A REPORT ON
ORGANIZATION STUDY AT
DPK ENGINEERS PVT LTD
Internal Guide:
External Guide:
Mr.G.C.Nandeesh
Mrs.Prabhamani
Professor
HR Manager
NSM
Place: Bangalore.
N.Sobhanadeeswara Rao
Date: 01-09-2015
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
TABLE OF CONTENTS
Nitte School of Management, BangalorePage 4
CHAPTER NUMBER
PAGE NUMBERS
ECONOMIC SCENARIO
INDUSTRY PROFILE
13
COMPANY PROFILE
19
FUNCTIONAL DEPARTMENTS
26
SWOT ANALYSIS
46
LEARNING EXPERIENCE
47
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.
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.
CHAPTER-2
INDUSTRY PROFILE
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 users 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 panels, AMF
(Automatic on Main Failure) panels, synchronizing panels are available. These panels
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
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.
Age
Qualification
Position
S. Sampathraman
68
M.A (Economics)
55
A.M.I.E
MadanSampathraman
32
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
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.
Air cooled
5 10 kVA
15 70 kVA
Water cooled
20-82.5 kVA
100 - 160 kVA
180 250 kVA
320 625 kVA
Clients
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
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 PassivationAA50.After
manufacture of the Acoustic process they are assembled in Bomsandra Plant.
In the plant-2 Base frame, Fueltank, AchousticEnclosure,
Control panel 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.
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 Passivation bath
Remove the loaded parts from passivation 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:
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)
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 CPCB and also compliant with the
latest international emission norms.
Smart Genset Monitor Control (GMC) for closely monitoring the engine, genset and
safety system.
Water-cooled
engine
Model
6R1080TA
Power kW (hp)
113.2 (154)
Prime Power
Genset
rating at 0.8 pf
(kVA)
100
Overall canopy
dimensions
L x W x H (mm)
Approx. weight
(with canopy) kg
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 CPCB and also compliant with the
latest international emission norms.
Smart Genset Monitor Control (GMC) for closely monitoring the engine, genset and
safety system.
Water-cooled engine
Model
6SL8800TA
Power kW (hp)
228.2 (310)
250
Overall canopy
dimensions
L x W x H (mm)
Approx. weight
(with canopy) kg
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 CPCB and also compliant with the latest
international emission norms.
Smart Genset Monitor Control (GMC) for closely monitoring the engine, genset and safety
system.
Water-cooled
engine
Model
DV12 SR I
Power kW (hp)
552 (750)
Prime Power
Genset
rating at 0.8 pf
(kVA)
625
Overall canopy
dimensions
L x W x H (mm)
6670 x 2000 x
2750
Approx. weight
(with canopy) kg
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 CPCB.
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
Cooling
Model
Air-cooled engine
HA694T
Power kW (hp)
61 (83)
Prime Power
Genset
rating at 0.8 pf
(kVA)
70
Overall canopy
dimensions
L x W x H (mm)
3980 x 1240 x
1680
Approx. weight
(with canopy) kg
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 CPCB 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
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)
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
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.
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 donts 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
Wrong size
inlet and
outlet pipes
Feed Pump
Failure
Air Lock in
DG Sets
Dust/Foreign
materials in
tank
No 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
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
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.
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.
Having friendly relationship with all the departments is seen in DPK Engineers pvt
ltd.
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 advertisement and publicity as part of sales promotion.
Timely introduction and implementation of market driven decisions. The whole
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
CONCLUSION:
BIBLOGRAPHY
Designation
HOD
Department
HRD
Executive
Marketing
HOD
Marketing
Mr. lakashmaiah
Executive
HRD
MR.Ganesh
Manager
Store
MR.Sreemanth
General manager
www.wikipedia.com.
JOURNALS REFFERED
Company manual
Company broucher.
Manufacturing plant
Photographs:
Bending machine and Genset