approval. On obtaining the approval from HOD (PUR), the new subcontractor is added to the Approved List of Subcontractors Performance monitoring of subcontractors The performances of subcontractors supplying minerals and packing materials are monitored continuously. Their performance is assessed once in two months and the results are recorded in the Subcontractor Assessment Form The performance of the subcontractor is evaluated on the following parameters: A) Quality B) Adherence to Delivery Schedule C) Promptness in meeting emergency D) Price

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Purchase Specification The specification for Raw materials are established and maintained as Technical Specification for raw materials. The HOD (GLASS) is the approval authority for Purchase Specification List for raw materials. Purchasing The minimum stock level for various raw materials is established. The daily Stock statement of these materials is received from the stores. Based on the available stock level, Purchase Department initiate the procurement action for these materials. The materials are procured from approved subcontractors as per the requirement. The original copy of the Purchase Order is issued to the subcontractor. The duplicate copy is forwarded to the Store and the triplicate copy is maintained in the file of Purchase Department. For items other than raw materials and fuels, like production consumables, spares and other miscellaneous items, stores departments raises the Purchase Indent and forwards to the Purchase Department after obtaining the approval DGM (W). Quotations are invited for purchase with value of Rs.3000/- and more for a single item from reputed manufactured or their authorised dealers against Invitation to Tender and Instruction to Tenders Once the Purchase Department receives the recommendation with due approval from DGM (W), a formal Purchase Order is prepared and release to the selected subcontractor. For purpose of value more than Rs.25000/- approved is obtained from the Vice Presidents prior to the placement of Purchase Order. Emergency purchase may be done through verbal order, over Telephone or Through Fax. A formal P.O is released later. Cash purchases are done with the impressed money available. Such purchases are limited to only small value items, which are available off the shelf. Silica sand is primarily procured from silica sand mines owned by the company in Cherthala area. The purchase department coordinates the mining activities and further transportation to the factory. At times sand is also procured from other mines in Cherthala
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3.5 Glass Department

These are the activities of the glass department 1. Receiving Inspection of Raw Materials 2. Storage and Processing of Raw Materials 3. Batch Preparation 4. Monitoring of Furnace Parameters 5. Calibration of Laboratory Equipment Receiving Inspection of Raw Materials The intimation regarding arrival of raw material is received from the stores. The required sample of material is collected from the truck as per Sampling Plan. The raw material is inspected for the specified parameterises per the Quality plan. The analysis is carried out as per Quality plan. The inspection results are recorded in Daily Analysis Report Based on the inspection results, Stored in advice either to unload the material or to reject. Lime stone, Dolomite and Feldspar are subjected to receiving inspection before unloading. No above said material is released for emergency production purpose without carrying out inspection. Storage and Processing of Raw Material Accepted raw materials are stored in specific storage area in Raw Material Godown. Display boards identify the raw materials. Cullet received in trucks is inspected physically and an approximate percentage of rejection is recorded on the weighment slip by Asst.Manager or above. Cullet is processed and screened prior to charging to ensure that it does not contain any form of coloured glass, stone, Aluminium rings etc. Sand is processed in the sand beneficiation plant to ensure that required sizes of sand grains are only passed for processing. The sieve analysis of sand is carried out at the laboratory and the analysis results are recorded in Analysis of Processing Sand Report Other raw materials are also sieved and passed through magnetic separation before stored in silos. Results are recorded in Daily Analysis Report

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Batch Preparation The batch formulation for glass making is specified in the Quality plan. But based on the analysis results of raw material and furnace condition, HOD (GLS) is authorised to make suitable changes in the formulation. The details of formulation are specified in the Format Batch Changes Report by the HOD (GLS). The proportion of various raw materials for batch preparation is fixed as per this formulation. Original of Batch Changes Report is received by Dy. Manager (GLS). The various raw materials are mixed as per the formulation in the mixer along with other chemicals and stored in silos. The processed cullet is also stored in a silo. A fixed proportion of cullet, as specified by the HOD (GLS), is mixed with the mixed batch and kept in the Day Bin to charge into the Glass Melting Furnace. Once the batch is made ready, random sample is drawn from the mixed batch and is analysed in the laboratory as per Quality plan. The analysis results are recorded in the daily analysis report the batch mixing operation is controlled through computer programs. The details of batches fed into the furnace in each shift can be obtained from the computer. The details are also recorded in Batch Report the batch house operation are carried out as per Instruction for Batch House Operation. Monitoring of Furnace Parameters The furnace parameters are monitored on a continuous basis and the values are recorded at the specified frequency in Furnace Log Sheet. The operating range for various parameters is specified in the quality plan. The monitoring of furnace operation is carried out as per Instruction for Furnace Operators. The various possible abnormalities. That can occurred in furnace operation along with suggested corrective actions is specified in Instruction for Corrective Measures for Furnace Irregularities. The sample of glass bottles are collected from different working lines as per the frequency specified in the Quality Plan. The bottles are subjected to chemical analysis in the Laboratory and the analysis results are recorded in Glass Analysis Report

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Calibration of Equipments Calibration details of Sieves and Melter balance are maintained in the lab. List of all Inspection, Measuring and Test Equipment and Calibration details are maintained by Instrumentation Department Records maintained in the department Batch change order Analysis of processing sand report Daily analysis of report Batch reports

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3.6 Quality Assurance Department

The two larger production lines are provided with single liners, dual inspection stations and lowerators for transporting bottles to the ground floor for packing. The inspection on all five lines is presently manual. AGR dual head ramp pressure tester, Thermal shock testing machine and a well-equipped analytical and chemical laboratory doing density, chemical analysis of glass and microscopy are some of the facilities available. Quality Policy of Excel glasses Limited Our quality policy is to give total satisfaction to our customers through manufacture and supply of quality glass bottles We ensure that we comply with all the regulatory requirements and commit ourselves to continuously improve our performance Department Structure Structure of Quality Assurance Department

Manager Quality Assurance

Asst.Manager Q.AA

Quality Controllers

Line Inspectors

Sorters

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Functions of the Department 1. Inspection & Testing 2. Inspection & Test Status 3. Control of Nonconforming Product 4. Corrective Action on Product Conformities 5. Monitoring of Operation of Annealing Lehr Inspection & Testing Inspection and testing of finished glass bottles is carried out as per Quality Plan. The approved drawings (either by the customer or by HOD (MKT)) of glass bottles are maintained as reference for bottle dimensions. A list of all drawings available with its current revision status controlled by HOD marketing is maintained. The dimension of finished bottles are checked as per the Quality Plan and the inspection results are recorded in Bottle Dimensions Inspection Report The weight, capacity and gauge of the finished bottles is checked as per the Quality Plan and the inspection results are recorded in Bottle Weight, Capacity and Gauge Cold End report The glass bottles are subjected to on-line inspection for defects. All the defective bottles are rejected and recycled. Inspection & Test Status The inspection and test status of bottles undergone inspection at various stages are maintained in the associate Inspection records. Shift Quality Controller (In charge of the Shift) is the final authority for passing the bottles for despatch vide certificate for final clearance of bottles Labels A waiting Inspection identify the glass bottles collected from production line and kept at QA Laboratory. The master samples of various bottles are maintained at QA Laboratory for reference. Such bottles are identified as Sample Bottle. Sample of defective bottles are also exhibited in the lab. Control of Nonconforming Product On identification of repeated defects, the Production department is maintained is intimated about the same through Defect Rectification Note. The effectiveness of corrective action taken by the Production department is verified during the subsequent inspection. All the rejected bottles identified at various stages of inspection are disposed off by means of
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recycling the bottles. The bottles are fed to the Silos through conveyors to be fed into furnace. The QA inspectors/ Supervisors and personnel above them in QA Department have the authority to dispose off the rejected bottles. During inspection, if any batch is segregated for resorting, Rejection Tag shall identify the same. Senior Officer (QA) will verify and dispose off the same the next day. Corrective Action on Production nonconformities The product nonconformities are identified either through inspection at various stages or through customer complaints. For on-line rejection, the description of product nonconformity is maintained to the Production Department to initiate necessary corrective action. Wherever required, corrective measures are also suggested by the QA Department. Monitoring of operation of Annealing Lehr The temperature to be maintained at various Zones of the Annealing Lehr is specified in the quality plan. The guidelines for monitoring the performance of Annealing Lehr are established as Instruction for Annealing Lehr Control. The temperature at various Zones in the Annealing Lehr is monitored in each shift at every one hour. The details are recorded in Annealing Lehr Performance Report Records maintained in the Q.A Department Bottle Dimensions Bottle Weight capacity and Gauge Cold end report Daily Shift Wise Production Report Packed Ware Inspection Report Rejection Tag Defect Rectification Report Certificate of Final Clearance Of Bottles Corrective Action Register

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3.7 General Maintenance Department

These Department deals with the maintenance of the machineries as well as the various equipments in the factory and the various activities of the department in detail as follows: Preventive Maintenance Activities Breakdown Maintenance Activities Spare parts planning Monitoring of Equipment Operation Installation of new equipments Functions of the Department Preventive Maintenance Activities The equipments that require preventive maintenance is listed in List of Equipment. An Annual Preventive Maintenance Schedule is prepared detailing the schedule for preventive maintenance of critical equipments during each month. However for equipments which cannot be individually stopped since they are running along with the ISM/cs, following procedure is adopted: i. Preventive maintenance will be done along with the nearest job change, which normally takes place two/three times in a month in each line. ii. If there is no job change, it will be carried out during the stoppage for change of refractory tube and plunger, which invariably happens once in four months iii. In case, if it is noticed that a stoppage is inevitable during daily checks, a planned stoppage will be made with due approval of DGM (Works).

The Preventive Maintenance Plan provides the details of check carried out as part of Preventive Maintenance for each equipment. The daily checking of equipment is carried out as per Daily Checklist and the observations are recorded in the Checklist itself. The details of maintenance activities carried out as per the Preventive Maintenance Plan is recorded in Preventive Maintenance Record
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The preventive maintenance activities for various equipment are carried out as per the following work instruction: Instruction for Monthly Maintenance of Batch Mixer Instruction for Monthly Maintenance of Batch Charger Instruction for Monthly Maintenance of Single Liner Instruction for Monthly Maintenance of Annealing Lehr Instruction for Monthly Maintenance of Lowerator Instruction for Monthly Maintenance of Shrink Packing Machine Instruction for Daily Check of Critical equipment

Breakdown Maintenance Activities On breakdown of equipment, intimation is received from the User department regarding the same. The details of breakdown are recorded in Breakdown Maintenance Record upon completion of the rectification activities, the details of rectification along with the spare parts replaced are also recorded in breakdown Maintenance Record

The signature of the User department personnel is obtained in the Breakdown Maintenance Record while handing over the equipment to ensure that the equipment works to the satisfaction of the user. The summary of equipment breakdown is prepared on a monthly basis to analyse the trends and spare parts consumption pattern. Based on the analysis, if required, Preventive Maintenance frequency and checks are reviewed and are suitable modifications are effected. Spare parts planning A List of Critical Spare parts with its minimum stock to be maintained at Stores is established. The spare parts are collected from the stores against Material Requisition. Whenever the spare parts are to be procured, a Purchase Indent is prepared and

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forwarded to the Purchase Department through Stores after obtaining the approval from the concerned authorities. Personnel from General Maintenance Department carry out the inspection of spare parts. Based on the analysis of summary report of breakdown, if required, the critical spare parts list as well as their minimum stock level is redefined.

Monitoring of Equipment Operation The operation of general utility equipment is carried out by the General Maintenance Department. The Equipment operational parameters and details of running of equipment is recorded in the following records H.P Air Compressor Log Book L.P Air Compressor Log Book V H P Air Compressor Log Book Generator Log Book Installation of New Equipments Upon receipt of new Equipment/Machine, which comes under the purview of General Maintenance Department, will be inspected, installed and commissioned by the General Maintenance crew. After trial run and satisfactory performance, it will be handed over to the User Department for its stipulated use. The same will be brought under the procedure for the General Maintenance. Records maintained in the Department List of equipments Preventive Maintenance Schedule yearly Preventive Maintenance Plan Daily Checklist Preventive Maintenance record Break down Maintenance record

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3.8 Workshop Department

The workshop department carry out following activities New Mould Manufacturing Inspection of Moulds Storage and repair of Moulds Control of Drawings Maintenance of Equipment Calibration of Instruments Functions of the Workshop Department New Mould Manufacturing The request for mould manufacturing for new job is received from the Marketing Department duly approved by VP (T) along with drawings of the bottle or sample bottle. Wherever specified by the customer, a counter drawing of the bottle with all technical specification is prepared and forwarded to the Marketing Department for approval by the customer. Once the approval from the Customer/HOD (Marketing) is obtained, mould drawing is prepared with the help of standard design data available with the department. Inspections of Moulds The inspection results of Neck ring are recorded in Neck ring Inspection Report. The inspection results of Blow moulds and Blank moulds are recorded in Inspection Report for Blow Mould and Inspection Report for Blank Mould respectively. The inspection results of other items related to the manufacturing/repair of moulds is recorded in Inspection Report for other mould item.

Storage and Repair of Moulds The moulds for each job are separately stored with identification. The stock position of moulds is maintained in Stock Record for Moulds. The moulds are issued for production purpose as per monthly production schedule. The stock position of castings is maintained
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in Stock Register for Castings. The details of history of each mould are maintained in Mould Life Register. The details of moulds rejected after expiry of life is recorded in rejection report of moulds. The required repair work is carried out and the moulds are subjected to inspection before release to production purpose. The details of mould repair are recorded in Delivery Memo of Repaired Items. Control of Drawings The details of approved bottle drawings with current revision status are maintained in List of Bottle Drawings controlled by DGM (M) and issued to workshop. The drawings in use with latest revision status entered in the register are referred to as Current Drawings. Drawings not in use entered in register for reference purposes are referred to as non Current Drawings. Upon issue of drawings for mould manufacturing, the issue details are recorded in Drawings Issue Register. Upon receipt of a revised drawing, the list is updated. The old drawing is either destroyed or stamped Superseded and kept for reference.

Maintenance of Equipment The details of machines and concerned equipments available in the workshop are maintained in the Master List of Equipment. The Preventive Maintenance Plan is prepared on a Daily, Monthly and Yearly basis. The check points for all equipment for daily, monthly, and yearly maintenance is documented in the respective work instructions.

Calibration of Instruments List of all Inspection, Measuring and Test Equipment and Calibration details are maintained in the Department

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Records maintained in the Department Mould Manufacturing Schedule New Mould Release Note Approval for design change Neck ring Inspection Report Inspection Report for Blow Mould Inspection Report for Blank Mould Rejection Report for Mould Inspection Report for other item Stock Records for Moulds Stock Register for Casting Mould Life Register Delivery Memo of Repaired Items List of Mould Drawings (Current) List of Mould Drawings (Non Current) Drawing Issue Register Master List of Equipment Preventive Maintenance Plan Preventive Maintenance Record Breakdown Maintenance Record

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3.9 FINANCE DEPARTMENT Finance is considered as life blood of every business. Success mof any organisation depends on the efficient utilisation of its financial resources. The main function of the finance department is financial planning ie; raising and utilisation of adequate funds. STRUCTURE OF FINANCE DEPARTMENT:

GENERAL MANAGER

ASSISTANT GENERAL MANAGER

ACCOUNT OFFICER

CLERKS

PEONS

There are mainly three sectors in the finance department of Excel Glasses. They are Account Section Finance Section Cash Section

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ACCOUNT SECTION: The most important task done by account section is the recording of the dayto-dayaccounts. Routlne accounting functions like Sale Tax payment, Receipt and Payment of Cash, Cheque etc come under the preview of the account sectionof the finance department also under taken the employee payroll function. The accounts are maintained using computerised accounting system. Three categories of codes are used for accounting General ledger code (GL code) Sub ledger code (SL code) Cost center code (CC code) FINANCE SECTION: Finance section is mainly concerned with the maintenance of accounts. The various financial statement are kept in the computer as well as in the manual form. CASH SECTION: Cash section is concerned with the disbursement of cash. The Equity shares of the company are presently listed on the stock exchange, Mumbai (BSE).This provide national wide trading facility for shares. The investors/ member have access to online dealing in the companys Equity share on the terminal provided by BSE. Proper books of account as required by law have always been kept by the company. SIGNIFICANT ACCOUNTING POLICIES 1. Accounting System/ Revenue Recognition: Financial statement are prepared as a going concern onaccural basis under Historical cost converntion and in accordance with the generally accepted accounting principles. All expenses and income to the extent ascertainable with reasonable certainly are accounted for on accrual basis. Interest on overdue debts/insurance and other claims to the extent considered recoverable are accounted in the year of claims. However claims whose
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recovered cannot be ascertainable with reasonable certaintly are accounted on acceptance// receipt basis. The presentation of the financial statement in conformity with generally accepted accounting principles (GAAP) requires management to make estimates and assumption that affected the reported amount of assests and liabilities and the disclosure of contigent liabilities on the date of the financial statement. Actual result could differ from those estimates. Any revision to accounting estimates is recognized prospectively in the current and future periods. Sales exclude trade discounts, rejections and breakages

2. Fixed assets:

Fixed Assets are stated

at cost less depreciation. All major modification/

additionsincluded expenses interest during constructions period of fixed Assets, which resulted in increasing the operational efficiency of the assets are capitalised. A fixed assets is treated as impaired when the carrying cost of the assets exceeds its recoverable value. An impairment loss is charged to theprofit & loss Account in the in which an assest is identified as impared. If at the balance sheet date there is any indication that a previsously assessed impairment loss no longer exists then such loss is reversed and the assest is restated to that effect. Expenditure during construction period is included under capital work in progress and the same is allocated to respective fixed assets on the completion of its construction.

3. Depreciation: Depreciation on Buliding, plant and machinery including furnace, electrical installation and water system during the period is provided on straight line method at the rate specified in schedule XIV of the companies Act 1956 from the date of assets put to commercial use.

Depreciation on other assets is provided on written Down Value Method at the rate specified in schedule XIV of the companies Act 1956. Each individual fixed assetscosting below Rs 5000 are fully depreciated in the year of acquision.

4. Inventories:
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Raw materials, packing materials and fule are valued at cost determined on Weighted Average Method basis. Store and Spare parts are valued at cost. Loose tool and mould are valued at residual value. Finished good are valued lower cost or market value. Stock in process

5. Investment: All investments are of long term nature and are valued at cost

6. Retirement Benefits Provident fund and Pension fund: Contribution to provident fund and pension fund as per the requirements of the applicable laws are charged to revenue in the period they are incurred Gratuity: Gratuity payable to Employees is accounted on accrual basis Leave Encashment: Leave Encashment is accountable for on cash basis

7. Foreign currency Transactions: Transactions in foreign currencies are recorded at the exchange rate prevailing on date of transaction. Current Assets and current Libilities are reinstated at period end exchange rate and the profit or loss so determined and the realized exchange gain and losses are recognized in profit and loss account.

8. Borrowing Costs: Interest and other cost in connection with the borrowing of the funds to the extent related/attributed to the acquision/ construction of qualifying fixed assets are capitalised up to the date when such assets are ready for its intended use and other borrowing cost are charged o revenue.

9. Lease/ hire Purchase transactions: The actual cost of the assets acquired under the hire purchase transaction is capitalised while the annual finance charge are charged to revenue account. In respect of assets on leases the value thereof is not capitalisedbut contracted lease rental are charged to revenue account on accurual basis

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10. Taxation: Provision for current tax are determined in accordance with the Income Tax Act1961 The deferred Taxfor timing difference between two book and tax profit for using tax rate and laws that have been substantively enacted as a Balance sheet date.

3.10 PACKING DEPARTMENT Packing of glass bottles is carred out either as per the requirement of the customer or as per in house packing specification. The details of packing specification for various type of Glass bottles is established and documented as Guideline for packing. Packing slips are provided inside the packets for identification and details are recorded in identification Slip register.

The packing products are checked for the quality of packing at random. If the packing is not good the bottle are subjected to re packing. The packing materials is collected from store aganist Material Requision Slip. The details of packed products are recorded in the productionregister maintained by the packing Supervisors / charge hand. Utmost care is taken while packing to avoid any damageto the finished bottles. Packed products are transferred to the finished good godown. Any damage / defective bottles indentified during packing is segregated and sent for recycling . for customer- supplied cartons a separate register is maintained to monitor the stock, issue and inspection details.

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3.11 STORE DEPARTMENT

Stores department deals with the Receipt of materials, Storage of Materials, Issue of material initiation of procurement activities etc Receipt Of Materials : The raw materials and bulk items like fuels, steel casting etc are weighed at the weight Bridge and the weight is recorded in the weighment Certification. The intimation regarding receipt of raw materials is sent to the Glass Department for the inspection of the materials Based on the inspection results the accepted materials is uploaded as Raw materials Godown . A good Receipt note is prepared for all items received at store. The GRN is sent to the user Department for inspection of the items. For rejecting items, arejection Note is prepared detailing the reason for rejection. Two copies of rejection note are sent to the purchase departmentfor their reference and onward submission to the vendor.

Storage Of Materials: The raw materials godown is supervised by the Glass department, Packing department supervises Packing material godown. The store Department does storage of all other items expected moulds and raw casting. The items are stored at designed area in store and are indentified suitabily. The stock position of items is maintained in computer. Based on the daily consumption report of raw materials and receipt details a daily stock position report is prepared and submitted to the purchase department . For consumption of the raw materials a certain percentage of handling loss is added to the consumption. For items which require minimumstock to be maintained as advised by the user department the availability of minimum stock is ensured at stores. The physical stock verification is carried out once in a year to check the quality of the items under storage and to compare the physical quality with the book quatity. The physical stock verification details are recorded in physical stock verification report.
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Issue of Material: The raw material and fuels are consumed for production and based on the Material Consumption Report, the stock position is updated . For all other items are issued from Stores against Material Requisition Slip duly authorized by the concerned authorities .A list authorities for approving Material Requisition with their specimen signature is maintained at Stores. The issue details are recorded in the Material Requisition and entered in computer for stock updating.

Initiation of Procurement Activities: For items , which require minimum stock to be maintained , as advised by the user Department, the Stores Department raises the Purchase Indent once the minimum stock level is reached. For other items , based on the Material Requisition slip, if the item is not available in the stocks , Stores Department raises the Purchaseindent. The user department also raises purchase indent for the items which are not covered inthe list of items for minimum stock.

List of Record in the Department : Weightment Certification 1 month Good Receipt Note 1 year For inspection tag till Inspection Rejection tag disposal Rejection note 1 year Physical stock verification report

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3.12 INSTRUMENTATION DEPARTMENT

This department carries out following activities:

Calibration of Instruments: The details of instruments which requires calibration in Instrumentation, Quality Assurance, Production, General Maintanence, glass, Workshop,Store Electrical departments are maintained in the Master List of instruments. The instruments are calibrated either in houses or through approved external agencies. The calibration is done aganist Master Equipment having valid calibration and traceable to national/ international Standards.

Maintenance of instruments The processing instruments are maintained to ensure its operational efficiency. The preventive maintanances of instruments is carried out per Preventive Maintenance Schedule. The various checks to be carried out mentioned in the schedule. New equipment purchase modality: New instrument are purchased when Existing instruments are beyond repair during plant expansion

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CHAPTER 4

ANALYSIS

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4.2 SWOT ANALYSIS

STRENGTH: The following features possessed by the company act as its strengths:

Good product quality (ISO Certified) Customer are satisfied with Excel Glasses products Raw materials are locally available Good distribution network Computerized production system Efficient admistration system Good management and skilled workers Prime location Office are fully computerised

WEAKNESS: The company suffer from following weaknesses:

Website is not up dated regularly Over influence of union leaders Lack of Advertisement. Under utilisation of the plant capacity No sufficient funds
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OPPURTUNITIES:

Excel Glasses can make use of following opportunities:

In Kerala there is no other glass manufacturer. This is the most important opportunity Company can extend the market to more foreign countries More product variety can be introduced Increasing growth rate of food and breweries industry , one of the key customer of Glass bottle

THREAT: Excel glasses faces the following threats: Threats are being faced from unorganised market supplying second hand bottle at low cost Increased use of plastic bottles Increased price of raw materials Increased price of raw materials Change in government policy Increased competition

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CHAPTER 5

FINDINGS & SUGGESTIONS

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5.1 FINDINGS

Relationship among management and workers is healthy Enjoy maximum freedom in working field compared to other companies Good management and good worker are the strength. Customers are satisfied with Excel Glasses products. Trade union has their own influence on the employees. The pollution of temperature, noise and dust disturb a good working atmosphere. Organization structure of the company is good. A fair wage system prevails in Excel Glasses limited A good co-ordination exists between different departments. The workers are expecting an overall change in the management style. The cleanliness of the working atmosphere is not well. Rest room is not in a good condition. Safety measures and first aid measures are poor. Women labors participation is less.

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5.2 SUGGESTIONS:

Improve the communication between management and workers. The training programs should be made effective Fire drill and basic safety awareness should be done periodically. Since the demand for the glass bottle is showing a high growth rate the firm can utilized the maximum. Introduce new and advanced machinery instead of the old one Collect feedback from the workers at proper time. Take necessary step about employee graveness Conduct healthy recruitment and selection procedure Website is to be update regularly. Improve women participation. Give more advertisement. The company can produce different varieties of glass bottles. Performance appraisal should be done to motivate the workers. Reward management should be properly carried out. Take steps to keep the working atmosphere clean and hygienic. Provide proper restroom and toilet facilities. The activities should be both production oriented as well as welfare oriented.

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5.3 CONCLUSION:

From the close study on Excel Glasses Ltd it can be stated that the products of the company have gained high influence among the customers and the company can be proud of the quality of the product, maintained by them. Obviously the product has attracted market extensively as they have strived hard to get on with customer satisfaction.

The strategic location of the plant in God Own Country Kerala where there are no other glass bottle manufactures have provided the company with steady and easy entry into market. The company works through several functional departments Each of this departments is properly organised and has well defined authorities and responsibilities

If the company keeps this strength and develop more scientific methods to improve the efficiency in production there is a scope for further developments in the years to come. Thus the researcher found that the company can improve the status and can capture the market easily by effectively utilising the existing resources of the company.

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BIBLIOGRAPHY

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REFERENCE
Annual reports of EXCEL GLASSES 2010-2011. Kotler Philip, Marketing Management, New Delhi, Prentice Hall of India Ltd,2009 Robbins Stephen, Fundamentals of Human Resource Management, New Delhi, Wiley India Ltd 2009 Kothari C.R, Research Methodology, New Delhi, New Age International Private Ltd 2004 Chary S.N, Production and Operations Management, New Delhi, Tata Mcgraw Hills Publishing Company Ltd,1997

WEBSITES
http://aigmf.com/the-federation.php http://www.excelglasses.com/html/e0100frm.htm http://www.excelglasses.com/html/e0200frm.htm http://www.excelglasses.com/html/e0500frm.htm http://en.wikipedia.org/wiki/Glass_production http://en.wikipedia.org/wiki/History_of_glass

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