INTRODUCTION

Fabrication, when used as an industrial term, applies to the building of machines, structures and other equipment, by cutting, shaping and assembling components made from raw materials. Small businesses that specialize in metal are called fab shop. Fabrication comprises or overlaps with various metalworking specialties:
y

Fabrication shops and machine shops have overlapping capabilities, but fabrication shops generally concentrate on the metal preparation aspects (such as sawing tubing to length or bending sheet metal or plate), welding, and assembly, whereas machine shops are more concerned with the machining of parts on machine tools. Firms that encompass both are also common.

Blacksmithing has always involved fabrication, although it was not always called by that name.

The products produced by welders, which are often referred to as weldments, are an example of fabrication.

Boilermakers originally specialized in boilers, leading to their trade's name, but the term as used today has a broader meaning.

Similarly, millwrights originally specialized in setting up grain mills and saw mills, but today they may be called upon for a broad range of fabrication work.

Ironworkers, also known as steel erectors, also engage in fabrication. Often the fabrications for structural work begin as prefabricated segments in a fab shop, then are moved to the site by truck, rail, or barge, and finally are installed by erectors.

Metal fabrication
y

Metal fabrication is a value added process that involves the construction of machines and structures from various raw materials. A fab shop will bid on a job, usually based on the engineering drawings, and if awarded the contract will build the product.

Fabrication shops are employed by contractors, OEM's and VAR's. Typical projects include; loose parts, structural frames for buildings and heavy equipment, and hand railings and stairs for buildings.

Engineering
The fabricator may employ or contract out steel detailers to prepare shop drawings, if not provided by the customer, which the fabricating shop will use for manufacturing. Manufacturing engineers will program CNC machines as needed.

Materials Stainless steel

y The three most common stainless steel grades available in sheet metal are 304, 316, and 410.
y

Grade 304 is the most common of the three grades. It offers good corrosion resistance while maintaining formability and weldability. Available finishes are #2B, #3, and #4. Note that grade 303 is not available in sheet form]

Grade 316 offers more corrosion resistance and strength at elevated temperatures than 304. It is commonly used for pumps, valves, chemical equipment, and marine applications. Available finishes are #2B, #3, and #4.

Grade 410 is a heat treatable stainless steel, but does not offer as good corrosion resistance. It is commonly used in cutlery. The only available finish is dull.

Aluminium
y

The four most common aluminium grades available as sheet metal are 1100-H14, 3003-H14, 5052-H32, and 6061-T6.

Grade 1100-H14 is commercially pure aluminium, so it is highly chemical and weather resistant. It is ductile enough for deep drawing and weldable, but low strength. It is commonly used in chemical processing equipment, light reflectors, and jewelry.
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Grade 3003-H14 is stronger than 1100, while maintaining the same formability and low cost. It is corrosion resistant and weldable. It is often used in stampings, spun and drawn parts, mail boxes, cabinets, tanks, and fan blades.

Grade 5052-H32 is much stronger than 3003 while still maintaining good formability. It maintains high corrosion resistance and weldability. Common applications include electronic chassis, tanks, and pressure vessels.

Grade 6061-T6 is a common heat treatable structural aluminium alloy. It is weldable, corrosion resistant, and stronger than 5052, but not as formable. Note that it loses some of its strength when welded.

Gauge
The sheet metal gauge (sometimes spelled "gage") indicates the standard thickness of sheet metal for a specific material. For most materials, as the gauge number increases, the material thickness decreases. Sheet metal thickness gauges for steel are based on the weight of steel, allowing more efficient calculation of the cost of material used. The weight of steel is 41.82 pounds per square foot per inch of thickness; this is known as the Manufacturers' Standard Gage for Sheet Steel.For other materials, such as aluminium and brass, the thicknesses will be different.

INDUSTRIAL PROFILE
Metalworking is the process of working with metals to create individual parts, assemblies, or large scale structures. The term covers a wide range of work from large ships and bridges to precise engine parts and delicate jewellery. It therefore includes a correspondingly wide range of skills, processes, and tools. Metalworking is a science, art, hobby, industry and trade. Its historical roots span cultures, civilizations, and millennia. Metalworking has evolved from the discovery of smelting various ores, producing malleable and ductile metal useful for tools and adornments. Modern metalworking processes, though diverse and specialized, can be categorized as forming, cutting or joining processes. Today's machine shop includes a number of machine tools capable of creating a precise, useful work piece.

Prehistory
Metalworking predates history. No one knows with any certainty where or when metalworking began. The earliest technologies were impermanent to say the least and were unlikely to leave any evidence for long. The advance that brought metal into focus was the connection of fire and metals. Who accomplished this is as unknown as the when and where, but the Egyptians are thought to have been one of the first civilizations to work gold. Not all metal required fire to obtain it or work it. Isaac Asimov speculated that gold was the "first metal. His reasoning is that gold by its chemistry is found in nature as nuggets of pure gold. In other words, gold, as rare as it is, is always found in nature as the metal that it is. There are a few other metals that sometimes occur natively, and as a result of meteors. Almost all other metals are found in ores, a mineral bearing rock, that requires heat or some other process to liberate the metal. Another feature of gold is that it is workable as it is found, meaning that no technology beyond eyes to find a nugget and a hammer and an anvil to work the metal is needed. Stone hammer and stone anvil will

suffice for technology. This is the result of gold's properties of malleability and ductility. The earliest tools were stone, bone, wood, and sinew. They sufficed to work gold. At some unknown point the connection between heat and the liberation of metals from rock became clear, rocks rich in copper, tin, and lead came into demand. These ores were mined wherever they were recognized. Remnants of such ancient mines have been found all over what is today the Middle East. Metalworking was being carried out by the South Asian inhabitants of Mehrgarh between 70003300 BCE. The end of the beginning of metalworking occurs sometime around 6000 BCE when copper smelting became common in the Middle East. History By the historical periods of the Pharaohs in Egypt, the Vedic Kings in India, the Tribes of Israel, and the Mayan Civilization in North America, among other ancient populations, precious metals began to have value attached to them. In some cases rules for ownership, distribution, and trade were created, enforced, and agreed upon by the respective peoples. By the above periods metalworkers were very skilled at creating objects of adornment, religious artifacts, and trade instruments of precious metals (non-ferrous), as well as weaponry usually of ferrous metals and/or alloys. These skills were finely honed and well executed. The techniques were practiced by artisans, blacksmiths, atharvavedic practitioners, alchemists, and other categories of metalworkers around the globe. For example, the ancient technique of granulation is found around the world in numerous ancient cultures before the historic record shows people traveled seas or overland to far regions of the earth to share this process that still being used by metal smiths today. As time progressed metal objects became more common, and ever more complex. The need to further acquire and work metals grew in importance. Skills related to extracting metal ores from the earth began to evolve, and metal smiths became more knowledgeable. Meta lsmiths became important members of society. Fates and economies of entire civilizations were greatly affected by the availability of metals and metal smiths.

Company Profile
Established in 1990, Sri Lakshmi Narayana Engineering Industries is functioning in our own premises at Narasimmanaikenpalayam for the past 15 years. G. DORAISWAMY is the CEO of the company. We are a sheet metal fabrication company with good client base that includes leading players like Indian Railways, Lakshmi Machine Works, Eureka Forbes and True Air System to mention a few. The company specialize in performing high accuracy jobs and some of our products include CNC machine covers and parts, outer chasing for water purifiers, paddy thrasher in agricultural segment blowers and dryers for humidification plants and the like. Our latest foray has been into the fields of hospital equipments and kitchen equipments where we are making good strides. The company expertise in particular includes 15 years of experience in the fabrication of electric panels board both for PCC, MCC and M.V.PANELS, SSB, DB The company machinery infrastructure includes all facilities for fabrications are also available at our premises. Our ultimate impetus is on quality and values and in our quest to become global players in our field we continuously aspire to provide valueadded products and services to the society. Innovation in a sustained and determined manner and integrity are our key goals.

Infrastructure
Our infrastructure is a backbone of our company and allows us to produce product conforming to international quality standards and latest market trends. Our entire manufacturing operations comprise adequate raw material storage, work product storage, loading and dispatch facilities. We have got all the modern and sophisticated machines in our workshop & wide distribution network which enables us to undertake timely execution of our orders.

ORGANISATIONAL CHART

CEO

TECHNICAL MANAGER

Purchase / Stores

Marketing

Prod/Maint

Quality Assuranc

Accounts

Operators/Fitters

Inspectors

Assistants

RESPONSIBILITY AND AUTHORITY CEO

A) Reports to the Board of Directors B) Responsible for: y y y y y y y y y y y Overall management of the company Laying down quality policy and objectives Carrying our management reviews Approval of product & process, Design & quality. Ensuring the compliance to the quality management system of the company Review and approval of quality management system documents Finance management Approval for purchase of raw materials, consumables and spares Review and authorizing all agreement / contract (customer / suppliers) Overall responsibility for new products and projects Defining responsibility and authority of functions who are expected to take the independent decision y y y Providing resources as identified including training Appointment of management representative Review the performance of the quality management system in line with ISO 9001 / 2000 STD requirement y y y Review of orders received from customers Review of nonconforming products as a member of review meeting Approval of corrective actions taken against customer complaints and purchased products including productions operations y Coordination and spear heading the continuous improvement activities of the organization y y Receive and record customer complaints in the register Maintaining the data related to delivery schedule adherence to customers
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y y y

Outsourcing Operations (Productions) as required Identification of training needs of functions reporting to him Has the authority to stop production

TECHNICAL MANAGER
A) Reports to Chief Executive Officer B) Responsible for: y y y y y y y y Overall activities of the day to day production operations Planning and review of production against plan Process design and development Identification of training needs of functions reporting to him Preparation of work instruction for production activities Initiation of corrective action with regard to in process / final stages of production Maintaining customer satisfaction and taking suitable corrective action Implementing the corrective actions for the customer complaints in coordination with CEO y y New Product Development Initiating the corrective action against the customer complaint in coordination with CEO y y y y y y y Proposal of corrective action and verification of effectiveness of corrective actions Monitoring customer satisfaction and taking suitable corrective actions Ensure safe working practice Drawing control in related to distribution and revision and over all maintenance Control of customer supplied products / documents Has the authority to stop production, to correct the quality problems.

PURCHASE STORE IN CHARGE

A) Reports to CEO B) Responsible for: y Preparation of purchase order / Arranging for purchase of Raw Materials, spares and consumables y Supplier evaluation and maintenance of approved suppliers list follow up with suppliers y y y y y y Maintenance of record in relation to purchase of products Maintenance of minimum stock level Maintenance of FIFCO system for Self Life Item Stock register and material identification Preservation of materials identification Preservation of materials stores

MARKETING IN CHARGE
A) Reports to CEO B) Responsible for: y y y y y to material Inward and Inspection Receipts of enquires / Orders from the customers and enter in the register Receives and record customer complaints in the register Maintaining records related to customer related processes Tracking of customer satisfaction and on time deliveries

SUPERVISOR-PRODUCTION
A) Reports to technical manager B) Responsible for: y y Production , quality as per planning Man, Materials, Methods, Machineries Management
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y y y y y

Monitoring House Keeping Ensure safe working practice Maintenance of records related to production & quality Identification of training needs of functions reporting to him Has the authority to stop production, to correct the quality problems

MANAGEMENT REPRESENTATIVE
A) Reports to CEO B) Responsible for: y y y y y y Planning, establishing and implementing quality Management system in consultation with CEO Organizing internal quality audits Organizing management Reviews meeting and taking follow up actions Initiate preventive actions with regard to repeated system non conformities Liaison with certifying agencies and arranging for external audits Ensuring internal communication in regard to effectiveness of quality management system

MAN POWER
 There are 165 employees  72 Skilled technicians  17 Engineers  12 Administrative staff members

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CLIENTS
Kerlosker Poduval sons Indian Railways Lakshmi Machine Works Eureka Forbes True Air System

PRODUCTS
Heavy Fabrication Equipment

We undertake heavy fabrication equipments in stainless steel, CS and aluminium. We supply pressure vessels, Heat Exchangers, Silos, Plant and Machineries for Food, Chemical and allied industries. We have qualified welders and fitters to execute the job. Sheet Metal Fabrication

We handle everything in the metal fabrication realm. We are large enough to handle large scale metal fabrication. We manufacture all kinds of Precision Sheet Metal Fabrications ranging from Prototypes and Production to Laser/ Turret/ Brake Press and Tube Bending. Special Type Fabrication for Silos

We manufacture various kinds of silos, in the form of plate-bottom or conical bottom. Both are kinds are available according to the customers demands and drawings. We also manufacture many types of dry storage silos for products ranging from heavy limestone or coal to lightweight plastic pellets. We have the facility to design and produce silos from various materials like stainless steel, aluminum, duplex stainless steel, or carbon
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steel, along with any other special material the customer prefers, and our engineering and quality assurance programs guarantee a product of the highest quality. Plastic Product We are a major manufacturer, importer and supplier of a range of plastic products required in various industries. Being in this field for almost fifteen years, we have earned immense experience and have managed to become well known as a highly trusted brand. Our product range includes-

- Plastic Injection Moulded Parts - Plastic Clips - Cable Ties - Auto Parts.

We are engaged in Mould Making Activity and Die Development from the last 4-5 years. We have designed dies for a number of reputed companies in Pune with critical dimensions and precision components. Quality has always been our utmost concern and that is the reason, we are now a forerunner in the industry, well known as a brand synonymous to trust and reliability. Our products - Plastic Injection Moulded Parts, Plastic Clips, Cable Ties and Auto Parts are widely acclaimed all over India because of their premium quality and the high precision level that they offer. We crave for perfection and do an extensive research to consistently upgrade the quality of our products so that you can get the best products from us PRODUCTS CNC machine covers Outer chasing for water purifiers Paddy thrasher Hospital equipments Kitchen equipments
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INSPECTION PROCESS

QUALITY CONTROL
Process input Mode of output Process Measures

1.Quality plan/Work Instruction 2.Drawings/Specifications 3.Incoming specification 4. Measuring devices 5. Inspection skill 6. In formations/feedback from the customer with regard to quality of the product. 7. Inspection status Raw

1. Inspection report

1. Number of customer

2. Non conformance complaints material report Related to quality of the

3. Corrective action product report 4. Test certificate 2. Customer rejection percentage

We earnestly work towards optimizing our customer's delight by delivering quality products within the stipulated time frame at an economical cost. We at Lunar Engineers, consider quality as a next corner stone of our success. To achieve customer satisfaction and ensure top-notch quality, we have been a front runner in adopting a concerted program on Total Quality Management. Our procurement department is fully conversant with the requirements for local purchasing and overseas indents & source raw material from reliable sources and checks them for ingenuity at our end. During various production stages such as machining, assembling, finishing every
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part of the product is thoroughly inspected & checked by quality assurance department. Certainly our in-house quality control experts also ensure that only the best reaches our invaluable customers The purpose of this section is to display the general parameters and guidelines for the quality control of products manufactured on a day to day basis at the manufacturing facilities of Fast Fabricators It is the intent of Fast Fabricators to furnish products of the highest quality, using the best materials and workmanship available. All personnel involved in the quality control process, whether they are the location manager, or their designee, will conduct themselves in a professional manner, with the best interests of Fast Fabricators, and the customer in mind.

INCOMING STAGE:
A. On action on receipt of raw materials from suppliers/processed products from the service providers are inspected as per incoming/process/product wise quality B. The raw materials/production operations are accepted based on the test certificates/inspection reports wherever required as applicable received from the suppliers/service providers. C. The quality supplied and accepted criteria is ensured against P.O/job order as applicable and the same is updated in the material inward inspection report/service providers register D. The consumable are checked for the quality and specification (Visual through labels or stickers etc.) as per purchase order/purchase orders register and accepted. The result are updated in MIIR The non-conformance identified during this inspection, are handled as in continual improvement process

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IN PROCESS AND FINAL STAGE

A. In process and final inspection are carried out as per the process and final inspection quality plan. The inspection results are recorded in inspection reports. B. Final inspection/Testing are done on the finished 100% Qty of the product as per the final inspection quality plan C. Final inspection/Testing results are recorded in the Final /stage inspection report. D. If result are not meeting accepted criteria/tolerance during in process /final stage ,then non-conforming product control process is implemented as per the process module-continual improvement process E. Inspection status is identified on the components through tag/board/respective location/paint mark identification. F. Inspection skill is measured through skill matrix and necessary action is taken as per the process module. G. Proper instrument with valid calibrated are selected for the inspection. Instrument are selected such that its least count is 10% of the size under measurement.

SUPERVISOR-QUALITY CONTROL
A) Reports to technical manager B) Responsible for: y y Overall quality control and assurance Maintenance of records related to incoming materials, in process materials and final stage productions inspection reports including dimensional inspection y y y Calibration of inspection and testing equipment / instruments Identification of training needs of functions reporting to him Has the authority to stop production, to correct the quality problems

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Responsibilities The manager of quality assurance reports directly to the V.P. Operations. The quality assurance manager's responsibilities shall encompass the following:
y y y y y

Interpretation of conformance to customers quality requirements. Review of customer drawings and specifications. Determination of necessary inspection points. Documentation of necessary inspection and test instructions and changes thereto. Planning, developing, initiating, coordinating, implementing, and maintaining the most effective and efficient procedures for quality assurance.

y y y y

Maintenance of adequate quality assurance records. Review of quality assurance and corrective action follow-up. Vendor quality assurance and corrective action follow-up. Original and continuing periodic inspection of special and standard gages, test equipment, and tooling used to manufacture product. Assuring inspection and test equipment remain calibrated within established time.

Coordinate in plant corrective action on items rejected by the customer, notify customer of the action taken and evaluate the action for effectiveness.

Assure that inspection personnel are capable of rendering an unbiased decision to accept or reject material inspected.

y y y y y y

Promote quality improvement projects. Review Purchase Orders. In house Surveys. Vendor Surveys. Assist in Customer Surveys. Initiate concise written work instructions for the acceptance or rejection of a product.

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ACCOUNTS
A) Reports to CEO B) Responsible for: y Overall responsible for accounts related activities includes sales tax, excrise & banking y y Maintaining commercial records and invoice Coordinating with auditors for carrying out annual audit

RESPONSIBLITIES OF OTHER PERSONNELS

Concerned sections in charges define and communicate the responsibilities of personnel working in their respective areas. It is the responsibility of the location manager, or their designee, to ensure that materials received for a specific project are the proper materials for that project, and that the materials are marked for the project for which they were purchased. If the material for a project, or order, is to be pulled from stock, the location manager, or their designee, continually monitor production to ensure the proper materials are being used. It is the responsibility of the location manager, or their designee, to be sure that all materials being shipped to customers, or project locations, meet the requirements set forth on the work order, or the "job specification sheet". Any questions concerning product description, or other criteria, will be directed to the order originator, or the location manager. No products are to be released to the shipping department without the approval of the location manager, or their designee. The location manager, or their designee, will escort any visiting outside inspectors and furnish them with any documentation required, as set forth on the work order, or on the job specification sheet, pertaining to the material, and/or workmanship of products they are to inspect.

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It is also the responsibility of the location manager, or their designee, to communicate with the project manager, and/or inspector, should on-site problems arise. If on-site repairs, or meetings, are necessary, the location manager, or their designee, will accompany, and assist any personnel required to go to project job sites for such repairs, or meetings, until all parties concerned are satisfied that Fast Fabricators has furnished an acceptable product. The location manager, or their designee, will keep the management of Fast Fabricators advised of any, and all problems at project job sites, and their final outcome. It is the responsibility of the location manager, or their designee, to preview all work orders prior to their release for production. Any discrepancies will be brought to the attention of the order originator.

QUALITY ASSURANCE
The management of SRI LAKSHMI NARAYANA ENGINEERING INDUSTRIES is fully committed to the development and implementation of modern quality management system and continually improving its effectiveness. Towards these requirements, the company has oriented all its systems and procedures inline international quality management standards and practices The quality manual of SRI LAKSHMI NARAYANA ENGINEERING INDUSTRIES is issued on 31.08.06, which incorporates companys quality policy and the basic procedures. The company has decided to obtain ISO 9001/2000 certificate to fulfill the requirements of its discerning customers, who are constantly upgrading their own requirements and making increasing demands on their supply chain to enable better competitiveness. The quality management system is oriented to achieve, maintain and improve overall organization performance, capability and also to identify and meet the needs and expectations of the companys customers, employees, suppliers and owners.
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The quality management system procedures in the quality manual are supplemented with further supporting work instructions, check sheet and together they form a comprehensive documented quality management system, designed to result in better customer satisfaction, a basic requirements of the companys quality policy The Chief Executive Officer/MD, Technical Manager/section in charge is committed to the development and implementation of the quality management system and continually improves its effectiveness by A) Communicating within the organization, the importance of meeting the customer as well as statutory and regulatory requirements b) Establishing the quality policy c) Ensuring that quality objectives are established D) Conducting management reviews E) Ensuring the availability of resource The Chief Executive Officer is authorized to approve the quality management system procedures incorporated in this manual and subsequent amendment to them. The Management representative is authorized to approve other work instructions, check sheet and formats o the quality management system to maintain uniformity within the company. It is mandatory on the part of all employees of SRI LAKSHMI NARAYANA ENGINEERING INDUSTRIES, to faithfully implement the quality management system and work towards continuous improvement based on regular analysis of current performance data and keeping in view the increasing expectations of the customers.

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MANUFACTURING PROCES

MECHINARY LIST SL NO 1 2 3 4 M/C NAME SHEARING BENDING CNC BENDING CNC PUNCH POWER PRESS NIBBING WELDING MAKE TEE TEE JFY JFY CAPACITY 4MM*2500MM 3MM*2500MM 4MM*3100MM 6MM*2500*1250MM WITH 32 STATION 30 TONS 6MM 300A 300A 250A 15KVA4+4MM QTY 1 1 1 1

5 6 7

SME AMC L&T MIG SUPREME TIG BHARAT ARC MALIK SPOT

1 1 2 1 5 1

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CUTTING

The first step in the process of sheet metal fabrication is cutting. In this process firstly the sheet has been cut into different angles and then the sheet is shift to the next process for punching. While in cutting process the sheet has been cut in some structure for the making of the outer cover of the machines. For cutting NC cutting has been used (Numerical control). The sheet that has been used in this cutting process can be up to 3500 meters and 8 to 6m thickness capacity can be cut in this machine then the sheet is shifted to the next process punching

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PUNCHING (SHEARING)

The next step after cutting is punching. In punching CNC machine is used the machine is used to make holes in the sheet. The first step only cut the sheet and the second step make holes in it. In CNC machine 6 tone power punching is used. 2m and 1.6m thickness sheet can been use in it and .30 clearance is used to make holes. After punching the sheet will be shifted to the next stage for bending

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BENDING

After finishing the first and second step the sheet will be taken to the third step that is bending. The sheet which has been altered that has to be bend in a proper way to make it into a proper design so it has to be bend. If we want to bend the sheet to 200m we can change the machine by altering it and by altering it the clam will be coming back to adjust 200m. After the bending process the next step is welding.

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WELDING

After bending the next step is welding. The bended sheet must be welded. For welding here they are using thick welding. Copper wires are used for welding. After welding the next step is finishing. Finishing means cleaning. Finishing is done to get a good look for the finished sheet. There will be some scratches or some dots while welding so these things are cleared by the process of finishing The last step is dispatching it means checking. At last all the work of the sheet metal has been done the quality control manager or the production manager is coming for inspection and if the work has been properly done the work has been given the quality department acceptance
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NIBBING

In nibbing machine it will cut the sheet metal or the clam into rounded pieces. This machine is only used for making round piece metals

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CUTTING
-Ordinary cutting machine

In the machine the sheet has been cut by taking centimeters. The machine is ordinary cutting machine

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POWER PRESS PUNCHING MACHINE

This machine is used for cutting the sheet notching size

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PROCESS STEPS

BENDING

PUNCHING

BENDING

WELDING

FINISHING

DESPATCHING

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PROCESS MAP BASIC PROCESSES FOR PRODUCT REALISATION

RECEIVING CUSTOMER ENQIURIES AND EXAMINING FEASIBILITY OF MANUFACTURE BEFORE COMMITTING TO CUSTOMER

PLANNING FOR DESIGN/DEVELOPMENT, PRODUCTION AND TOOLING PROCUREMENT AND STOCK OF RAW MATERIALS DEVELOPMENT OF INITIAL SAMPLES CUSTOMER APPROVAL OF SAMPLES PROCESS CONTROL AND REGULAR PRODUCTION DELIVERY TO CUSTOMER IN-PROCESS AND FINAL INSPECTION INSPECTION OF INCOMMING MATERIALS

DESIGN AND DEVELOPMENT OF PROCESS/QUALITY PLAN

AFTER SALES SERVICE

CUSTOMER FEED BACK/COMPLANTS/INVEMEGATION AND 30 CAPA

PROCESS FOR QUALITY MANAGEMENT SYSTEM

DEVELOP QUALITY POLICY AND OVERALL OBJECTIVES AND COMMUNICATE

DEVELOP QUALITY MANAGEMENT PROCEDURES/WORK INSTRUCTIONS, CHECKS SHEETS AND IDENTIFY QUALITY RECORDS

PROVIDE NECESSARY RESOURCES INCLUDING TRAINING

IMPLEMENTING QUALIYY MANAGEMENT SYSTEM

MONITOR EFFECTIVE IMPLEMENTATION

FEED BACK TO MANAGEMENT FOR ASSESSING SYSTEM EFFECTIVENESS AND FUTHER IMPROVEMENT

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PROCESS FOR MEASURMENT

PROCESS CONTROL MEASURMENT

PRODUCT CONTROL MEASURMENTS

CONTROL OF MEASURING SYSTEM

CUSTOMER SATIFICATION MEASURMENT

QUALITY MANAGEMENT SYSTEM MEASURMENT THROUGH INTERNAL AUDIT

ANALYSIS OF RESULTS OF MEASURMENT AND CONTINUOUS CONTINUAL IMPROVEMENT OF THE QUALITY IMPROVEMENT
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CONTINUAL IMPROVEMENT OF THE QUALITY MANAGEMENT SYSTEM

CONTINUAL IMPROVEMENT OF THE QUALITY MANAGEMENT SYSTEM

MGNT. RESPONSIBILITY CUSTOMER SATIISFACTION CUSTOMER REQUIRMENT

RESOURCE MANAGEMENT

MEASUREMENT, ANALYSIS, IMPROVEMENT

PRODUCT REALISATION INPUT OUTPUT

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PURCHASE AND STORE PROCESS PROCESS MANAGEMENT PROCEDURE ACTIVITY

The purchase in-charge maintains the list of materials list of suppliers and list of services providers SELECTION OF SUPPLIERS (PURCHASE PROCESS) All the existing suppliers/service provider as on 31.08.06 are brought into the list of approved suppliers and the list of service providers based on the past experience with respect to quality and delivery. If there is a need for any new suppliers/service providers, purchase in-charge source the information about the potential suppliers/service providers through market information. Purchase in-charge sends the assessment questionnaire for supplier registration to them, and their details are collected. CEO review the information provided by the suppliers/service providers and decides about their approval. If approved, their names are included into the list of suppliers/service providers. A new/unapproved suppliers/service provides is included in the list of approved suppliers based on the following conditions. a) Quality feedback received from the production/Q.C for at least 3 trail supplies. b) Filled supplier registration from approved by CEO

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PLANNING

AND

PROCRING

OF

MATERIALS

(PURCHASING DATA)

The Raw material and the production related consumables are purchased based on monthly orders/schedule or during day to day work orders and subsequent stoke verification. If production in charge found stock Qty is less, raises the material requisition to stores and stores in turns raises indent to purchase in charge for the procurement of the materials. Purchase orders are raises against the stores indent/purchase requisition memos to the approved suppliers on a yearly/ monthly/daily basis as applicable and required. If there is any change in the contract within the financial year, amendment of purchase order is raised to the suppliers. Further if purchases are made through letter or orally, the same is monitored through purchase order register Emergency purchase is done from the suppliers other approved suppliers on ane time basis if approved by the CEO.

PLANNING OF SERVICES
The list of service providers contains the name of the service providers and their scope of supply is maintained by purchase/prod in charge. The production in charge/CEO orders the service to those in the list on a need basis. The communication about the services requirements is communicated through

drawing/sketches/work instructions.

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The material is send to the service providers through the delivery channel and sends and returned details are recorded in the service provider register

RECIEIPT OF MATERIAL (VERIFICATION OF PURCHASED PRODUCT)

The material received from the suppliers/service providers are inspected and stored in the material storage area. The raw material/consumables received are checked for the quality against the advised quality and updated in the MIIR. If there is any excess/shortage the supplier is informed suitably. The accepted material is stored in their respective storage location and the stock ledger for raw materials and consumables are updated for the receipt of corresponding quality. The material received from service provider like machined casting is updated in service providers register. The machined castings are accepted based on the service provider inspection report or Q.C/inspector carries out the inspection as per the requirement and the inspection is recorded in the inspection report. If any deviations occur, is informed to the service provider suitably and CEO/Q.C in charge is responsible for making decision based on the severity of the deviations either to rework or accept conditionally. The accepted materials are stored in their respective storage location and the records are updated.

ISSUE OF MATERIAL
The material in storage is under the control of stores in charge. The material required for production is issued against the material requisition by production. The material are updated in the stock ledger the store in charge The CEO/production in charge review the stock status of the material periodically to ensure the availability the material for production against the minimum stock level

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maintained at stores. Shelf life item are issued as per FIFO system by maintaining the shelf life item list in stores

EVALUATION OF SUPPLIERS/SERVICE PROVIDERS

The performance of the suppliers/service providers are monitored and rated based on the quality of the supplies and delivery performance. The supplier/service providers rating is carried out on half yearly basic. The rating is done on two aspects namely quality (60%) and delivery (40%) weight age and rating in recorded in suppliers / service provider rating from

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FOR PRODUCT QUALITY

A) For purchase products

Total Quality Accepted X 60 Total Quality Supplied Qty. Rejected X 60 Qty.

Reworked
B) For Productions operations: 60+

Tot. Qty Supplied supplied

Tot. Qty

For Delivery Adherence Qty. Supplied on time A) For purchase products: Ordered Quality X40

B) For productions operations: 40- Sum of fraction of delayed Qty. Supplied X No. of days of delay

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PRODUCTION PROCESS
Process inputs 1.Customer order 2.Work order/Daily plan 3.Customer Drawings 4.Quality plan/Work Instructions 5.Trained human resource 6.Machines 7.Raw materials and consumables 8.Safty precautions 9.Feed back received from QC,IA,MRA and customer complaints 10.Product nonconformities 11.Product identification method Mode of Output 1.Production Process 2.Products Process Measures 1.Adherence to planning

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PROCESS MANAGEMENT PROCEDURE ACTIVITY

1. The schedule/orders from the customers are received by the CEO. After consolidating the schedule, CEO reviews the availability of the capacity along with technical manager/concerned section in charge received from the customers marketing in charge raises the work order to production in charge 2. Based on the work order received from marketing, production plan is arrived by the production in charge in the work order rear side itself. 3. Based on the weekly plan, the raw material/consumables planning is carried out by the CEO interacting with the production in charge and the material requisition is raised to stores about procurement. Stores in charge after verifying the stock raised the indent to purchase in charge for procurement 4. If any additional schedules are received from the customers CEO along with technical manager section in charges in consultation with CEO amend the monthly/Weekly planning. The raw material/consumable planning are also reviewed for additional and if necessary, requirements are informed to purchase in-charge 5. In case of no-availability of the required from the capacity CEO decide about the action to be carried out, including the action of the service providers. 6. CEO instructs the production departments highlighting technical and quality requirements. 7. The production is carried out under controlled condition based on the customer drawings/requirements. The work instructions/process flow charts/activity charts, quality plan-product wise as applicable, are available in the work spot skill to carry out production process are identified through skill matrix once in a year and the appropriate records are maintained by the section in charges.
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8. Production details are recorded in daily production logbook maintained by the concerned section in charges. 9. The in process inspection is carried out as per the quality plan-product wise it is section in charges responsibility to ensure that operators follow the work instructions. It is ensured that inspection/testing is carried out all stages as per work instructions/quality plan-product wise. 10. Process parameters and product characteristics are monitored as per work instruction or as per customer requirement/quality plan-product wise. 11. In case of any out sourcing productions operations is required it is done through the service providers. The performance of service providers is evaluated and monitored by rating once in 6 months by CEO/Q.A in charges 12. The products after completion of all processes are offered for pre-delivery/final inspection as per the quality plan-products wise are available at work spot. 13. Based on work order/production plan whenever products are already for dispatch, they are dispatched either in loose condition or packed as per customer requirements and the relevant documents are sent along with products. Test certificates and inspection reports are verified by quality control before dispatch. 14. Section in charge in consultation with CEO, decides the corrective action to be taken, in case of any problems related to production and dispatch.

IDENTIFICATION AND TRACEABILITY INCOMMING STAGE:

a. Raw materials/consumable are stored in bags/containers/loosely at identified areas or through tag/labeling as applicable

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b. Raw materials like rough casting are stored in casting stores identified with name boards or as suitable.

IN PROCESS STAGE
Product at various stages of production process is identified with its status displayed on the boards viz. under process, for inspection, for fitting, for painting, for dispatch as applicable.

ACTIVITY FINAL STAGE

Manufactured products are identified by manufactures name board detailing the product name, manufacturing date, specification, etc. As required by the customers

TRACEABLITY
Manufacturing details including the name of the manufacturer date of manufacturing, working capacity and other specifications as applicable and as required by the customers are affixed on the product.

CUSTOMER PROPERTY: CUSTOMER PRODUCTS

No customer products either supplied or involved in manufacturing process. If at all in future, the customer products will be maintained for its suitability to use.

CUSTOMER DOCUMENTS
The documents supplied by the customers such as drawings, specification are maintained in the relevant file. Section in charge maintains list of customers supplied as /internal drawing.
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The control of documents, issue of documents, revision of document are carried out as per the documentation process.

PRESERAVATION OF PRODUCTS
a. The products are preserved in such a way as to no damage is done to the product in any form. b. After the completion for each stage of process, the products are stored in the respective identified area with status. c. Shelf life and FIFO is not applicable for the products as its quality is not deteriorated due to storage. d. If required by the customer by contractually, products are provided with rust preventive oil or paint coating or as required by customer on preservation of products e. Based on production plan, whenever the products are ready for dispatch, they are packed as per contractual requirements/customer requirements to avoid transit damage. f. Products are packed as per the contractual requirements/customer requirements either in wooden cases or in carton boxes or wooden creates or as suitable to avoid any damages. When the quality is not affected during transport, products are also dispatched in loose conducting the number of products taken.

WORK ENVIRONMENT
The following factors are managed to achieve conformity of product 1. Proper Housekeeping 2. Identification of products 3. Proper illumination 4. Proper Air Circulation 5. Proper safety equipment is available.

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Feedback received from internal audit, Management review and customers are reviewed to improve the process performance

SERVICING
y Complaints received after warranty period are taken as servicing calls are entered in service register by making in charge y Most servicing is done at customer premises, and on special request by the customer is done at customer end y Q.A Executive test the motor received for service as per the quality plan and detect the problem and forward to production executive for necessary action. y Production executive attend the problems and make the motor functionally o.k. y Q.A Executive re-inspects the motor and gives clearance to dispatch to the customers. y If any service is due to operating mistakes, the concerned customers are properly trained for correct operating procedure. y All the details of the service activities and any spares replaced are recorded in service register and the service report is send to the customer along with test report.

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EQUIPMENT MAINTAINANCE PROCESS

Process inputs 1.Preventive Maintenance plan 2.Equipment 3.Spares 1.Measuring instruments/gauge

Mode of output 1.List of machinery 2.Preventive maintenance record 3.Machine History Card

Process measures 1.Machine down time

1.List of measuring instruments

1.No of occasions instrument having error

2.Calibration history cards and found reports

exceeding acceptable error limit

PROCESS MANAGEMENT PROCEDURE ACTIVITY

INFRASTRUCTURE
The Management of SLN identifies, provides and maintains the facilities it needs to achieve the conformity of product, which includes,  Buildings, Workspace and associated facilities,  Equipment, hardware and software,  Supporting services(Such as transport, Communication etc) Equipment used for manufacturing activities is listed in list of machineries measuring instruments are listed in the list of measuring instruments

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MAINTENANCE OF MACHINERY
Preventive maintenance of machinery is carried out as per the preventive maintenance plan and the result/observations while checking are recorded in the preventive maintenance record Preventive parameter are reviewed at least once in 3 months during the MRM meeting. On the basis of repeated break down occurred and the plan is revised if necessary. Problems/break down and the corrective action taken is recorded in the machine history card

CALIBRATION OF MEASURING/TEST INSTRUMENT

A. All the measuring instruments or any other devices used to measure are listed in the list of measuring instruments B. The acceptable error limit is fixed based on the measurement tolerances of the dimensions measured using the instrument. The calibration frequency is fixed based on the usage of the instrument. If required in the future, based on the calibration results the Q.C review the frequency suitably. C. It is ensured that the master instrument used by the calibration agency have been calibrated against national/international measurement standard by receiving a calibration report of master instrument used. D. After receipts of calibration report, the results are reviewed against the accepted error limit fixed in the list of measuring devices. The calibrated details are recorded in the calibrated history card. E. If the result of calibrated is not acceptable, inspection result taken before the calibration is assessed for the past 6 months from the date of calibrated against customer complaints/product acceptance/quality rating report from the customer. Results of assessment including documents verified are recorded in the calibrated history card.

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SWOT ANALYSIS
Sri Lakshmi Narayana Engineering Industries - SWOT Analysis company profile is the essential source for top-level company data and information. Sri Lakshmi Narayana Engineering Industries - SWOT Analysis examines the companys key business structure and operations, history and products, and provides summary analysis of its key revenue lines and strategy Sri Lakshmi Narayana Engineering Industries is a steel manufacturer and recycler in the coimbator. The company manufactures hot-rolled steel (angles, rounds, flats, channels, sheet, wide-flange beams, pilings, billets, blooms, beam blanks, and plate), cold-rolled steel, steel joists and joist girders, steel deck, cold finished steel, steel fasteners, metal building systems and light gauge steel framing.

Reasons to Purchase
- Support sales activities by understanding your customers businesses better - Qualify prospective partners and suppliers - Keep fully up to date on your competitors business structure, strategy and prospects - Obtain the most up to date company information available

STRENGTH
y y y y y y High reputation Well qualified and technically skilled manpower Company has very long period of experience Good employee management relationship Product Quality Company reputation

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WEAKNESS
y y y y Workers are not able to adopt new technologies Lack of Export. Less importance for advertisement and promotional activities Costly installation charge.

OPPORTUNITIES
y y y Uses of machines are increasing New technologies are developing Increasing demand of steel day by day

THREATS
y y y Heavy competition Increasing in the price of raw materials Adopting old techniques of manufacturing

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FINDINGS
1. The company have structured organization 2. Absenteeism of the company comparatively large. 3. There is a heavy competition from other companies 4. Increase in the price of the raw materials is one of the main thread 5. They have a effective team work 6. They have a full team of experts

SUGGESTIONS
Welfare activities of the worker should have to be improved. Company should ensure participative management.

Promotion and adverting activities should be improved Scope for expansion Company focuses on modernization & up gradation

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CONCLUSION

Our machinery infrastructure includes all facilities for fabrications are also available at our premises. Our ultimate impetus is on quality and values and in our quest to become global players in our field we continuously aspire to provide valueadded products and services to the society. Innovation in a sustained and determined manner and integrity are our key goals

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BIBLOGRAPHY
y y y y y y y y Company manuals Direct interview with managers Internet Google Wikipedia Company website Manuals, Booklets -Philip Kotler Marketing Management, Printice -Hall of India Pvt Ltd New Delhi y C.B.Mamoria & S.V.Gankar,Section I Marketing Management

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