1. BIOGREEN ENERGY SYSTEM Pvt.Ltd.
Operation Management Assignment
Manu Singh Baghel – 25

2. About the Firm –
 Company Owner – Mr. Vijay Kumar Dumbali
 Business Type – Exporter / Importer / Service Provider / Manufacturer /
Whole Seller / Distributor / Supplier / Trading Company
 Established in 2003.
 Area of Expertise / Functionality – Generators , Control Panel ,
Turbines, Commissioning,
Value Engineering.
 Head Office – Aishwarya, Bhusari Colony, Opposite Sringeri Mutt,
Kothrud, Pune - 411023, Maharashtra
 Assembly Centre – Honga Industrial Area, Belgaum , Karnataka
 Turn over last year – Rs. 16,38,000,00 on March 2012.

3. Various Functional Block –
 Sales / Marketing – 04 employees
 Sales Engineering – 03 employees
 Project Technology (Design, Research & Development) – 05 employees
 Purchase / Procurement – 02 employees
 Assembly / Production – 07 employees
 Quality Control (Expert + Project Tech. Ass. / Sales Engg. Ass.) – 03
employees
 Export / Dispatch – 02 employees
 Commissioning – 07 employees
Strategy and Tactical Management – 03 employees

4.  Post Dispatch Services – same as
Commissioning ~ 02 employees
 Finance / Accounts – 02 employees
 Human Resource – 02 employees
 Mechanical Deptt. – 2 engineers + 3
technicians
 Electrical Deptt. – 2 engineer + 2 technicians
 Project Innovation – 03 employees (all
engineers – electrical, mechanical, service)
 Sales & Application Engineering – 04
employees
 Purchase, Supply – chain & warehousing/
Storekeeping – 07 employees

5. They distribute their goods
to many cities like –
 Nasik, Malegaon, Mumbai, Pune urban and
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sub – urban like pimpri –
chinchwad, Ahmadnagar
West Bengal (HUL),
Karnataka,
Rajasthan (Hindustan Zinc)
Assemble at from Belgaum, Karnataka as
well as Pune plant.

6. Turbine parts are being
imported/procured from
 Skinner Power System (Pennsylvania, USA)
 Triveni Garebox, Karnataka.
 Tharmocompressor are procured from
Mazada, Gujrat.

7. Components and assembling
process (operation) –
 It is casing with rotor mounted at the top
containing a bearing assembly part rotating
the shaft.

8.  Following is a bearing consolidating the overall
weight of the rotor.
 It is turbine casing both upper and lower
encapsulates the main turbine structure.

9.  Side view of rotor and its blade - Rotor shaft is
assembles to the upper case of the turbine.
 It is trip valve, which get tripped in case of turbine generating
abnormal speed or parameters.

10.  This component is the governor valve disc. In
case of trip valve getting tripped this valve gets
stick with steam inlet pipe and stop the further
steam flow.

11. Steps in turbine assembling –
 Putting/placing turbine and gearbox on skid.
 Placing of lubricant oil cooler at the support.
 Placing gear pump, level gauge, 3 way valve and filters on the
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support mounted on the skid.
Placing pressure and temperature gauge at place.
Main oil pump to bearing of turbine and gearbox has been
established.
Ermotto coupling joints pipe to pipe without threading. With
its help
Lubricant oil coming out of the turbine is piped to recycling
and cooling purpose mingled with lubricant oil cooler.
Piping and instrumentation take place as per the lubricant
piping diagram.
Hydraulic testing after whole assembling process.
Painting and packaging.

12. Steps in supply chain –
 Enquiry for the turbine as per the requirements of customer
 Parameters mentioned such as temperature, pressure and
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process pressure for the plant (normally less than the actual
pressure generated) are desired specifications.
After this calculation takes place for the power generation as
per the specifications thermodynamically.
HMBD (heat mass balance diagram) issued to the customer for
feasibility checking purpose.
If client agrees and feels satisfied with the model, then technical
and commercial quotes are sent to customer, where negotiation
takes place.
Purchase order is generated from client side, 20% of the capital
cost is being paid by the client.
Customer drawings are made available within 1 month and 20%
money is again being paid by the same party.
Detailed engineering takes place based on which turbine and its
components are procured as it is a time consuming process.

13.  Skid drawing and prototype is developed.
 After getting the ordered material assembling and
manufacturing of other parts and components start
taking place.
 After assembling customer can witness a quality
assurance test at the factory.
 After getting ready rest 60% of the amount is being
paid and turbine is dispatched.
 Commissioning engineer set the synchronizing,
aligning and skidding operations at the site and
mount on the foundation.
 A commissioning certificate is being led from the
client side.
 Service is provided on the site over the 1 year
warranty period.

14. IT – Enabled SCM –
 Electronic data interchange – EDI
 Internet/extranet
 Electronic commerce
 Enterprise resource planning – ERP
 E- procurement
 Supplier relationship management – SRM
 Advanced planning and scheduling – APS
 E-logistics

15. Leading to following results –
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Reduced latency and reaction time
Decreased contingency and obsolete inventory
Lower operating costs
Fewer or no shortages
Improved overall performances
Enhanced customer responsiveness
More predictable forecasting
Enhanced speed to market
Sharing of best practises
Collaborative R&D
Profit sharing

17. Interview Pattern –
We have manage  Semi structured Interview to ensure Flexibility and
Relaxed context.
 One – to – One Verbal Interview.
 Informal Interview.
Questionnaire Pattern –
 Some Questions were differed according to the designation of the interviewee.
(e.g. More stress on Motivational and satisfaction factors for some employees)
 To include at least 2 questions per segment i.e. –
 Operations and workings
 Motivational Elements
 Job Satisfaction
 Working Environment and culture
 Job Profile Satisfaction (3-4 questions)
 Problems / Conflicts Resolution
 Coordination Element.

18. Four Employees we interviewed  Mr. Swapnil Kumbhar  Senior Executive Engineer (32 Years)
 Mr. Vilas Chinke  Executive Engineer (31 Years)
 Mr. Abhay Singh Parihar  Application Engineer (27 Years)
 Miss Vaishali Dhangar  Technology Engineer (23 Years)
Two Customers / clients for the organization –
 Satyam Petrochemical (Mr. Rajendra Kute) located at Uraj (Pune -
Kolhapur Highway)
 Mr. Dasgupta (Hindustan Uniliver Limited)

19. Functional Blocks with the arising problems –
1. Sometimes Unable to match with the commitments.
2. Dysfunctioning of control panels and other tools  operating and
maintenance issue.
3. Inefficiency in execution by customers  error in execution of
diagrams, prototype, designs.
4. Too much dependency upon IBR (Indian Boiler Rule) by NEMA (National
Electrical Manufacturer Association)-23 & Inter changeability Rule 
Standardization.
5. Lack of coordination between employees having various streams of
engineering and academic backgrounds  Dispute / Conflicts.

20. Problems Continued ...
6. Miscommunication between client and dispatching /
exporting department  cargo movement / date of delivery.
7. Errors in technical / required specification  deviation in
delivery from requirements.
8. Working hour pressure (load of work)  8+2 hours with
negligible motivating factors.
9. Slow rate of enhancement in job profile  employee
unsatisfaction
10. Low market demand  Low Salary increment.