CHAPTER-1 INTRODUCTION

As part of my curriculum the students of RVS Institute of Management and Research (RVS IMSR), were scheduled to undergo an organizational study for a period of 14 days. The study was conducted for the purpose of increasing the awareness of students regarding the functioning of an organization. I conducted the study in Goodwill Team Papers Limited, Madurai. The study was under taken for a period of two weeks in May 2011. This report is about Goodwill Team Papers Limited, Madurai. The study is intended to find out human resource activities, manufacturing activities, production process, and functions of the company and intended to obtain an overall view of Goodwill Team papers (P) Ltd.

INDUSTRY PROFILE
The Indian paper industry has been historically divided on a three dimensional matrix identified by size, grades manufactured and raw material utilized. Generally, tariff rates have protected smaller units utilizing unconventional raw material. Over the years, the growth of various segments, investments levels in specific segments, technological changes, industry fragmentation and intensity of competition have been significantly influenced by the Government tariff policy. The three main grades of paper manufactured in India are:1. Newsprint 2. Writing and printing. 3. Industrial Variety (Kraft paper and Duplex Board) The term Kraft paper means that it is sturdy machine made paper that is created using wood pulp, corrugated boxes and indigenous waste papers. It is mainly uesd for wrapping process. That is covering boxes, book and heavy products to protect against scratches. The name Kraft is derived from the German that means strong. Kraft paper can be utilized for many different purposes. One of the most common uses of the plain brown Kraft paper is in the manufacture of paper bags for use in grocery stores. The solid construction of Kraft paper makes the bags ideal for use with all sorts of grocery items. While many grocers have switched to the use of plastic bags, many supermarket chains continue to offer customers the option of receiving their purchases in bags made from Kraft paper. Kraft paper is also utilized in other industries as well. In the publishing industry, Kraft paper is often used as the lining for the inside cover spine of hardback books. In the world of electronics, Kraft paper is often used as an insulating agent on electrical components, providing a sturdy yet inexpensive means of protecting the material. Envelopes for both mailing and use as interoffice communications are often made with Kraft paper, owing to the relative thickness and sturdy nature of the paper

COMPANY PROFILE
The company name is GOODWILL TEAM PAPERS LTD .This Company is located in Uthappanickanur. The company is located under the valley of a hill. This company is started in the year 1997.It is a private limited company. Managing Director of this company is Mr.P.Rajendran.The raw materials source for making papers is not a scenario like pulped wood but here the source is taken from waste paper material. The main raw material of this company is used corrugated boxes and indigenous waste paper.The finished goods of this company is KRAFT PAPER.The company concern stretches their marketing to the cities like Madurai, Sivakasi, Coimbatore and some parts of Andhra. Where papers are vastly used for only packing.

COMPANY OVERVIEW

Name of the company Managing Director Address

GOODWILL TEAM PAPER LTD Mr. P. Rajendran Team Garden, Uthappanaickanur post, Usilampatti Taluk, Madurai District. Indigenous imported waste paper,corrugated boxes Kraft paper Public Limited company July 1997 10 Lakhs 120worker,20 satff 100 contract workers 3 shifts per day 45Tones per day

Raw material Used Name of Finished Goods Ownership Production started Starting initial investment Employees Shift Tones produced

OBJECTIVES OF THE STUDY

To know about the factory environment.

To understand about the management functions. To know about the general history of the company . To know about the facilities provided for the employees in the factory. To learn about the various functions of various departments.

ORGANIZATIONAL STRUCTURE

MANAGING DIRECTOR 5

MANAGER

ENGINEER

SUPERVISORS

WORKERS

CHAPTER-2 FUNCTIONS OF VARIOUS DEPARTMENTS

The following are the various departments in Goodwill Team Papers ltd.

Purchasing department Production department Packaging department Marketing department Sales department Personnel department Accounting department Electricity department

PURCHASE DEPARTMENT
The Main raw material used in the paper company was the waste paper and used corrugated boxes. The purchase will be within state and interstate. Raw materials are bought
7

on credit basis. Over all purchasing is maintained in the purchase department. It depends upon the customer order. Chemicals, machine parts will be purchased from registered dealers and accounted in computer.

RAW MATERIALS USED

The main raw material used in this company was the used corrugated boxes or cartoon boxes and Indigenous imported waste paper ans some of the chemical should be used for colouring the kraft paper and drying the kraft paer such as alum ferric, alamine, rousine.

PURCHASING PROCESS

Checked stock level

8

Get quotation from suppliers

Review quotation

Place order

Receive materials

Inspect the quality and quantity

Stock register

Receipt of requirement from user

Supply to user from stock

PRODUCTION DEPARTMENT
The function of production department is to convert the raw materials in to the finished goods.It is essential that production is carried out in the best manner of the lowest cost and the goods are of right quality and then delivered at the right time.
9

Production department will be very keen to reduce the wastage. To have the maximum output it perorms the ancillary function of creating wealth out of the waste.That is this firm should recycle and reuse the wasted water and kraft paper occurs in this firm.The department uses zero wastage formula for its success. It uses almost every possible material for production with out any wastage. Per day production is 45 tones. Good Will Team papers ltd is the only producers of the coloured Kraft paper. The Marketing department receives the order from the customers and then the production will start .The production is mainly based on the order they received. The marketing department receives the complaint and feedback from customers, and the complaints are send to the production department for their rectification. The production department has modern technology machines. All the machines are automated and are supervised by the workers. Less man power required in the production department.

PRODUCTION PROCESS
1. Pulper 2. Chest-1 3. Seper Plast
10

4. Centric Cleaner 5. Slide Hill Screen 6. Chest -3 7. Chest-7 8. Head Box 9. Wire part 10 Vacuum Box 11. Press section 1st Press 12. 2nd Press 13. Pope reel 14. Rewinding
These fourteen processes are followed to produce the Kraft paper. Here they follow line layout.

PRELIMINERY PROCESSING STAGE

Pulper

11

Chest-1

Seper plast

Centric cleaner

Slide hill screen

Chest-3

SECOND PROCESSING STAGE

Chest-7

Machine chest

12

Head box

Wire part

Vacuum box

THIRD PROCESSING STAGE

Vacuum box

13

First press

Second press

Dryer

Pope reel

FINAL PROCESSING STAGE

Pope reel

14

Rewinding

Kraft paper (Finished good)

BOILER
It is a separate production department. The main function is converting the water into steam. It is used for drying the paper. It is different from manufacturing. The main fuel is wood for heating the water. The maximum capacity is 12 tones of water. The mill uses the soft water for producing the steam. if we use soft water then the plantlife will be long up to 20 years. Two types of tubes are mainly used in the boiler,
15

1. Water tube 2. Smoke tube.

PULPER
It is the first process in the production department. In this section raw materials are grinded into pulp. The raw materials are fed into the Pulper. It is a hollow cylindrical, cone shaped bottom structure. It consists of impeller, Perforation place in bottom of the Pulper. It is operated by motors. During pulping more water is required and also in the bleaching process.The capacity of the pulper is 120hp-1440 rpm motor. After completing, the pulps are forwarded by next process. Approximately 1 kg of pulp release 15 % of wastage. (i.e.) in 1000 kg of pulp, 150 kg of wastage is released. The pulp passes through the storage chest. The wastages are pin, plastic etc., the 1 st stage of cleaning is finished in this Pulper section. The wastages are not fully filtered in this stage. The remaining cleaning is done in the next level. Another Pulper machine also runs for grinding the wastage from the finished product section. In the finishing section, the cutting paper also comes under the wastage. The mill uses the wastage to make a new paper. This pulp does not need not stages of cleaning. It is directly send to the approach flow system.

CHEST-1
The pulp is send to the Chest-1 through pump.The pin and fabric waste are removedfrom the pulp in the Chest -1.

SEPER PLAST
In the Seper Plast the plasting wastage found in the pulp should be removed here.And then the purified pulp should be sent to the Centric Cleaner.
16

CENTRIC CLEANER
In the Centric Cleaner it removes the pin and the sand pariticles that is found in the pulp.And then the pure pulp will be sent in to the Slide Hill Screen.

SLIDE HILL SCREEN

The pure pulp comes out from the Centric Cleaner is sent through the Slide Hill Screen and subsequently water is filtered from the pulp.

CHEST-3
The pulp which comes out from the Slide Screen reaches the 3rd Chest through the pump and the pulp id refined in the TDR machines.Here we add the chemicals like AlumFerric, Alamine, and Dye for colouring the kraft paper and removing the waste.

CHEST-7
In the Chest no 7 we add Rousine.It is used to filtered the water from the pulp ans sent the pulp to the Head box.

HEAD BOX

To provide sufficient head to correct discharge velocity across the width of the wire. To even out the flow of stock across the width of the wire. For release of entrained air.

HEAD BOX CONSISTS OF THREE PARTS:

1. 2.

Intel arrangement Head box proper

17

3.

Slice

WIRE PART
This process is used for drying the pulp fully. It consist vacuum box to make the pulp dry. Moisture (or) coater is removed by this method. It seperates the unwanted water and pulp and both will again sent in to the pulper.The reamining will sent in to the Vaccum Box.

VACCUM BOX
There are four vaccum boxes are there it si used to suck 80percent of water in the pulp.Here the pulp is drained by the steam obtained from the boiler.

PRESS SECTION
In this section the water is removed. Generally two types of presses are used:-

1ST PRESS (PLAIN) Nip formed between two plain rolls

1. 2.

Sheet Felt enter nip As the load increases water from the sheet fills the voids in the felt. When felt is

saturated water is forced out and run down the in going side of the bottom roll. Generally the water removal rates are low in this press and hence not used in high - speed machines. 2ND PRESS (SUCTION) Nip formed between suction roll at the bottom and a plain roll and top water pressed from the paper is forced down through the felt and removed by suction. Hence water removal rates are better.

POPE REEL
It is the final process in the manufacturing department. In this stage having calendar, winding, rewinding. In this stage the final output is released for packing. The paper is
18

automatically rolled into bundle. The waste paper also cut and sends to the pulper section for grinding.

CALENDER
The papers come from dryer without moisture. Main work of calender is rolling the paper sheet. It helps reduced the fold in paper sheet. Size of the paper sheet role = 171/2 inches

WINDING
Winding to cut and wind full width large diameter paper roll in to suitable size rolls. There rolls may then to rapped and directly to the customer (or) they may be processed through subsequent coating. The bending (or) sheeting operating baring windings the two edges of the reel (Trically 3.5cm) are trimmed off and conveyed back to the dry and pulper. Winding is usually defined as a process when changes a material manufactured is not form in to roll from for further processing the true winding process occurs the paper machine during reading subsequent winding process are roll to roll and could more accurately be called rewinding operation. However terminology is already well enriched the first roll - to - roll operating is called winding.

THE MAJOR COMPONENTS OF WINDER AND ITS FUNCTIONS:

1. UNWIND STAND

Supports the roll Provide the breaking to control acceleration and declaration.

2. TENSIONING ROLL
19

Provides feedback to unwind stand break benison.

REWINDING
It is the next process for the winding. It helps cuttings the paper sheet. According to customer requirements.Rest of the waste paper again send to the pulper for reuse.

PACKAGING DEPARTMENT
Packaging is very essential for every product. It is the silent sales man. It attracts the customer easily. So the concern gives the first preference for the packaging department. Packaging attracts and gives publicity. Packaging department works by the packing the goods. The paper is reeled at the rope level. This roll is send to rewinding section.
20

In rewinder sections rolls are cut to correct sizes depending upon the customer`s requirements for sheet. Order 9 (or) reel order. Then it is finished and packed. These products are ready for transferring and sales.The pulp is packed according to the custome needs in respective of weights. That is pulp is packed in roll as the weight of around 400kg or 500kg.And then the correct weight and the correct quality of the paper should be mentioned in the coner of the packing .The customers detail and the date of delivery is also mentioned in the cover.

MARKETING DEPARTMENT
I have learned how they market their products from this department. It was very useful for my studies. It is a very important department in the concern. The main function is to sell the finish product to the customer, and to get the order from the customer and send to the production department for production.
21

Marketing is a system consisting of several interdependent and interacting subs system. It obtains the inputs from the environment. the output. It includes receiving the order through mail or phone calls, and sends the order details to the finishing section. Customer can access the website for the product detail and for further they can collect the sample through courier. The colour type and size of the paper is made by the customer preference. The mill follows the first in first out method to dispatch the goods to the customers. (i.e.) receive the orders from customers and supply the goods in priority wise.The main function of marketing department in GoodWill Team Papers ltd is to get an order from the customer. The main objectives of the Marketing department are Increasing the sales in every quarter Individual sales representative achievements based on target fixed upon her previous target achievements Increase the customer satisfication To increase the areas of operation Transforms these inputs and supplies

Goodwill Team Paper ltd streches their marketing in some parts of Kerela, Andhra and in many parts of Tamilnadu.

SALES DEPARTMENT
Sales department is the only department selling the whole sale goods to various states such as Tamil Nadu. Kerala, Andhra Pradesh, Karnataka.

TYPES OF SALES:
22

A. B.

Direct sales Depot sales The concern sells their goods to the party direct only. So, if any theft (or) any

DIRECT SALES fire (or) any damages occurs to the product. The company has to take the sales. DEPOT SALES Here the government takes the full responsibility. The selling takes place with the prior confirmation from government.

RATE FIXING
Basic Value + Commission + Freight + Handling Charges 1. Cost of raw materials 2. Add consumption of stores item 3. Power and fuel 4. All direct Expenses (freight) 5. Depreciation 6. Interest (Funds, secure loan, Funds) Sum + Profit margin is sales value (Basic) Price fixing depends upon the quality of the goods.

PERSONNEL DEPARTMENT
The personnel department is playing vital role in the functioning of the mill. The main objective is to create good relationship between management and employees of the organization. Every department is running with separate functions, but this personnel department relating with all the department of the organization and all departments
23

employees. Recruit the employees, providing training to the workers, maintain the employee welfare these are the important functions of the personnel department. Goodwill Team Papers ltd does not have a specialsed Personnel department.The people in the Top level and Manager should take care of this department. The Top level people and Manager are selected by the Managing director of the company. The Middle level and Low level people are selcted by the Top level people that is Manager of this firm. Majority of the workers are selected around the plant location area.

FUNCTIONS OF THE PERSONNEL DEPARTMENT

Job evaluation Counseling Employees benefit and services Recruitment and selection Training and development Salary administration Grievance handling Appointment and placement

In every concern the personnel department is essential. The department superior should know about the workers grievance and superior should rectify that immediately. Salary is fixed by the personnel department. Training is provided for the new employees within the company. The trainee is trained by the experienced person within the company. The employee salary statement, PF, Gratuity, Bonus details, employee attendance all are maintained by this personal department. Since the mill follows shift basis, the personnel department heads a lot of work schedule for the workers. The superior should maintain the
24

disciplinary activities to the workers. Every department is running for profit motive but this department is only running for the employee welfare.

LEAVE FACILITYS FOR WORKERS

The workers should compulsory work for 340days per year. For every 20 days they take 1 day leave. (i.e.) the company allows 12 days leave for the workers. The mill also provides medical leave and maternity leave to the workers. Govt and local holidays are permissible.

TRAINING
The purpose of the training is to identify the training needs for all persons and providing the same in appropriate time. The company gives training both to the labour and administrative staff.

TRAINING NEED IS IDENTIFY BY ANY ONE OF THE FOLLOWING:

To meet the needs of the implementation of new systems. Requirement of new staffs. When continuous decreases in productivity. When worker is transferred a new department. When additional responsibilities are entrusted.

LABOR WELFARE FACILITIES

The labor welfare facilities are extending to the work force. These facilities enable the workers to increased production. The facilities motivate the employees to work more for the concern. It creates job satisfaction among the employees.

THE FACILITIES IN THE ORGANIZATION ARE:

25

1. 2. 3. 4. 5. 6.

Pure drinking water facility Medical checkup Rest room facility Vehicle stand for parking the vehicle Sanitary facility Canteen facility

TIME CARD / LABOR CARD

Under this system every worker is provided identity bearing his identification number. All such cards are kept in the entrance of the organization a few minutes before the operating time. All the workers should bring their time card. Daily workers time card is signed by the time keeper daily.

GRATUITY
A worker is eligible for getting gratuity only after 5 years of entering into service. The gratuity act 1972 is eligible for gratuity. The amount payable shall not exceed Rs.3, 50,000/Gratuity = No. of years X 15 days of wages.

BONUS
Every employee shall be entitled to get bonus in accordance with the provision of the payment of bonus act 1965. But for this establishment not less than 30 working days worked in an accounting year. The bonus is paid in particular percentage on the salary of 12 months. The minimum bonus of 8.33% on salary (or) wages earned by the employee during the accounting year.
26

PROVIDENT FUND SCHEME

Under the employees provident fund act 1952 a provident fund scheme and pension are under operation in the company. Provident fund collected from the employee contribute 12% on salary out of the employees contribution of 12% of salary out of the employers. Contribution of 12%, 3.67% is transferred to provident fund account and 8.33% transferred to person account provident fund should be remitted within 15th of every next month.

ACCOUNTING DEPARTMENT
Accounting departments are maintained by the Accountant. All the accounts details are maintained in Tally 9.2 version software. It reduces the manual work. It is an easy way to maintain the accounts clearly and correctly. In GoodWill Team Papers ltd they maintained the accounting department in Madurai.

27

It is the private limited company.75percent of the company capital should be invested by the ManagingDirectors and the reamining will obatin from the bank loan. In the current financial year 2010-2011 the annual turn over of this company is around Rs.160000000 (Sixteen crore rupees).

FUNCTIONS OF THE ACCOUNTING DEPARTMENT

1. 2. 3. 4. 5. 6.

Voucher posting Sales bill posting Basic accounts Purchase and other journals Inventory details + Ratio analysis Profit and loss accounts

MAINTENANCE OF DAY BOOK

Each and every day any cash out going should be entered in day book. Every purchasing product as sales is entered in the day book. These day books after preparation of all details are submitted weekly or monthly. When the company requires the accounts details at the time it will be submitted to the management. It helps for finding the production level It helps for finding profit level It helps for finding stock level

PREPARATION OF FINAL ACCOUNTS

Every month all the sales and with in state purchase would be reported to sales tax department paying the necessary taxes, under from A1 from 1. Profit and loss accounts should be taken on is before 10th of every month and to be submitted for monthly - received board meeting. Accumulation of yearly account of profit and loss account should be
28

prepared for submission of balance sheet at yearly once for sales tax, income tax and register of companies.

ELECTRICITY DEPARTMENT
In the paper mill (or) any other factory the major (or) high expenses in electricity only. Per month expenses for electricity is 3.5 lakhs.

CONSUMPTION OF UNITS
29

Per hour Per day (24 x 1200) Per month (28800 x 30)

= = =

1200 units 28800 units 864000 units

Machine running motors VFD (variable frequency drive). Machine required power depends upon the machine motors. Per unit cost are 5.6rs.

LOAD DETAILS OF THE MACHINE

Si.no 1. 2. 3. 4. Name of the motor New - pulper pump Pulper B/W Pump Washer -2 Coloring - pump 1
30

HP 60 7.5 20 15

RPM 1440 1440 960 1440

Full current 77.1 10.7 27 21

Loaded

5. 6. 7. 8. 9. 10. 11.

Coloring - pump 2 1 Press 2 Press Dryer Calander Pope Rewinder

15 125 150 75 100 40 100

1440 1475 1485 1470 1475 1470 990

21 152 190 98.5 132.5 54.5 129

QUALITY CHECKING
In the quality control department GoodWill Team Papers ltd has conducted the following test to check the quality of the kraft paper. That is 1. Grammage test 2. Cobb value test

GRAMMAGE TEST
The mass per area of the paper is measured as GSM. Paper sheets are cut to a size of 10cm*10cm then the sheets are weighted individually.The mean of the weught is used to
31

calculate the mass of the paper per square meter and the SD will determined from all samples. If the weight is higher than the specified then it is a loss for publisher.

COBB VALUE TEST

The Cobb value indicates that the paper should have the capacity to absorb water.

High cobb- High absorbed water Low Cobb Low absorbed water

The quality checking test is conducted to find out the following qualities such as Strength Chemical reistance Load bearing capacity Moistured level

SWOT ANALYSIS
STRENGTH

The company has sound financial position. Working Environment of the company is so liberal to work. Company gives more importance to the quality. Discipline and morale followed by employees Good business environment
32

Concentrating on satisfaction of customer

WEAKNESS

If any of the machine stops in between the production process which leads to decrease in per day production of the company. Employees which are under the contract takes leave will also affects the per day production of the company.

OPPORTUNITIES

Chance for future expansion in plant capacity. Technological changes Improved buyer or supplier relationships Growing industry

THREATS
33

Increasing labor shortage Increasing competition affecting in cases of hiking labor and material cost. Slow market growth Tax increases Changes in government policies

OBSERVATIONS

GoodWill Team Papers ltd is the only producers of coloured kraft paper in The waste paper and Waste water found in the company should be recycled it All the process should be automative it helps to reduce the worker capacity. In current days they are not able to meet their demands and orders. That is
34

south Tamilnadu. helps to reduce the pollution.

their production level was low when comapred to the order they received.

The palnt location has the great chance for their future expansion.

SUGGESTIONS

They have the sound financial position and plant location so they install one more Because in current days they will not able to meet their demand. The company should give proper respect and the job safety to their low level

production palnt for their production. people.

35

The MOQ (minimum order quantity) of the company is 15 tones. Because of this

bulk volume retail outlets do not prefer this company. For this we can locate the stockiest in areas of demand will help the company to boost their sales.

More concentration is to be laid upon the employee welfare. Measures such as

organizing meeting among the employees of the organization, so as to develop rapport among them. Celebrating festivals within the company premises are to be developed.

CONCLUSION
In the tow weeks of training I was able to relate theory to practice. I was able to understanding the business environment in a better manner. I could feel the difference between text book and corporate culture. I gained skills and experience that will be invaluable to my future career throughout my entire life. This In Plant training has been an incredibly positive experience that was far more valuable to me than I had expected. I explored the relationships between theory and practice, including reviews which examine emergent practices and interpret them in light of curretnt status of the company.
36

I was able to relate theory to practice to a large extent, from the point of view of the structure of the organization, the various forms of skills adopted for training the employees, the leadership style, the pricing strategy adopted, day to day decision, the system of order execution by the company, work flow, the skills, the shared value, the duties and responsibilities of staff and much more. Theory to Practice was related where the skills of the company were classified on the basis of Technical and Functional, where different safety measures and welfare measures were adopted by the company. Overall I had a great experience while undergoing in plant training in Goodwill Team Papers ltd. The experiences have gained will stay with me for a lifetime. I think it was very important for me to be exposed to the workplace. I have gained invaluable international perspectives that will surely be of great advantage to me in the future.

37

BIBLIOGRAPHY
BOOKS 1. Aswathappa k, 2008, Human Resource & Personel management, Tata M.C. Graw
Hill publishing co.Ltd, New Delhi,

2. Kothari.C.R, 1997, Research Methodology,Viswa Prakasam New Delhi, 3. Maheswari.S.N, 2003,cost&management Accounting Sultan chand&sons, New
Delhi,

4. Pannerselvam, 2007,production and operation management, prentice hall of India

Pvt.Ltd, New Delhi,

5. Philip kotler, 2000, Marketing management, Prentice Hall of India Pvt.Ltd, New
Delhi, WEB SITES: 1. www.google.com 2. www.wikipedia.com

38