Report On Dpk Engineers Ltd., 1a76u

ORGANIZATION STUDY AT DPK ENGINEER PVT LTD A REPORT ON ORGANIZATION STUDY AT DPK ENGINEERS PVT LTD

Submitted in partial fulfillment of the requirement of AICTE approved PGDM program Submitted by: N.Sobhanadeeswara Rao Reg No: NSM 1450 Batch: 2014-2016

Internal Guide:

External Guide:

Mr.G.C.Nandeesh

Mrs.Prabhamani

Professor

HR Manager

NSM

DPK Engineers pvt ltd.

NITTE SCHOOL OF MANAGEMENT Govindapura, Yelahanka, Bangalore-560064 Nitte School of Management, BangalorePage 1

ORGANIZATION STUDY AT DPK ENGINEER PVT LTD DECLARATION I hereby declare that this Organizational Study at “DPK ENGINEER PVT LTD” submitted in partial fulfillment of the requirement for III-Trimester PGDM Degree examinations 2015 of NITTE school of Management, Autonomous Studies is my original work and not submitted to any other university. This work has been done under the supervision of Prof.G.C. Nandeesh in NITTE School of Management, Bangalore. .

Place: Bangalore.

N.Sobhanadeeswara Rao

Date: 01-09-2015

Reg no: NSM 1450 PGDM 2014-2016

Nitte School of Management, BangalorePage 2

ORGANIZATION STUDY AT DPK ENGINEER PVT LTD

GUIDE CERTIFICATE

This is to certify that the report of an organization Study at “DPK Engineers Pvt Ltd”. It is a bonafide work carried out by N.Sobhanadeeswara Rao (NSMI450), student of Post Graduate Diploma in Management of 3rd trimester, Nitte School of Management, under my guidance and direction. This project report is the record of authentic work carried out during the year 2015.

Prof.GC.Nandeesh. Faculty NITTE School of Management

Acknowledgement Nitte School of Management, BangalorePage 3

ORGANIZATION STUDY AT DPK ENGINEER PVT LTD I thank the almighty God for giving me the opportunity of doing this dissertation work successfully. I thank Dr. Manjunath.VS the director NSM and other faculty for and guidance .In particular I owe gratitude to Professor G.C.Nandeesh for being my internal guide and source of end from time to time. I am thankful to the Mr.S.SAMPATHRAMAN Chairman and Managing Director and Mr.MADAN SAMPATHRAMAN Operations Director of DPK Engineers pvt ltd for giving me an opportunity of visiting their premises towards completion of this project work. In this instance I acknowledge the whole hearted by Miss.Prabhamani HR Manager of DPK Engineers Pvt Ltd. I value the insight and understanding that I received is my association with him as my external guide. I am thankful to the management and employees of DPK Engineers Pvt Ltd Bangalore for providing us all the information throughout the internship period for the success completion of organization report.

TABLE OF CONTENTS Nitte School of Management, BangalorePage 4


CHAPTER NUMBER

NAME OF THE CHAPTER

PAGE NUMBERS

1

ECONOMIC SCENARIO

6

2

INDUSTRY PROFILE

13

3

COMPANY PROFILE

19

4

FUNCTIONAL DEPARTMENTS

26

7

SWOT ANALYSIS

46

8

LEARNING EXPERIENCE

47

9

OBSERVATION, CONCULSIONS & SUGGESTIONS

48

10

BIBLIOGRAPHY


50


CHAPTER – 1 PRESENT ECONOMIC SCENARIO



OVERVIEW: Economic Scenario Analysis is a process to ascertain and analyze possible events that can take place in the future. This is an important tool in the world of finance and economics, and is used extensively to make projections for the future. The process of estimating the expected value of a portfolio after a given period of time, assuming specific changes in the values of the portfolio's securities or key factors that would affect security values, such as changes in the interest rate.

GDP TRENDS: The Gross Domestic Product (GDP) in India was worth 2066.90 billion US dollars in 2014. The GDP value of India represents 3.33 percent of the world economy. GDP in India averaged 550.27 USD Billion from 1970 until 2014, reaching an all time high of 2066.90 USD Billion in 2014 and a record low of 63.50 USD Billion in 1970. GDP in India is reported by the World Bank Group. The gross domestic product (GDP) measures of national income and output for a given country's economy. The gross domestic product (GDP) is equal to the total expenditures for all final goods and services produced within the country in a stipulated period of time. This page provides the latest reported value for - India GDP - plus previous releases, historical high and low, short-term forecast and long-term prediction, economic calendar and news.



India’s GDP in A GRADE:

PER CAPITAL INCOME: The per capita net national income (NNI) of India at current prices during 2014-15 is estimated at 87,748 Indian rupees as compared to 80,388 INR for the year 2013-14, showing a rise of 9.2 percent. The per capita income in real (at 2011 -12 prices) during 2014-15 is estimated to have attained a level of Rs. 74,104 showing a rise of 5.9 per cent as compared to Rs. 69,959 during 2013-14. In earlier estimates released on 9th February 2015, per capita income of country at constant and current prices was 74,193 and 88,533 INR, respectively. According to International Monetary Fund World Economic Outlook (April-2015), GDP (nominal) per capita of India in 2014 at current prices is $1,627 compared to $1,508 in 2013. By 2015, Rank of India will be 141th and 124th with per capita income of about $1,808 and $6,266 in nominal and ppp method respectively.



MONETARY AND FISCAL POLICY: Monetary authority or monetary policy refers to the use of instruments under RBI control to regulate availability, cost and of money and credit and providing the citizens the appropriate available monetary facilities. Central bank does this to maintain pricing stability, low & stable inflation as well as promoting economic growth of country. When the government makes use of its revenue and expenditure programmes (to achieve the above mentioned goals) and affects the aggregate level of demand for goods and services in the economy, and then this action is essentially known as fiscal policy. Related to fiscal policy are deficits and surpluses. When the government's expenditure exceeds its revenue, then there is a fiscal deficit and the opposite of this is known is fiscal surplus. The present fiscal stimulus packages are being given away by the government because of the impact of the global financial meltdown on the Indian economy. The global crisis had a huge impact on our exports, financial markets, production (due to a slowdown in demand) and also on job market to a certain extent. The present fiscal policy actions aim at stimulating domestic demand and have focus on sectors that provide huge employment. Roughly 70% of our demand is domestic hence the government believes such policy actions should pull out India out of the slowdown. Nitte School of Management, BangalorePage 9


INTEREST RATE ON INDUSTRY: The benchmark interest rate in India was last recorded at 7.25 percent. Interest Rate in India averaged 6.71 percent from 2000 until 2015, reaching an all time high of 14.50 percent in August of 2000 and a record low of 4.25 percent in April of 2009. Interest Rate in India is reported by the Reserve Bank of India. In India, interest rate decisions are taken by the Reserve Bank of India's Central Board of Directors. The official interest rate is the benchmark repurchase rate. In 2014, the primary objective of the RBI monetary policy became price stability, giving less importance to government's borrowing, the stability of the rupee exchange rate and the need to protect exports. In February 2015, the government and the central bank agreed to set a consumer inflation target of 4 percent, with a band of plus or minus 2 percentage points, from the financial year ending in March 2017. This page provides - India Interest Rate - actual values, historical data, forecast, chart, statistics, economic calendar and news.

FUNCTIONS OF CAPITAL MARKET: The capital market plays an important role immobilizing saving and channel is in them into productive investments for the development of commerce and industry. As such, the capital market helps in capital formation and economic growth of the country.



The capital market acts as an important link between savers and investors. The savers are lenders of funds while investors are borrowers of funds. The savers who do not spend all their income are called. “Surplus units” and the borrowers are known as “deficit units. It diverts resources from wasteful and unproductive channels such as gold, jeweler, real estate, conspicuous consumption, etc. to productive investments. A well-developed capital market comprising expert banking and non-banking intermediaries brings stability in the value of stocks and securities. It does so by providing capital to the needy at reasonable interest rates and helps in minimizing speculative activities. Such a market can go a long way in providing a link between savers and investors, thereby leading to capital formation and economic growth.

EXCHANGE RATE FUNCTION: With increasing integration of the Indian economy with the global economy arising from greater trade and capital flows, the foreign exchange market has evolved as a key segment of the Indian financial market and RBI has an important role to play in regulating & managing this segment. RBI manages forex and gold reserves of the nation. On a given day, the foreign exchange rate reflects the demand for and supply of foreign exchange arising from trade and capital transactions. The RBI’s Financial Markets Department (FMD) participates in the foreign exchange market by undertaking sales / purchases of foreign currency to ease volatility in periods of excess demand for/supply of foreign currency.

PRIORITY ASSIGNED BY THE GOVERNMENT: (i) Categories of the priority sector: Medium Enterprises, Social Infrastructure and Renewable Energy will form part of priority sector, in addition to the existing categories. (ii) Agriculture: The distinction between direct and indirect agriculture is dispensed with. (iii) Small and Marginal Farmers: A target of 8 percent of ANBC or Credit Equivalent Amount of Off-Balance Sheet Exposure, whichever is higher, has been prescribed for Small Nitte School of Management, BangalorePage 11

ORGANIZATION STUDY AT DPK ENGINEER PVT LTD and Marginal Farmers within agriculture, to be achieved in a phased manner i.e., 7 percent by March 2016 and 8 percent by March 2017. (iv) Micro Enterprises: A target of 7.5 percent of ANBC or Credit Equivalent Amount of OffBalance Sheet Exposure, whichever is higher, has been prescribed for Micro Enterprises, to be achieved in a phased manner i.e. 7 percent by March 2016 and 7.5 percent by March 2017. (v) There is no change in the target of 10 percent of ANBC or Credit Equivalent Amount of Off-Balance Sheet Exposure, whichever is higher, for Weaker Sections. (vi) Target for Foreign Banks: Foreign Banks with 20 branches and above already have priority sector targets and sub-targets for Agriculture and Weaker Sections, which are to be achieved by March 31, 2018 as per the action plans submitted by them and approved by RBI. The sub-targets for Small and Marginal Farmers and Micro Enterprises would be made applicable post 2018 after a review in 2017. Foreign banks with less than 20 branches will move to Total Priority Sector Target of 40 percent of ANBC or Credit Equivalent Amount of Off-Balance Sheet Exposure, whichever is higher, on par with other banks by 2019-20, and the sub-targets for these banks, if to be made applicable post 2020, would be decided in due course. (vii) Bank loans to food and agro processing units will form part of Agriculture. (viii) Export credit: Export credit up to 32 percent of ANBC or Credit Equivalent Amount of Off-Balance Sheet Exposure, whichever is higher, will be eligible as part of priority sector for foreign banks with less than 20 branches. For other banks, the incremental export credit over corresponding date of the preceding year will be reckoned up to 2 percent of ANBC or Credit Equivalent Amount of Off-Balance Sheet Exposure, whichever is higher. (ix) The loan limits for housing loans and MFI loans qualifying under priority sector have been revised. (x) The priority sector non-achievement will be assessed on quarterly average basis at the end of the respective year from 2016-17 onwards, instead of annual basis as at present.


ORGANIZATION STUDY AT DPK ENGINEER PVT LTD The revised guidelines are operational with effect from the date of this circular. The priority sector loans sanctioned under the guidelines issued prior to this date will continue to be classified under priority sector till repayment/maturity/renewal.

CHAPTER-2 INDUSTRY PROFILE



HISTORY OF ELECTRICAL INDUSTRY: Electricity is one of the most necessary items of living. Today we cannot imagine anything without electricity. It is required to perform day-today activities. Electricity is useful in lighting, fan, computers, train etc. It is important and so important are the conductors. The Conductors are those which allow current to through them. These are the points which regulate the flow of electricity. These are also called electrical equipments and accessories or electrical products.

ORIGIN OF ELECTRICAL INDUSTRY: The starting point of electrical industries is the great invention of electrical bulb in 1876 by Thomas Alva Edison. This invention made the world to know the power of electricity, and these helped for the invention of many other electrical items like fans, lightings, wires and cables, meters and so on. Electrical industry is one of the most developed industry and many new inventions are yet in the induction stage. General Electrical (GE) is the largest manufacturer of electrical items and Anchor is the largest manufacturer of switches in the world.

1.2.1 ELECTRICAL INDUSTRY IN INDIA: First electric industry in India was KIRLOSKAR ELECTRIC COMPANY PVT.LTD. Electricity is one of the most necessary items of living. Today we cannot imagine anything without electricity. It is required to perform day-today activities. Electricity is useful in lighting, fan, computers, train etc. It is important and so important are the conductors. The Conductors are those which allow current to through them. These are the points which regulate the flow of electricity. These are also called electrical equipments and accessories or electrical products. Electrical industry has the history of more than 50 years in India. In 1950’s the distribution of electricity was confined to a limited area. Only big cities have the power plants and the level of electrical markets. In 1956 seeing big opportunities in this market, Finolex group started the wire coil production and gained market by introducing multi stand cables for house wiring. At the Nitte School of Management, BangalorePage 14

ORGANIZATION STUDY AT DPK ENGINEER PVT LTD beginning only single copper wire was used for transmission of current which was changed in modern stage to leaded copper wire. Now there are different varieties of wire coils and other materials available relating to electricity and more than 300 firms and companies producing wire coils with different names. When electricity was first introduced in India, the black coloured tumbler switch with porcelain base dominated the Indian premises. This was during 1950’s and 1960’s when electricity was reaching different parts of the country. There existed a high degree of dissatisfaction about these switches, as they were hard to operate and lacked in aesthetics. These tumbler switches were installed on wooden surface mounting box and wiring was done with the help of batten strips (Patti).It also offers you the flexibility of adding or removing functions to adapt to your changing needs. For example, you could easily replace a 6A with a 16A switch or replace one two modular socket with two single modular switches. The latest trend in modular switches is that of a smooth scoreless appearance. Some companies are even offering a complete range of wiring solutions that include switches; trucking and VDI (Voice Data Image) structured cabling system. Gradually the Indian switch market is upgrading to modular switches. In additions to switches and wire coils, there are a number of items which helps in the smooth running and efficient usage of electricity and power. The big names in Indian market if electrical products manufacturer are:Finolex - Specialist in wire and cables. Havell’s - energy meters. MDS - Miniature circuit breakers Philips - Manufacturer of lighting and luminary items. Anchor - manufacturer in switches and accessories. These are serving Indian Electrical Industry for more than four decades and their markets are enlarged to foreign countries also.



GROWTH OF INDUSTRY IN INDIA: Indian electrical industry has ed about 30% growth in the year 2011 from Jan – mar. It has ed a growth of 15 percent in 2010-2011 (5.73 percent in 2009-2010). As compared to the same period for the year 2005-06. The well conceived APDRP programme and ing of Electricity Act 2003 have provided a ray of hope to the industry. Almost all sectors of electrical industry are indicating growth. Product like meter shows technology shift, as there is more demand for static meter than conventional electromagnetic meter. The general buoyancy in the Indian Economy would then create a demand for electrical products through growth of general industrial and economic development. From the experiences of the past few years, it can be confidently said that the Indian industry has faced the critical challenges well and survived in the most difficult times. In current favorable market scenario today, the electrical industry can certainly look forward for growth.

PRESENT POSITION OF ELECTRICAL INDUSTRY: The domestic market in India is itself large, and one must firstly satisfy this market with products that meet international quality standards. With increasing globalization, every international player is now operating in India, providing goods and services complying with international quality. Once we deliver high quality products and services within the domestic market, accessing the international market for exports should not pose a serious challenge. The Electrical/Electronics Industry in India is growing to its full potential in the coming years and no doubt that India will soon come to be recognized for quality products and services which in turn, will bring this industry to a position of true leadership. Indian electrical industry has grown because of government's thrust on it and also due to overall economic growth. It has also reached a stage where the industry has demonstrated its capabilities. The industry has seen a growth of 20% and should continue at the same level for the next few years. Nitte School of Management, BangalorePage 16


PROBLEMS FACED BY THE ELECTRICAL INDUSTRIES :  Increase in price due to entry of new players in market.  Increase in manufacturing capacity by some original manufactures.  Profitability and margin of the companies are adversely affected.  Poor distribution network in rural and semi urban areas.  Low awareness of consumer electronics products in rural India.  Increases in access to internet information.  Availability of wide range of choices.  Consumers have become quite smart.  They want the products which are easy to handle.  Good in quality and low price.  They want guarantee for the product they buy.  They want the product which can be used for long years.  They do not end on the sale of the product but continues till the end of guarantee period.

GOVERNMENT POLICY TOWARDS ELECTRICAL INDUSTRY: The sentiment of the industry is generally measured in of research intensity, export & import capacity, expertise development, infrastructure enhancement, and etc. The entire structure of the industry is determined by the government policies & provisions which should be conducive& optimal Indian government has envisioned augmentation in the capacity of power generation would be 86,500 MW in 12th plan period. A blueprint for investment is drafted for the distribution & transmission segments with an eye to domestic electricity plan and the Integrated Energy Policy. Enforcement of Electricity Act 2003, National Electricity Policy-2005 and proposal of schemes like the APDRP(Accelerated Power Development and Reform Program) & RGGVY (Rajiv Gandhi GrameenVidyutikaranYojana) are meant for reducing loss that takes place in


ORGANIZATION STUDY AT DPK ENGINEER PVT LTD transmission and distribution annually owing to traditional & degraded lines, overloading of the 11 KV systems, Distribution transformers and low tension lines and understanding the intricacy of the various factors and its impact on the demand for electrical equipment. IEEMA (Indian Electrical and Electronics Manufacturers Association) opted Private company (PWC) Price water house Coopers for evaluating the power sector development program and its impact on electrical device & equipment industry. Government of India offers central for strengthening and elevation of transmission and distribution network. 25% of the project cost is provided as Additional central plan assistance in form of Grant to the state utilities. Indian Government keeps on pursuing the policy of self-reliance, laying emphasis on building up indigenous ability, is also dedicated to development and utilization of indigenous capabilities. It follows the strong policy including encouragement of entrepreneurship, expansion of domestic technology by virtue of significant investment in R&D, taking in new technology, and scraping the regulatory system. Government is also liberal to foreign investment and technology collaboration in order to acquire higher technology, maximize exports, and expand the production base.

FUTURE PROSPECT OF ELECTRICAL INDUSTRY: The domestic market in India is itself large, and one must firstly satisfy this market with products that meet international quality standards. With increasing globalization, every international player is now operating in India, providing goods and services complying with international quality. Once we deliver high quality products and services within the domestic market, accessing the international market for exports should not pose a serious challenge. The Electrical/Electronics Industry in India is growing to its full potential in the coming years and no doubt that India will soon come to be recognized for quality products and services which in turn, will bring this industry to a position of true leadership. Indian electrical industry has grown because of Government’s thrust on it and also due to overall economic growth. It has also reached a stage where the industry has demonstrated its capabilities. The industry has seen a growth of 20% and should continue at the same level for the next few years.



CHAPTER-3 COMPANY PROFILE



COMPANY PROFILE DPK – Engineered Solution for Reliable Power DPK is a leading name in captive and standby diesel generator sets and pump sets since 1984. DPK DG sets have proved indispensable to their various s in every possible application: small and large industries, hospitals, construction projects, government institutions, IT companies and agriculture and a few.

Today DPK provides over 1500MW of power to more than 20,000 satisfied customers – our contribution to the growth of the Indian economy. Backed by the Best DG sets are built at our state-of-the-art, ISO9001:2008 certified, 50,000 sq ft factory; spread over two acres, with renowned Kirloskar engines and Alternators. Base frames, Fuel tanks, Acoustic Enclosures and other fabricated inputs, manufactured by DPK strictly in accordance with the Kirloskar design & specifications to ensure reliable service – year after year.

Wide Spectrum of Control Gears Choice of specially designed control s, AMF (Automatic on Main Failure) s, synchronizing s are available. These s incorporate reliable, accurate instrumentation and protection features to meet the expectations of discerning clients. The DPK Advantage Marketing and manufacturing expertise for over 25 years. Significant player in Diesel Generating sets, Pump sets and other specialized equipment. DPK is the preferred choice of customer enjoying their total loyalty. Providing end to end customized solutions. Recommending the right equipment, supplying, installing, commissioning and Nitte School of Management, BangalorePage 20

ORGANIZATION STUDY AT DPK ENGINEER PVT LTD providing the necessary after sales service. High importance laid on process based and cost effective management to ensure the best quality at the least cost to customer. All with strict adherence to a value system that ensures total satisfaction to all stake holders.

Vision, Mission and Values Vision: Our vision is to become a significant player in specialized industrial equipment and be the preferred choice of the customer.

Mission Grow at a rate of 25% - 30% per annum in top line and bottom line in the next 10 years by vertical and horizontal expansion in the areas of core competence through Process based management Cost effective process Lean and flat competent team and to satisfy all the stakeholders.

Values Customer satisfaction, value for money and care for all the stake holders’ are our core values.


ORGANIZATION STUDY AT DPK ENGINEER PVT LTD Board of Director Name

Age

Qualification

Position

S. Sampathraman

68

M.A (Economics)

B.K. Mohan Rao

55

A.M.I.E

MadanSampathraman

32

B.E (Mech.), M.S (I.E) Operations

Chairman

Years

and

Managing Director

Marketing

27

23 5

Manufacturing facility One shift 9 am to 5:30 pm.Ten DG sets per shift can be increased 12 DG sets per shift with addition of more skilled labors.In-housefabrication shop with CNC turret punch, CNC press brakes, CNC plasma cutting, welding machines, drilling machines, pretreatment, powder coating and painting facility.

Quality Excellence



Products Customized product range: Ready to use Gensets, available in wide range from 5 to 625 kVA.Gensets powered with Air Cooled & Liquid Cooled Engines.DG Sets available in Multiple Sets in synchronization for running parallel operations. Custom built tailored to meet your exact power needs.

Smart Aesthetics: State-of-the-art design. Compact in size, smaller footprint saving money on space. Aesthetically superior, fully integrated weather proof acoustic enclosure. Light weight design.

Environment Friendly: The power to save environment and the earth.Gensets conform to low noise emission norms as Nitte School of Management, BangalorePage 23

ORGANIZATION STUDY AT DPK ENGINEER PVT LTD per CB.Certified by ARAI, Pune, nodal agency of CB, through annual Certification of Production (COP), for very low noise level. Engine complies with latest stringent international emission norms.

Highest Reliability: Utmost reliability ensuring continuous power for smooth operation. Wet liner design ensures high Reliability. Electronic Governor for Isochronous governing & paralleling operations is in standard scope from 140 to 625 kVA.Extremely rugged, durable design. Low lifecycle cost. Safety for low lube oil, high cylinder head, high water temperature, low fuel level etc.State-ofthe-art technology for operations in low / high ambient temperature, high humidity and high altitude.

Unmatched Performance: Low fuel & lube oil consumption ensuring excellent economy. Low noise & vibration levels. High fuel efficiency at part operating load. Lowest power to weight ratio in its class. No oil top up required between two services.K-cool super plus for longer life.

Maintenance friendly design, ease of operation: Ready to use design. Easy serviceability for routine maintenance, replacement, overhauls. Modular design, ensuring lower maintenance cost. Ensures long maintenance intervals Easy availability of spare parts. Minimum cost for maintenance, spares &services.SmartGenset Monitor Control (GMC) for closely monitoring the engine, genet& safety system. Annual Maintenance contract through service dealers.

Gensets Air cooled We are recognized as one of the world’s leading generating set manufacturers. “ Kirloskar Green Genset “ is a major player globally, specialized in manufacturing of both air cooled & water cooled Engines / Diesel Gensets with power output covering from 5 kVA to 625kVA & 1800kVA to 6300 kVA. We have been instrumental in developing the latest technology driven products to suffice power requirements of every individual customer from different market segments. We provide reliable & high quality products at competitive cost. We also provide variety of alternative fuel gensets, which efficiently run on Bio Diesel, Bio Gas, SVO ( Straight Vegetable Oil ) and Natural Gas as per customer



Air cooled • 5 – 10 kVA • 15 – 70 kVA

Gensets Water cooled We are recognized as one of the world’s leading generating set manufacturers. “ Kirloskar Green Genset “ is a major player globally, specialized in manufacturing of both air cooled & water cooled Engines / Diesel Gensets with power output covering from 5 kVA to 625kVA & 1800kVA to 6300 kVA. We have been instrumental in developing the latest technology driven products to suffice power requirements of every individual customer from different market segments. We provide reliable & high quality products at competitive cost. We also provide variety of alternative fuel gensets, which efficiently run on Bio Diesel, Bio Gas, SVO ( Straight Vegetable Oil ) and Natural Gas as per customer

Water cooled • 20-82.5 kVA • 100 - 160 kVA • 180 – 250 kVA • 320 – 625 kVA

Clients        

All private sector manufacturing industries, Information Technology Technology companies. Agriculturists and individuals. Hospitals, educational institutions and all service facilities. All large construction companies and builders Bharat Sanchar Nigam Limited. Private telecom companies like Airtel, Hutch, Spice and Idea Cellular Government and public sector undertakings





Chapter 4 Functional Analysis

Functional Departments:  Human Resource Department  Production department  Marketing Department  Materials Department  Stores Department  Service Department  Finance Department Nitte School of Management, BangalorePage 27


Human resource development: In HRD there are two Employees working in DPK Engineer Private Limited. 1.Mrs. Prabhamani (HR Head) 2. Mr. Lakashmaiah (HR executive) The selection, Recruitmentand Training is based on Both Internal and Outsourcing References. The CVs are filtered by the HR Head based on the technology and Experience related to Job. The labours are recruited based on the manpower. The selected candidate will be having face to face interview, Telephonic interview. Training is given to candidate for 4 months, and for technical candidate nearly 1 year training is given and it differ according to Nitte School of Management, BangalorePage 28

ORGANIZATION STUDY AT DPK ENGINEER PVT LTD different departments.HRD head will look after the pay scales of the employees. s and profiles of the each Employee are handled by the HR Executive. Bonus is given to employees for daussera.Education facility like MBA is provides for 3 trainers in NITTE College. Mode of promotion of employees is based on Performance and achievements. The company has an effective human resource department where in the employees are given good remuneration, incentives and extensive care is taken by providing facilities such as canteen, medical facilities, and extracurricular activities.



PRODUCTION DEPARTMENT



Production Department: DPK will not manufacture Gensets Engine. They will get engines and alternator from the Kirloskar oil and engine limited Pune.Dpk will produce up to gensets of 5kVA625kVA.There are two production departments Plant-1 inHarohalli and Plant-2 in Bomsandra consists of two general manager MR B.S Devi Vasur in Harohalli and MR Srimanth in Bomsandra.They are the authorized gensets of engines manufacturer to Kirloskar oil and engines limited. These two plants work in a line balancing process where the acoustic enclosure is carried out in Harohalli and assembly of gensets is carried out in Bomsandra plantengine.Inharohalli high technology equipment like Trumpt-3000 sheet master and Trapunch machine a German company machine for Punching and two Bending machines one with 135/30 and other with 35/15,.Raw materials is procured from Triveni steels Jayanagar. DPK will get 5540 kgs with 4416 iron CR CA sheets with the thickness of 5mm, fabrication shop with CNC turret punch, CNC press brakes, CNC plasma cutting, welding machines, drilling machines pretreatment, powder coating and painting facility are present in plant1.To clean ivory sheets and to remove rust DPK use pretreatment method consists of different Hot water Generator Baths at a temperature of 90-95 deg c. It consumes diesel. Different Baths should be in order of PowderIvory,Powderblue,Degreasing-1,Sagreation101,Degreasing-2,SagreationHD,ActivationDSM-SP,Phosphatingstarter,Phosphating ZLPCold-55,Derusting AP-SP,Phosphating-Oxy-Salt and finally ivationAA50.After manufacture of the Acoustic process they are assembled in Bomsandra Plant. In the plant-2 Base frame, Fueltank, AchousticEnclosure, Control is manufacture by the DPK.Engine, Alternator, Radiator, Silencer is Manufacture by the Kirloskar oil and Engine limited. Time required of single genset manufacturing is 55 min.six sigma process is not applied in production department because of no corporate head in Quality. It certifies by ARAI regarding pollution control.DPK undertakesmarketing, transportation.electrical, fuel, exhausting system and approved by electricians, sound of the genset less than 75db is neglected. Smoke of the genset is exhausted above 3meters.

Pre-treatment method: This method is used that components are free from rust, dent, dirt.In case of any burr ensure that it is removed. NOTE: All the transportation of the loaded parts will be in the Auto Mode.


ORGANIZATION STUDY AT DPK ENGINEER PVT LTD Operating procedure:  Switch on the mains of the Transporter and turn on the Auto mode.  Switch on the mains of the Hot Water Generator.  the readiness of Pretreatment plant.pointang/concentration of chemicals used for degreasing,activation,phospating and ivation shall be as per supplier recommendation  Load the Fabricated parts on the flight bars which are mounting on pretreatment loading trolleys.  Ensure that all the flight bars seating is in proper position for transportation of loaded     

profile on the flightbar Dip the loaded parts in Degreasing-1 bath Remove the loaded parts from Degreasing-1 bath and dip in Degreasing-2 bath Remove the loaded parts from Degreasing-2 bath and dip in water rinse-1 bath Remove the loaded parts from water rinse-1 bath and dip in waterbRinse-2 bath Remove the loaded parts from water rinse-2 bath and dip in Derusting bath (if

necessary)  Remove the loaded partsfromDerusting bath and dip in water rinse-3 bath (if        

necessary) Remove the loaded parts from water Rinse-3 bath and dip in water rinse-4 bath Remove the loaded parts from water rinse-4 bath and dip in Activation bath Remove the loaded parts from Activation bath and dip in Phosphating bath Remove the loaded parts from Phosphating bath and dip in water rinse-5 bath Remove the loaded parts from water rinse-5 bath and dip in water rinse-6 bath Remove the loaded parts from water rinse-6 bath and dip in ivation bath Remove the loaded parts from ivation bath and dip in Dry-off oven bath Move the pretreated parts to the powder coating section.

Safety Instructions: 1. Wear all personal protecting Equipments (Gloves, masks, goggles&helmet) before starting the work. 2. Check lifting equipments for any defects.

Punching: Operating procedure:    

Clean the table/bed,sheetmaster and machine before starting the machine. Check the tool Lub oil level, grease and air pressure before starting the machine. Check the c2 axis and X-Y axis bearings before starting the machine Check and clean the punch adapter and stripper adapter before starting the machine


ORGANIZATION STUDY AT DPK ENGINEER PVT LTD  the tools position with respect to die when tools are changed  Check the pneumatic and hydraulic Hoses for any leakages.  Select and send the punching program from program system to machine system for required model as per Production order sheet master will load  Inspect and clean the vacuum blower and Air dryer before starting the machine  Select the required thickness of the sheet and load on the machine pallet  Butt the sheet perpendicularly so that the sheet master will load the sheet accordingly. Ensure proper clamping of sheet  Start the machine for punching by switch on the “Cycle start” button  After the completion of punching the sheet master removes the parts and keep on the unloading pallet.  Compare the punched layout configuration with punching layout drawing and record in job card  Continue the punching operation  Remove micro ts completely if found and keep all the individual parts production order/model/wise Safety Instructions: Use Personal protective Equipments (Gloves, Ear plugs) before starting the work.


ORGANIZATION STUDY AT DPK ENGINEER PVT LTD 4R1040TA - 82.5 KVA R Series water -cooled Genset Cooling

Water-cooled engine

Model

4R1040TA

Power kW (hp)

77.2 (105)

Prime Power Genset rating at 0.8 pf (kVA)

82.5

Overall canopy dimensions L x W x H (mm)

3240 x 1140 x 1585

Approx. weight (with canopy) kg

1950

FEATURES  Specially designed for heavy-duty, continuous applications.  Available in wide range from 20 kVA to 82.5 kVA.  Electronic governer as option available in above 30 kVA for running gensets in synchronisation for parallel operations.  12 V electric start system.  Least maintenance and lowest operating costs  Lube oil change period of 500 hours.  Aesthetically superior compact design and smaller foot print, fully integrated weather proof acoustic enclosure.  Conforms to low noise emission norms as per CB and also compliant with the latest international emission norms.  Smart Genset Monitor Control (GMC) for closely monitoring the engine, genset and safety system.



6R1080TA - 125 KVA R1080 Series water - cooled Genset Cooling

Water-cooled engine

Model

6R1080TA

Power kW (hp)

113.2 (154)


100


3490 x 1340 x 1885


2700

FEATURES  Specially designed for heavy-duty, continuous applications.  Electronic governer as option available for running gensets in synchronisation for parallel operations.  12 V electric start system.  Least maintenance and lowest operating costs  Lube oil change period of 500 hours.  Aesthetically superior compact design and smaller foot print, fully integrated weather proof acoustic enclosure.  Conforms to low noise emission norms as per CB and also compliant with the latest international emission norms.  Smart Genset Monitor Control (GMC) for closely monitoring the engine, genset and safety system.



6SL8800TA - 250 KVA

SL Series water - cooled Genset Cooling

Water-cooled engine

Model

6SL8800TA

Power kW (hp)

228.2 (310)


250


4940 x 1700 x 2050


4660

FEATURES  Extensively used for heavy-duty applications  Electronic governer as a option available in 180 &200 kVA and as a standard scope in 250 kVA.  DG sets available in multiple sets in synchronisation for running parallel operations.  Heat exchanger type cooling for basement installations also available  Least maintenance and lowest operating cost  Lube oil change period of 500 hours  Aesthetically superior compact design and smaller foot print, fully integrated weather proof acoustic enclosure  Conforms to low noise emission norms as per CB and also compliant with the latest international emission norms.  Smart Genset Monitor Control (GMC) for closely monitoring the engine, genset and safety system.



DV12 SR I - 625 KVA

DV Series water - cooled Genset Cooling

Water-cooled engine

Model

DV12 SR I

Power kW (hp)

552 (750)


625


6670 x 2000 x 2750


7500

FEATURES 4 valve HPCI technology for lowest fuel consumption in its class. Emission compliance to stringent norms of EU COM stage II. V type engine design for lower footprint. Electronic governer as a standard scope of supply. Highest block loading capacity in its class. Centrifugal filter as additional filter in lube oil system. Least maintenance and lowest operating cost. Lube oil change period of 500 hours. Aesthetically superior compact design and smaller footprint, fully intergrated weather-proof acoustic enclosure.  Conforms to low noise emission norms as per CB.  Smart Genset Monitor Control (GMC) for closely monitoring the engine, genset and safety system.  Nine free service visits during the warranty period.         



HA694T - 70 KVA

HA Series air -cooled Genset

Cooling Model

Air-cooled engine HA694T

Power kW (hp)

61 (83)


70


3980 x 1240 x 1680


1920

FEATURES  World's number one manufacturer of air-cooled engines / generating sets.  Only Indian manufacturer to offer widest range of air-cooled generating sets up to 70 KVA.  Kirloskar HA series is the most preferred engine series in telecom, defense, railways and other government departments.  Least maintenance and lowest operating cost.  Lube oil change interval of 500 hours.  Aesthetically superior compact design and smaller foot print, fully integrated weather proof acoustic enclosure  .Conforms to low noise emission norms as per CB and also compliant with the latest international emission norms.  Smart Genset Monitor Control (GMC) for closely monitoring the engine, genset and safety system. Nitte School of Management, BangalorePage 38


Advantages of Diesel and Air-Cooled Generators Diesel air-cooled used generators have been used for many years and have a long track record of being reliable, easily adaptable and relatively inexpensive. The output these workhorses produce in relation to maintenance and initial costs makes used diesel generators one of the most popular choices for power generation across the world. In addition to low costs, the simple design insures the used generators can operate in a variety of environmental conditions including; extreme heat, cold and dust, all while using a cooling process that is always in ample supply.

Diesel-powered used generators can be adapted to fit almost any type of application. Most commonly air-cooled diesel generators are used in the following industries:

• Agriculture • Military (Air-cooled diesel generator units are most preferred due to their resistance to varying environmental conditions) • Construction • Main Power Source • Backup Power Source (Most backup power sources are used generators) • Oil Production • Mining and Forestry • Medical Field (Uses new diesel generators vs. used diesel generators) • Rental Property (Used generators are the best rental property option for its costs vs. benefits) • Stand Alone Prefabricated Buildings (Low long-term up keep makes used diesel generators the most popular choice for prefabricated remote buildings) • Maritime Operations / Ships (Air-cooled diesel engine units are the most common engines on ships across the world)


ORGANIZATION STUDY AT DPK ENGINEER PVT LTD • Telecommunications • Refrigeration (Air-cooled diesel generator systems are preferred for their open design) • Pumping Stations / Irrigation Operations (Used generators or air-cooled engine components are optimal for seldom used septic or waste water systems)

diesel

Advantages 1. Efficient Design: All used generators require a cooling component. An air-cooled diesel generator or engine does not require a water pump, radiator, temperature gauge or hoses. There is no coolant to freeze, leak, evaporate, boil, become contaminated or cause corrosion within the cooling system. Because the cooling system is uncomplicated it requires less short-term maintenance, is less prone to cause system wide failure and reduces overall downtime.. 2. Use of Diesel Fuel: By using diesel as the fuel source used generators use less fuel overall than natural gas units. The used diesel generators fuel is safer to handle than other fuel sources and traditionally more readily available on site. (Construction, military, agriculture etc…)

3. Flexible Design: Due to the reliability and simplistic design, air-cooled diesel generators can be used to accommodate a variety of applications. For the most part critical long-run operations such as maritime and navigational lighthouses or telecommunications equipment use air-cooled diesel generators. Response teams working in disaster areas typically use lightweight portable air-cooled diesel generators. Fire, flood, avalanche or earthquake areas are often times full of debris and dirt which can clog other used generators much easier than air-cooled diesel generator systems. Failure rates among aircooled diesel generators are much less common due to their stand-alone capacity. Military operations use air-cooled diesel generators due to their track record of being reliable under battle conditions.

4. Operational Efficiency: The main advantage for diesel generators have other types of engines is that they run at higher operating temperatures and rapidly warm-up. This significantly reduces cylinder bore, and piston/piston ring wear. By running used diesel generator at high temperature sludging of the lubricating oil is reduced especially in shortterm scenarious.The quick warm-up period also allows the air-cooled diesel engine to accept its full load capacity much faster than liquid-cooled engines

5. Ease of Installation: Air-cooled diesel generators, like liquid-cooled engines, are Nitte School of Management, BangalorePage 40

ORGANIZATION STUDY AT DPK ENGINEER PVT LTD fairly easy to install however air-cooled diesel generators are less prone to vibration failures. Both liquid-cooled and air-cooled diesel engine systems require cool, clean air for combustion and secondary cooling, ventilation, exhaust piping, mounting racks and guards applied over hot and rotating parts.



MARKETING DEPARTMENT



Marketing Department: The main objective of the marketing department is sales and be the preferred choice of the customer because DPK has a wide range of market in states of Karnataka and Telangana..DPK itself sells more generator sets than all the dealers from both the states. And their second objective is service. It was said that DPK hadn't faced any complaint from any of their customers in the last survey which is because of their well finished commissioning. The sales department of DPK covers mostly in Bangalore city itself. They have ten marketing executives who will cover the entire territory of and Karnataka and 15 in Telangana.The mostly target locations like Construction projects, hospitals, schools, multi complexes etc. the mode of collection is direct. The customer should pay half of the amount in advance and the next half during the time of commissioning of the generator set. They don't provide any installment facility or any loan but they will help the customer for a loan procedure which will be financed by Kirloskar itself. Coming to the promotional activities, the main source they use in promotional activity is using KIRLSKOR's brand name. They don't use any media sources like T.V's, radio etc. Coming to the distribution of the product, they produce the product only when they receive an order from the customer according to load capacities. The mode of transportation will be done based on the size of the generator set. The transportation should be arranged by the customer itself. Commissioning is done only when there is sufficient place and should have good surface so that it can tolerate vibrations of the Genset for operating and servicing and it should not create pollution to that place so exhausters are used. The company undergoes in three steps in finding its clients: •

Inbound cells: They get calls directly to the company through company websites or through just dial and by Emails.


ORGANIZATION STUDY AT DPK ENGINEER PVT LTD •

Existing customer’s reference: Existing customers recommend to other customers about the product since they have a good experience on the product usage.

•

Cold cell: This is a direct approach to the clients, where the marketing executives will directly go to the Customers like construction locations or hospitals or schools etc and take quotations according to the customer requirements.

SERVICE DEPARTMENT



Service Department: This refers to Service Bulletin and Technical Bulletin circulated on K Cool Super Plus. They have modified K COOL Super Plus coolant from premix percentage 25:75 to 50:50(Glycol: De-mineralized water) in January 2009.. The Increased percentage of Glycol in coolant is able to take care of 1. Elimination of radiator core electrolysis, 2. Reduction in formation of scale, sludge and rust in the system If plan water is used to top up the cooling system, it will lead to early failure of Aluminum Radiator due to 1. Electrolysis process 2. Formation of sludge, scale and rust 3. Evaporation /condensation from compensatory tank. To arrest these issues on field, following dos and don’ts to be followed by AGOEM, KDGSD and Service Dealer on Genset. AGOEM/KDGSD: 1. Ensure the cooling system is leak free by a. Tightening Radiator drain plug firmly b.Hose are securely inserted in connection C.Tightening all the hose clamps firmly 2.Put K cool super plus 50:50 coolant in cooling system up to the neck of the radiator 3. Remove air vent screw system while filling the cooling system to allow removal of air from the system


ORGANIZATION STUDY AT DPK ENGINEER PVT LTD 4. Wait for half an hour to allow coolant to completely fill up in intricacies of the cooling system and then again fill the coolant up to the filling neck of the radiator 5. Thighten all the vent screws 6. After coolant is filled completely run the Genset an idle speed with radiator filling cap open for 5 mins, this will remove all the air gaps from the cooling system 7. Fit the radiator gap observing the sealing of the cap is proper and there is no leakages from radiator neck 8. Fill in the coolant in compensatory tank up to high level marked as indicated 9. Ensure there is no coolant leakage while transporting and handling the Genset on site 10. AGOEM to ensure supply of 1 liter K cool super plus 50:50 coolant to customer with genset 11. While commissioning check for coolant level, in case of low level in the radiator AGOEM representative to ensure the top up of the system with k cool super plus 50:50 coolants only 12. Do Not top up the coolant with plain water, this will drop glycol concentration in cooling system leading to premature radiator failures and engine overheating. 13. Ensure there are no coolant leakages while giving theGenset trail run.



Problem: Air Lock Problem in DG Sets

Cause and Effect Diagram Improper Tightening of fuel lines

Wrong size inlet and outlet pipes

Feed Pump Failure

Air Lock in DG Sets

Dust/Foreign materials in tank

No fuel in tank

Less fuel in tank

Root Cause: 1) Wrong size inlet and outlet pipes used 2) observed less or no fuel in fuel tank Corrective/Preventive Action: Nitte School of Management, BangalorePage 47

ORGANIZATION STUDY AT DPK ENGINEER PVT LTD 1) Correct size of fuel inlet and outlet pipes used. 2) More instructions given to customer to maintain minimum quantity of fuel in tank 3. Regular precleaning of fuel tank before assembly 4. Fuel tank filled with fuel and tested.

SWOT Analysis: Strengths:  Branded KOEL Engines and Alternator.  DPK is the AGOEM to KOEL Pune.  Had vast experience in market

Weakness:  Completely depend on KOEL Pune,DPK should be answerable to KOEL.  High Transportation cost due to location of plants at different places.

since 1984.  Idea of placing both the plants

together.

Opportunities:  HITech equipment is avalilable to manufacture Gensets in a specific time.  Have service dealers in Telangana and Karnataka.

Threats:  KOEL have power can cancel license in case of any issues occurred.  Different Gensetscompetetors like Ashokleyland,Jakson,Supernova etc.  Competetive AGOEM in Andrapradesh

 KOEL services are tieup with local company shops,along with DPK.  Market development.



Learning experience:  The learning experience gained by us during the in-plant training was very much practical oriented. 

Being a part in DPK Engineer for one month was a good experience. I have spent more time in Production department and had good exposure in Technical features of machine and functioning of sub departments in both the plants. As a technical and management student it gives me a clear vision in practical as well as theoretical.



I feel fortunate to be a part in the commissioning in the Indian Air Force Station, and I got to know that 50% of the share occurs due to KOEL brand image.



Gained the knowledge of functions different parts in the Genset.



In the head office of DPK Recruitment, training process is carried out by the HR Head and Marketing Head, they have explained clearly about how they market their product to the customer.



No finance matter is disclosed due to company rules.



Having friendly relationship with all the departments is seen in DPK Engineers pvt ltd.


ORGANIZATION STUDY AT DPK ENGINEER PVT LTD SUMMARY, SUGGESTIONS AND CONCLUSION SUMMARY:   

The company will be working on new innovative products The company has its own research and development department The employees are more in number in the production department than the other



department They make the small changes in the product by making the drawings with small

   

improvements. Market leadership plays a critical role in this company to earn profits. Introduction of new trade schemes to increase sales. Aggressive ment and publicity as part of sales promotion. Timely introduction and implementation of market driven decisions. The whole



process in the company depends on the quotations The company is assure of orders from big clients throughout the year.

SUGGESTIONS:  

The company should implement the six sigma and kaizen for better performances. R&D should work effectively and can make the company to earn more profits by cost



cutting. The opportunities should be open towards youngsters and also experienced candidates, as this might increase the chances of new innovative ideas of production



along with marketing for the benefits of the company in the long run. Should constantly keep updating the technology as and when it comes with regards to



computers, employees must undergo significant training on the same. The management must plan for such value additions in the area of talent workforce and bigger markets.

CONCLUSION:


ORGANIZATION STUDY AT DPK ENGINEER PVT LTD The study indicate that the positive aspect is that the company insist on good labour relation and works for good harmony within the organization .More than earning profit the company concentrates on many other aspects that it needs to survive the competition in the market . Employee motivation is most required in the organization Many employees require motivation in order to achieve productivity .Genset Industry is an industry and definitely the employees will have enough opportunity and future career growth in the Industry. The company has an effective Human resource, Marketing, Production &Service departments. The organization has excellent communication system as the organization’s short term and long term goals are communicated to the employees on regular basics. Employees are well equipped for handling the day to day requirements keeping the future in mind and the needs of globalization the company has to move up the value chain.



BIBLOGRAPHY

Guides of DPK ENGINEER PVT LTD Name MRS.Prabhamani MR.Lakshmanaswamy MR.Prakash.s

Designation HOD

Department HRD

Executive

Marketing

HOD

Marketing

Mr. lakashmaiah

Executive

HRD

MR.Ganesh

Manager

Store

MR.Sreemanth

General manager

 Web Sites: www.DPK engineers Pvt Ltd.com.

 www.wikipedia.com.

JOURNALS REFFERED  Company manual  Company broucher.


Manufacturing plant


Photographs: Bending machine and Genset


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