The document is a summer training project report on Bharat Pumps and Compressors Limited (BPCL). It provides an overview of BPCL, including its location, vision, mission, objectives, capabilities, products, and clients. Some key points include: - BPCL is located in Naini, Allahabad and manufactures pumps, compressors, gas cylinders and other equipment for sectors like oil, gas, fertilizers and power. - Its vision is to become an Indian multinational in fluid handling and gas equipment, with a mission to provide quality products and services. - Products include centrifugal pumps, reciprocating pumps, compressors, gas cylinders up to 400kg/cm2 pressure

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more<br />Summer Training Project Report On BPC Ltd. - Document Transcript<br />A Summer Training Project Report A Summer Training Project On Marketing Plan & Project Analysis At BHARAT PUMPS AND COMPRESSORS LIMITED (A Government Of India Undertaking) NAINI, ALLAHABAD – 211006 U.P. INDIA Ph. 0532-2687412, 2687413; Fax. 0532-2687075 e-mail: bpclindia@sancharnet.in Duration (10-06-2009 to 29-07-2009) SUBMITTED TO: Mr. R.B.Singh Administrative Officer Bharat Pumps And Compressors Ltd. Naini, Allahabad SUBMITTED BY: Peush Prabhakar M.B.A. Reg. No. – VT/168/M.B.A./09 H.I.M.C.S. Farah, Mathura U.P. e-mail: peush_prabhakar_2007@yahoo.co.in Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 1 <br />A Summer Training Project Report CONTENTS • INTRODUCTION • ACKNOWLEDGEMENT • PREFACE • OVERVIEW • Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 2 <br />A Summer Training Project Report INTRODUCTION Bharat pumps & compressors ltd. Incorporated 1970 was established at Naini, the Trans yamuna area of Allahabad with objective to design, manufacture and supply of capital goods in the fluid handling field including provision of services connected therewith. BPC which caters to the need of core sector of the economy such as oil exploration, refineries, petrochemical, chemical and fertilizer, process industries nuclear and thermal power plant had in its earlier phases entered into technical collaboration with world renowned manufacturers of indigenously design and manufacture heavy duty centrifugal and reciprocating pumps, reciprocating compressors and high pressure gas cylinders and other hi-tech oil filed equipments such as cementing units, suckers rod pumps etc. In a very short span, the company absorbed the technology and established itself as the world renowned manufactured of a wide range of hi-tech products. BPC has supplied its products to the total satisfaction if the customers in almost all national projects of companies like ONGC, OIL, BPCL, IOCL, HPC, RCF, Nuclear Power Corporation, Deptt. Of Atomic Corporation, Deptt. Of Atomic Energy, IPCL etc. Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 3 <br />A Summer Training Project Report PREFACE I did my summer training in BHARAT PUMPS AND COMPRESSORS LIMITED, Allahabad. I completed my summer training for 50 days. I got training in the study of Marketing Plan and Product Analysis, Financial department is also being considered . Hence I am presenting the training report of Marketing Plan and Product Analysis. All the mistakes and problems had been carefully removed with the help of all the managers. So I am thankful to all the managers of BPCL Peush Prabhakar MBA (IInd Semester) Hindustan Institute Of Management And Computer Studies Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 4 <br />A Summer Training Project Report ACKNOWLEDGEMENT After completing my IInd semester curriculum. I went for summer training for 6 weeks duration and it bears inspirit of several person. I have achieve this training in one of the most esteemed organisation of the country BHARAT PUMPS AND COMPRESSORS LIMITED, NAINI, ALLAHABAD for their kind permission to undertaken its study I am grateful to my respected Mr. R.B.Singh (Training Administrative Officer). For there moral support and encouragement throughout my project work. This list will go incomplete without the special reference of the contribution and whole hearted support of manager’s and all other staff and department, which truly reflect their deep insight into the project and the professional touch which is their benchmark. I express my sincere thanks to Mr. Yashvardhan Nagayach incharge (training n placement department) Hindustan Institute of Management & Computer Studies, who gave me professional advice from time to time. Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 5 <br />A Summer Training Project Report BPCL-NAINI (An Overview) LOCATION- NAINI Naini is a satellite township of the city of allahabad, located on the banks of river yamuna and developed into an industrial centre. Some other manufacturing organizations located in Naini are ITI, TSL, AREVA, SAIL, etc. About: Bharat pump & compressor ltd.,, Naini , allahabad is a certified integrated management systems company having ISO 9001:2000, ISO 14001:2004, OHSAS 118001:1999 Includes Environment, occupational health & safety Management systems, with the objective to design, manufacture and supply capital goods in the fluid handling field including provision of services connected therewith. Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 6 <br />A Summer Training Project Report BPC caters to the need of core sector of the economy such as oil exploration and exploitation, refineries, petro-chemical, chemicals and fertilizers, process industries and power plants and indigenously designs and manufactures heavy duty centrifugal pumps, reciprocating pumps, reciprocating compressors and high pressure seamless gas cylinders and other hi-tech oil field equipments such as cementing units, sucker rod pumps etc. BPC : VISION • To become an Indian MNC in the field of fluid handling, gas compression, gas storage equipment, services and project management. BPC : MISSION • To provide quality products and services to core sector industries with special thrust on oil and natural gas, petro chemicals, refineries, nuclear and thermal power plants, fertilisers and public transport services complying to health and safety requirements. BPC : OBJECTIVES • To increase market share of their products and services. • To maximise customer’s satisfaction by providing quality product and services within stipulated delivery. • To increase the business of spares and rendering prompt after sales service including refurbishment. • Achieve export turnover of 15% by 20009-10. BPC is the only company in Asia to manufacture a wide range of high tech products, heavy duty pumps and compressors and high pressure seamless and welded gas cylinders, under one roof. Such high valued hi-tech products are functioning to the total satisfaction of the customers with least maintenance cost and optimum energy. BPC is the exclusive manufacturer in the country of carbonate and ammonia pumps for fertilizer plants, mud pumps, cement pumping units and high pressure reciprocating gas compressors for the oil and gas industry. The company’s important clients to name a few are the following : ONGC, IOC, IPC, GAIL, IOL and the Department of atomic energy. CAPABILITIES: • Such high valued hi-tech products are functioning to the total satisfaction of the customers with least maintenance cost and optimum energy conservation. BPC, the ISO 9001:2000, ISO 14001:2004, OHSAS 18001 :1999 Company, manufactures highly technically sophisticated and environmentally friendly products, equalling International Standards of quality and performance with the support of a most modern and sophisticated machining centre having latest CMC Machines, assembly, testing , heat treatment and fabrication workshops. • Test facilities. The factory is equipped for full load testing of various parameter for complete product range up to 2000 KVA • Quality Assurance. Quality Assurance Department ensures that the products-pumps and compressors meet the specifications of international codes such as API and are fully guaranteed for performance on the basis of proven and most updated designs. Gas cylinders are manufactured as per specifications of international standards such as DOT, BS, BIS, ISO etc. and usage approval from recognized national/international agencies. COMPETENCY: • Quality Assurance Programmes conform to International specifications and requirements. Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 7 <br />A Summer Training Project Report • Research and Development efforts are supported by test facilities for model testing in the centrifugal pumps, reciprocating pumps and compressors area and also carry out live testing of expendables etc. • • Fully groomed Installation, Commissioning and Spare Parts Division renders Product Support, Technical Assistance and advice besides providing quick and effective after sales service • • A strong Design Department has been established which houses Computer aided Design Centre. Highly qualified, trained, experienced and competent engineers are involved in application engineering, thermodynamic calculations, hydraulic calculations and systems design in the area of piping, instrumentation, electrical, operational control etc. • • The company undertakes long term maintenance contract of the equipments installed and commissioned at customers' plants, with the objective to maximise their profits and minimise their risks. CLIENTS • Oil & Natural Gas Commission. • Indian Oil Corporation. • Hindustan Petroleum Corporation. • Fertilizer Corporation of India Ltd. • Indian Farmers Fertilizer Corporation. • Gas Authority of India Ltd. • Indian Petro-Chemicals Ltd. • Madras Refineries Ltd. • Oil India Ltd. • Bharat Petroleum Corporation. • Engineers India Ltd. • National Fertilizer Corporation. • Indo Gulf Fertilizers Corporation. • Indraprastha Gas Limited. • Bongaigaon Refineries & Petro- Chemicals Ltd. • Cochin Refineries Ltd. • Tamil Nadu Petro-Chemicals Ltd. Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 8 <br />A Summer Training Project Report PRODUCTS Centrifugal Pumps Pumps for Application in Power Plants. Pumps and Reciprocating Piston and Plunger Pumps. Compressors Cementing Units. Sucker Rod Pumping Unit. Reciprocating Compressors. High Pressure Seamless Industrial Gas Cylinders. Welded Cylinders. Gas Cylinders Cylinders in Cascade for Storage of Compressed Natural Gas (CNG) Range of Products Centrifugal Pumps Maximum 2500 KW Power Maximum 140 kg/cm2 Pressure Maximum 12,000 M3/Hr Capacity Fluids Demineralised water, Sea water, Hydrocarbons, Handled Neptha, LPG, Carbonate Solution, Boiler Feed Water, Benefield solution, Alkaline and Acidic Solution, Ammonia liquor and slurry Reciprocating Pumps Maximum 1700 KW Power Maximum 675 kg/cm2 Pressure Maximum 315 M3/Hr Capacity Fluids Drilling Mud, Cementing Slurry, Crude Oil steam, Handled Condensate, Heavy Water, Fatty Acids, Ammonia Carbonate, Liquid Ammonia, Water Injection Reciprocating Compressors Maximum Power 25,000 KW Maximum Pressure 450 kg/cm2 Maximum Capacity 70,000 NM3/Hr Fluids Handled Air, Nitrogen, Oxygen, Carbon Di-Oxide, Hydrocarbons, Ammonia, Synthesis Gas, Hydrogen Sulphate, Coal Gas etc. Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 9 <br />A Summer Training Project Report GAS CYLINDERS Maximum Pressure 400 kg/cm2 Maximum Capacity 110 Litres. Fluids Handled Oxygen, Nitrogen, Hydrogen, Argon, Air, Helium, Carbon Di-Oxide, Nitrous Oxide, Acetylene, Ammonia, Chlorine, Freon, LPG, Compressed Natural Gas (CNG) C.N.G.CYLINDER FOR VEHICLE USE WORKING PRESSURE: 200 BAR (204 Kg/cm2) TEST PRESSURE: 334 BAR (340Kg/cm2) SPECIFICATION - IS: 7285-1988 WATER OUTER LENGHTH (L') (Approx) WEIGHT (APPROX) CAPACITY IN DIA(D') in in mm in Kgs LITRES mm TYPE-'A' TYPE-'B' TYPE-'A' TYPE-'B' 22 232 730 735 33.00 34.50 34 232 1045 1050 44.50 46.00 35 232 1070 1075 46.00 47.50 40 232 1200 1205 51.00 52.50 45 232 1335 1340 56.00 57.50 50 232 1465 1470 61.00 62.50 30 267 716 725 36.00 38.70 50 267 1115 1125 53.00 55.70 55 267 1215 1225 58.00 60.70 60 267 1315 1325 62.00 64.70 65 267 1415 1425 66.00 68.70 70 267 1515 1525 71.00 73.70 MANUFACTURING CAPABILITIES: • Modern & sophisticated machine facilities having at least CNC machines, assembly, heat treatment and fabrication workshop. • • In-house facilities of non destructive testing ultrasonic and chemical analysis, digital balancing machine, most modern boring and honing machines. • • CNC machines for manufacturing of high pressure industrial gas and CNC cylinders. Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 10 <br />A Summer Training Project Report • • Strong testing facilities for reciprocating compressors. • • Sophisticated standard room and modern tool room. CUSTOMER SATISFACTION In Time Delivery, Installation Commissioning of Products Common Long Term Objective To Preventive Maximise Profits Maintenance And Minimise Contract - Low Cost Of The Cost, Customer Low Downtime Just In Time Continuous Spare Parts And Rapid Management- Technological Low Downtime Upgradation On The Job Training Programme For Customer Operational & Maintenance Personnel RIGHT TO INFORMATION ACT, 2005: Right to information Act 2005(here-in-after called the act) provide for setting out the practical regime of Right to information to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority. Bharat Pumps & Compressors Ltd., Naini, Allahabad - 211010(India) is a Public sector Enterprise. POWER AND DUTIES OF OFFICER AND EMPLOYEES: BPCL is a manufacturing unit and a commercial organisation. Power and duties of the officials are well defined. DECISION MAKING PROCESS: The company is headed by Managing Director. Various functions of the organisation are managed by product managers and departmental heads (listed below) who report to Managing Director. Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 11 <br />A Summer Training Project Report Pump compressor design DGM(PDD) Pump compressor Pumps and compressors Business unit CGM(W) production technology DGM(DESIGN- TECH) Pump & compressor DGM(PCM) manufacturing Gas cylinder Business Unit DGM(GCD) Spares part Business Unit SM (SPCD) Marketing & EDP GM (Mktg ) Material management & stores GM (MM) Quality Control & Quality Assurance DGM (QC & QA) Engineering co-ordination & R & D. DGM (PDD & R&D) Financial Services CGM (F S,ROs & CSR) & I/C- CS Human Development , Welfare & PEX GM (PEX & HD) Workshop services , Plant GM (CS & PM) Maintenance and Safety As company in recent past was drowning so Government allotted some care takers for some time so as to revive the company and make it a profitable venture, for that Government decided to set: • E.I.L. – For Technology • B.H.L. – For Management • O.N.G.C. – For Funds. NORMS FOR DISCHARGING FUNCTIONS: • Conformance to systems ,procedures and Govt. guide-lines • Efficiency and effectiveness in performance • Good human relationship • Integrity and fairness in all the matters • Loyalty to company RIGHT OF DISCHARGING FUNCTIONS: BPCL has formulated the rules/guide-lines for conducting business in the company. Some major guiding documents are listed below: Articles and Memorandum of Association of the company • Delegation of Powers • Purchase Manual • Works Manual • Conduct, Discipline and Appeal rules • Standing orders Personnel policies and administrative orders • Right To Information Act, 2005 • Power and Duties of Employees • Decision Making Process • Norms for Discharge of Functions Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 12 <br />A Summer Training Project Report • Rights of Discharging Functions • Statement of Documentation • Arrangements for Consultation • Committees for Directions / Guidelines • Directory of Company Employees • Monthly Remuneration • Information Facility for Public • Public Information Officers • Other Useful Information STATEMENT OF THE CATEGORIES OF DOCUMENTATION: BPCL holds the commercial and technical documents regarding business operation of the company and data related to its employees. ARRANGEMENTS FOR CONSULTATION: BPCL has interfacing with various Govt. Departments and parliamentary committees. COMMITTEES FOR DIRECTION/GUIDE-LINES: BPCL has constituted committees to oversee its operation & provide directions/guidelines. The meetings of these committees are neither open to public nor the minutes are accessible to the public. DIRECTORY OF COMPANY EMPLOYEES: Details of all the employees are maintained by company. MONTHLY REMUNERATION RECEIVED BY EACH OF THE COMPANY'S OFFICERS AND EMPLOYEES (as on 01.07.09) ARE AS BELOW:- Grade Designation Pay Scale (Rs.) Strength E9 Managing Director 25750-650-30950 01 E8 Chief General Manager 20500-500-26500 02 E7 General Manager 18500-450-23900 04 E6 Deputy General Manager 17500-400-22300 10 E5 Senior Manager 16000-400-20800 19 E4 Manager 14500-350-18700 24 E3 Deputy Manager 13000-350-18250 77 E2 Senior Engineer 10750-300-16750 23 E1 Engineer 8600-250-14600 28 Total Executives 188 S3 Assistant Engineer 6400-180-10000 49 S2 Supervisor Grade-1 6000-160-9200 00 S1 Chargeman 5600-150-8600 09 Total Supervisors 58 W10 Chief Foreman 8600-250-14600 37 W9 Senior Foreman 6400-180-10000 222 Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 13 <br />A Summer Training Project Report W8 Foreman(W) 6000-160-9680 269 W7 Senior Technician 5600-150-9350 143 W6 HSW 5270-145-8895 49 W5 SKW-I 4925-135-8300 26 W4 SKW-II 4725-125-7850 22 W3 SKW-III 4550-115-7425 12 W2 SSW 4350-100-6850 12 W1 USW 4150-90-6400 18 Total Non-Executives 810 GRAND TOTAL(Executives + Supervisors + Non Executives) = 1056 INFORMATION FACILITY FOR PUBLIC: Nil. However company maintains a Library having technical books & specifications for reference of employees PUBLIC INFORMATION OFFICERS: Names, Designations and particulars of Public Information Officer. Mailing Address: Bharat Pumps & Compressors Ltd Naini, ALLAHABAD - 211010 Fax : 0532 - 2687075 E-mail : bpclindia@sancharnet.in Public Information Officers Mr. M.Shahabuddin. 91-9935595359 DGM (MKTG) Mr. Mohan Kumar 91-9935595377 DGM (GCD) Senior Public Information Mr. A.K. Mathur, 91-532-2687417 Officer GM(Marketing) 91-9935595369 Public Grievance Redressal System: A formal Complaint / Grievance handling procedure for all individuals except (i) Employees (ii) Vendors & (iii) Customers for whom a formal Grievance Redressal System already exists. A quot;
Grievancequot;
for the purpose of this Scheme would mean, a cause of distress felt on account of being wronged, to form a reason for complaint, relating to any Individual / Group (other than those not covered under the Scheme), arising out of any decision taken by BPCL in relation to that Individual/Group. A High-Powered Committee consisting of the following: i) Head of Finance Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 14 <br />A Summer Training Project Report ii) Head of P&A - Convenor iii) Head of Department to which the Grievance is related, decides on all the Grievances within 45 days of its receipt from the Personnel Grievance Officer(PGO) and thereafter informs the aggrieved person about the decision of the Committee within 7 days through the PGO. The decision given by the High-Powered Committee is final. Grievances that will not be taken up include : • Anonymous complaints / Frivolous cases / others in respect of which inadequate supporting details are provided. • Cases involving decisions/policy matters in which the aggrieved has not been affected directly/indirectly. • Cases where quasi judicial procedures are prescribed for deciding matters or cases that are sub-judice. • A grievance which has already been disposed of by the High-Powered Committee. • Complaints of corruption. These are to be lodged separately with the Chief Vigilance Officer. Complaint should be registered to: Mr. M. Shahabuddin DGM (MKTG) Bharat Pumps & Compressors Ltd. Naini, Allahabad – 211010 E-Mail: ms@bharatpumps.co.in Appellate Authority Mr. A.K. Mathur GM (Marketing) Bharat Pumps & Compressors Ltd. Naini, Allahabad – 211010 E-Mail: akmathur@bharatpumps.co.in TENDER NOTIFICATION: Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 15 <br />A Summer Training Project Report Notification Date of Opening BPT No. Description Date of Bids 461-16720 NON-RETURN VALVE 13.06.2009 04.07.2009 892-264 461-16510 FORGED BAR DIA 280X 15.06.2009 04.07.2009 791-270 461-24020 VANE CELL PUMP 15.06.2009 29.06.2009 19-271 461-16723 CONE. RED./ELBOW 15.06.2009 02.07.2009 691-273 461-16752 SMART LEVEL 15.06.2009 02.07.2009 79-274 TRANSMITTER 461-16771 SHIMSET 18.06.2009 29.06.2009 343-277 461-16741 SET OF GASKET 19.06.2009 06.07.2009 991-278 461-18020 MACHINING OF 19.06.2009 06.07.2009 094-279 CONNECTING ROD 461-18020 MACHINING OF 19.06.2009 06.07.2009 095-280 CONNECTING ROD 461-16771 FLEXIBLE RUBBER HOSE 20.06.2009 06.07.2009 44-281 ASSLY 461-16790 SET OF GASKET 20.06.2009 04.07.2009 391-282 461-16790 SET OF GASKET 20.06.2009 04.07.2009 392-283 461-16790 COMPLETE MECHANICAL 20.06.2009 06.07.2009 491-284 SEAL 461-16736 12 PAIR JUNCTION BOX 20.06.2009 09.07.2009 291-285 461-16753 SMART DIFF. PRESSURE 20.06.2009 06.07.2009 691-289 TEMP. 461-24020 INCREMENTAL 21.06.2009 06.07.2009 28-291 SHAFTENCODER TYPE 461-16771 quot;
Oquot;
RING ID 65.09 CHARD 21.06.2009 06.07.2009 221-292 461-16715 HEX BOLT M14 21.06.2009 06.07.2009 491-293 461-16753 SMART TEMP.TRANSMITTER 22.06.2009 09.07.2009 79-294 461-16783 SEAL RING PAIR TYPE 22.06.2009 09.07.2009 684-295 461-24010 ROTARY ENCODER 22.06.2009 13.07.2009 16-296 461-26790 PRESSURE GAUGE 22.06.2009 09.07.2009 69-297 461-16513 FLANGE 23.06.2009 09.07.2009 Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 16 <br />A Summer Training Project Report BOARD OF DIRECTORS NAME DESIGNATION ADDRESS PHONE EMAIL ID NO MANAGING DIRECTOR,, MANAGING B.P.C.L. NAINI, 0532- akjain@bharatpumps.co.in ABHAY KUMAR DIRECTOR ALLAHABAD, 2687320 JAIN 211010, INDIA DIRECTOR B 510 PRAGITI VIHAR LODHI 011- r.manohar@nic.in R. MANOHAR ROAD, NEW 23063707 (NOMINEE OF DELHI-110003, GOVT OF INDIA) INDIA DIRECTOR 690 ANNA SALAI 044- prshriram@bhelpssr.co.in PALLESENA NANDANAM, 24343382 RAJGOPAL (NOMINEE OF CHENNAI- SHRIRAM BHEL) 600035, INDIA DIRECTOR ONGC TEL BHAWAN S. DHANDAPANI (NOMINEE OF DHERADUN – 0135- sdhandapani53@yahoo.co.in ONGC) 248003 2793754 DIRECTOR 7045, SECTOR-B, 011- s.choubey@eil.co.in POCKET-10,, 26101458 SHYAM VASANT KUNJ, CHOUBEY (NOMINEE OF NEW DELHI- EIL) 110070, INDIA HIGHLIGHT: BPC marches ahead with turnover of Rs. 236.36 Crores (Growth 21.4% over last year) and Profit before tax of Rs. 26.88 Crores for the Financial Year 2008-09 TSX [TECHNOLOGY] DEPARTMENT Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 17 <br />A Summer Training Project Report Motto: To ensure the Right M/C ~ Rightsmooth flow of instruments to match that of material. Material ~ Right Tool ~ Right Job. OBJECTIVES: • To improve the quality of product. • To increase the productivity. • To reduce the cost. • To optimize facilities and machine utilization. • To enhance work culture, working conditions or environment. 5 M’s of Productivity: • Money ~ Capital • Man-Power ~ Workers(HR) • Management ~ Planning • Material ~ Direct / Indirect • Methods ~ Technology TECHNOLOGY FUNCTIONS: 1. To plan and specify methods and procedures for achieving special requirements. 2. Preparation of process sheets and procedures for specific processes and their qualification. 3. Designing jigs and fixtures, templates, special tools and gauges and initiate for the manufacture or procurement. 4. Preparation of vendor process specifications for operations to be off-loaded. 5. to approve / amend / modify changes in the processes as per the requirements, if needed. ORIGINATING DOCUMENTS FROM TSX 1. D.P.I. – For jigs and fixtures, thread rolls, gauges and special tools. 2. Drawings – For jigs and fixtures and special gauges. 3. Vendor process specifications – For operations to be off-loaded. 4. Process sheet (test estimates) – For manufacturing at fabrication and machine shop and assembly / testing. 5. Machine load chart – For annual production programme.. Process Sheet Contains: • Sequence of operation. • Work area / cost centre. • Machine tools used • Special tools requirements • Relevant technical specifications • Important inspection stages Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 18 <br />A Summer Training Project Report • Witnesses / hold points • Acceptance criteria • Identification and protection • Specific process specifications • Raw material supply conditions Jigs / fixtures / special tools (gauges) 1. Standard cutting tools 2. Special / form tools 3. Jigs / fixtures drill plates 4. Flanges for hydro test 5. Mandrill for DYN / STAT balancing. Purpose Of Tooling: 1. paper machining – surface finish / tolerance 2. to obtain the form / profile 3. to hold the work – piece / tool 4. to guide the tool during machining Manufacturing Processes: • To define process control at various stages of manufacture to meet the specified requirements. • Technology plans the manufacture processes in detail based on the drawing material specifications and quality plan as indicated in BM / drawing. Special Processes: These procedures are carried out by qualified professionals under controlled conditions following the documented procedures. Special processes qualifications: 1. Results of these processes cannot be fully verified by subsequent testing. 2. Production / QC to ensure that the procedure and the personnel are skilled. 3. Proper and regular record has to be maintained for every particular or attributes. 4. Technology shall issue specifications or instructions for special process qualifications and maintenance of records. IMS (INTEGRATED MANAGEMENT SYSTEM) IMS has world class standards through continuous improvements, research and developments. It comes under QMS (Quality Management System) and has been brought into application by API (American Petroleum Institute). Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 19 <br />A Summer Training Project Report Certifications: IMS has following three certifications: • ISO: 14001 • ISO: 9001:2000 • OHSAS: 18001 Note: ~ ISO: 14001 (environmental) management system standards to allow for easy integration of management systems. ~ ISO: 9001 is related to design, development, production, installation, testing activities and is following amendments of year 2000. ~OHSAS: 18001 has been designed to be compatible with ISO: 9001 and looking after employee’s health working in and for the organisation. ~ ISO stands for International Organisation of Standards. ~ OHSAS stands for Occupational Health And Safety Assessment System. APEX MANUAL: It covers the following features as per the IMS standards: 1. Organisational Chart 2. Departmental Procedures 3. Controlled and Uncontrolled Documents 4. Working Standards and Instructions 5. Research and Developments Note: ~ Business Quality = Product Quality + Product Service Quality TQM (TOTAL QUALITY MANAGEMENT) An integrated organisational approach in delighting customers (both internal and external) by meeting their expectations on a continuous basis through every one involved with the organisation working on continuous improvement of products, services and processes along with proper problem solving methodologies. Core Values Of TQM: S ~ Self Discipline Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 20 <br />A Summer Training Project Report P ~ Patience O ~ Openness R ~ Result T ~ Trust Essential Elements Of TQM: 1. Total employee involvement 2. Just in time / waste elimination 3. Total quality control (TQC) 1. Total employee involvement: SKILL ATTITUDE a) Able a) Willing b) Unable b) Unwilling (TQP)Total Quality People • Organisation is a tree(IMS) • Organisational fruits(TQM) • Organisational Stem(TQC) • Organisational roots(TQP) • Organisational resources(Cooperation, Communication and Commitment) Note: Total Quality People i.e. HR are the most important and integral elements of any Organisation. 2. Just in-time / Waste Elimination Wastes are those hidden problems or defects within an organisation which result in delay of production processes and also affect the cost of production. Hence, these need to be detected and eliminated at the earliest in order to meet the need of the customers just in-time. Wastes may result due to any of the following Abnormalities within the organisation: a) Inadequate System d) Sluggish Market b) High Defect Rate e) Low Work Standards c) Improper Work Method 3W Movement (WAGE WAR on WASTE) Identify & Eliminate wastage arising from: • Over producing Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 21 <br />A Summer Training Project Report • Time at hand • Transporting • Processing itself • Unneeded motion • Unnecessary stock at hand • Producing defective goods • Outdated instruments / machineries • Insufficient scheduling / routine • Congestive set-up / layout TOTAL QUALITY CONTROL(TQC) It means controlling: • Quality of work • Quality of service • Quality of process • Quality of people • Quality of system • Quality of objectives • Quality of information (verbal / non-verbal) • Quality of life QUALITY CONTROL DEPARTMENT Quality Control Department has control on all feeder sections. It checks the quality of raw material and finished products as per standard prescribed. The department can be categorised as: 1. Machine shop inspection 5. Chemical lab and ultrasonic testing 6. Mechanical lab 2. Non destructive testing 7. Gas cylinder quality control (NDT) department 3. Standard room 8. Stores(QC) 4. Assembly testing NDT (Non Destructive Testing): This section handles the following Tests: • Ultrasonic Test (UT) • Radiographic Test (RT) Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 22 <br />A Summer Training Project Report • Magnetic Particle Test (MT) • Dye / Liquid Penetration Test (PT) • Eddy Current Test (ET) • Helium Leakage Test Above four tests are mostly used. ULTRASONIC TEST: This is the test for checking inside defect in the material. Sound of frequency more than 20000 Hz (called Ultrasonic) is used for the test. A particular machine named Ultrasonic Testing Machine is used for the purpose with different probes (viz normal probes, angle probe of angle 30o, 45o, 60o, 75o). RADIOGRAPHIC TEST: This test is used for checking the internal defects of the material specially welded joints. These tests are done by X-rays or Gamma rays. TESTING FACILITIES IN RADDIOGRAPHIC LAB: 1) X-Ray Radiography: a. X-Ray Machine: Make: SEIFERT Type: PARVORAMIC Model: ERESCO 300/5 LRK Capacity: 300 Kw, 5 mA b. X-Ray Machine: Make: ANDREX Type: UNIDIRECTIONL Model: CMA-16 Capacity: 160 Kw, 5Ma This is used for steel thickness upto 10mm. 2) Gamma Ray Radiography: By IR – 192 Source (t ½ = 75 days) a. Tech – OPS Camera (Remote Operated) Make: USA Model: 660/664 Capacity: 100Ci Working Capacity: 60Ci Shielding Material: Uranium This is used for steel thickness 19mm to 75 mm. Along with test piece, pentameters are used for checking the standards of radiographs. Pentameters have two types: 1. Wire Type 2. Hole Type FORMULAE USED: % Sensitivity = Minimum Thickness of wire X 100/Material Thickness % Sensitivity = 2/(visible Hole /27) % Sensitivity should lie 1% to 3% ** Servameter ( Radiation detector ) : This is used for detecting every type of radiation. Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 23 <br />A Summer Training Project Report PRODUCT COLLABORATION PRODUCT COLLABORATORS NAME PERIOD Centrifugal Pump M/s Pumps Guinard France March 72 to March 82 Nuclear M/s Pumps Guinard France March 85 to December 95 Reciprocating Compressor M/s Nuovo Pig none, March 72 to March 82 Reciprocating Pumps M/s USS Oil Well, USA March 72 to March 82 Carhamete & Ammonia Pumps M/s Uraca Pumpenfabrik November 81 to November 91 Germany Cementing Units M/s B.J. Highes, USA January 85 to January 95 Gas Cylinders M/s Showa Koatsu Kogyo Co. March 72 to March 82 Ltd. Japan Porous Mass M/s Yokohama Chemical Japan March 72 to March 82 Porous Mass (Upgrade) M/s Coyne Cylinder Co. Ltd. July 85 to July 95 USA BPCL BRANCH OFFICES MUMBAI E – Mail : bpcldel@vsnl.net Bharat Pumps & Compressors Ltd., DIBRUGARH R&C Building, 4th floor, Byculla Iron Works, Bharat Pumps & Compressors Ltd., Sir J.J. Road (Adjoining J.J. Hospital – Rupam Building, Minal Nagar, Byculla) DIBRUGARH – 786 001 MUMBAI – 400 008 Tel. No. : 0373 – 2314324 Fax No. : 022 – 23750142 E – Mail : vcjaindib@sancharnet.in Tel. No. : 022 – 23716268 / 23774577 E – Mail : bpcmumbai@vsnl.net CHENNAI VADODARA Bharat Pumps & Compressors Ltd., Gemni Parson Apartment, Bharat Pumps & Compressors Ltd., “E” Block, 3rd Floor, 4 Manasmurti Flats, No. 3 Anna Salai, 14 J.P. Nagar, Opp. G.E.B. Colony, CHENNAI – 600 006 Old Paddara Road, Tel. / Fax No. : 044 – 28257107 VADODARA – 390 015 E – Mail : bpcchennai@vsnl.net Tel. No. : 0265 – 2336193 E – Mail : bharatpump@sancharnet.in KOLKATA NEW DELHI Bharat Pumps & Compressors Ltd., Room No. 222, Bharat Pumps & Compressors Ltd., 2nd Floor, Karnani Mansion, C-115 Lajpat Nagar – 1, 21 Park Street, Behind Gulshan Properties, KOLKATA – 700 016 NEW DELHI – 110 026 Tel. / Fax No. : 030 – 22269917 Tel. No. : 011 – 29815141 E – Mail : bpckol@sancharnet.in HUMAN RESOURCE DEVELOPMENT Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 24 <br />A Summer Training Project Report OUR MUSCLES IS OUR MANPOWER …………………….. AND IT SHOULD BE GOOD. BPC is engaged in a wide range of activities, which are design, manufacture, assembling testing, inspection, dispatch, after sales, commissioning of Pumps & Compressor and after sale service. A professional and progressive human resource development approach is what knits together the BPC family together the BPC family of over 1200 employees. The policies and practices have been formulated with well structured programme with objective of developing an organisation that will fulfil, comply with and adopt all the statutory requirement of Govt. Of India in terms of identifying including, training and development of Indian Nationals. Strive for total quality management through human resource development based on their strength and the organisation. CORPRATE PHILOSOPHY AND OBJECTIVES THINK BIG AND GROW BIG Corporate Objectives: • To increase the profitability through judicious productions. • To maximise customer satisfaction through effective Redressal of customer queries and complaints. • To optimise the utilisation of available resources through comprehensive ERP Techniques. MANUFACTURING CAPABILITIES EVEN PICASSO NEEDED A BRUSH AND A CANVAS And so does our committed force need an excellent and latest technology manufacturing infrastructure. Our manufacturing highlights are: • Modern and sophisticated machine facilities having latest CNC machines, assembly testing heat treatment and fabrication workshops. • In-house facilities of non-destructive testing, ultrasonic and chemical analysis, digital balance machines, most modern boring & honing machines. • CNG machines for manufacturing of high-pressure industrial and CNG cylinders. • Strong testing facilities for reciprocating compressors. • Sophisticated standard room and modern tool room. MARKETING PHILOSOPHY Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 25 <br />A Summer Training Project Report WORK SMART INSTEAD OF WORKING HARD Marketing Objectives: • To become a market leader in design manufacturer, testing, supply, creation and commissioning of pumps and compressors. • To be a leader in design, manufacturer, testing and supply of centrifugal and Reciprocating Pumps to Nuclear Power Projects Atomic Power Project. • To develop export market for BPCL products through target based pricing of products. • To improve upon market share for BPCL Products through target based pricing of products. • To increase the order booking for spare parts for BPCL supplied equipment through extensive overhauling and refurbishment activities for the equipment supplied earlier. ASSUMPTION ABOUT THE MARKETING PLAN What is marketing plan: Marketing plan is systematic anticipation and analysis of future changes coupled with the methodology for adapting to such changes. Methodology that will allow the industrial marketing manager to capitalise on the changes in order to meet objective and goals of the company and to gain an edge over competition. It take care of all the lapses of a marketing manager and also highlight the weakness of the company that should be removed for meeting the ultimate objective of the company i.e. profitability through customer satisfaction. Need for Marketing Planning: The marketing planning seeks to ensure perpetuity growth and continued profitability to a company through devising a suitable business portfolio and helping maintain a proper balance between short and long range objectives. It augments the health and image of a company through proper investment in business opportunities as well as in various resources. The absolute necessity of marketing plan becomes more conspicuous in its absence than in its presence. As without such a plan: a. The marketing manager losses control over the future of the firm. He has no ability to react in a logical and well-reasoned manner. b. The manager inevitably ends up managing by crisis rather than by design. c. The marketing manager is forced to remain on the defence with marketing decisions to counteract the well timed well offensive thrust of competition. Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 26 <br />A Summer Training Project Report STRATEGIES / ACTION PLAN: • BPCL have already initiated action for attainment of ISO 9000 certification. • BPCL is already registered with process consultants and various exports houses. We are receiving enquiries from EEPC, Mohan Exports and PEC etc. • BPCL has initiated action to become a member of international Trade Council. Exp. • As agents are the main contacts with the ultimate customers, we are also looking for appointing some agents of repute in foreign countries. • To participate in international trade fairs which are held in India & abroad. • Contacting ultimate customers and mailing our product leaflet and brochures to them. • Improve the level of customer satisfaction be mail questionnaires and personal discussion. Organising camps at various sites for a limited period listening to customer’s problems, resolving them and providing technical guidance. • Presentation to customers / consultants before project sets date through audiovisual presentation slides / films. • Tie ups with turnkey contractors. • Scanning and circulation of tender notices advertised in newspapers, Government bulletin. TYPES OF PLANS Mission The mission indicates primary beliefs and bedrock objectives, the central purpose of the business. The mission indicates precise answers to certain basic. Questions: • What is our business? • What will our business be? • What should be our business? • Who is our customer? • What does he buy? • What does he expect from the product? • What does he look for when he buy our product? • Why should consumer citizen tolerate our existence? And so on. If you have correct answers to these questions you can define your mission or line of business justifying its very survival. Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 27 <br />A Summer Training Project Report Objectives: Objectives are the aims and goals to be achieved by the enterprise. They point out where we want to go what is our end or destination. They provide direction for the enterprise efforts. They become the bench marks or standards for evaluation of efforts. The facilitate control. Planning is most successful when it is based upon clear-cut, attainable and verifiable objectives or goals. Please note that objectives prescribe ends, whereas strategy prescribed means to accomplish desirable ends. Strategy: R. Anthony has defined strategic “the process to deciding on objectives of the organisation on changes in these objectives and on the policies / strategies is a pattern of purposes and policies, which are unique to the firm”. Strategies are action – oriented programmes in order to give the organisation a unified direction towards achieving the company mission, objective and goals. Strategic decision is planned course of action to achieve clearly objectives, in the face of limited resources, a changing environment and intelligent completion. The word strategy has competitive implication. Strategies are planned response to external changes e.g. changes in customer tastes and preferences, changes in production do distribution, changes are based upon basic mission and objectives, resources to be delayed and changing marking opportunities. Strategies can establish favourable relation between the firm and its environment. Policies: Policies are the principles and consequent rules of action of achieving specific organisation objective or goal. Procedure: Procedures are a series of functions or steps performed to achieve a specific task or understanding. Programmes: Programmes are a series of necessary activities and resources that are guided by the corporate objectives, plans and strategies. Project: A project is a scheme for investing resources, resources which can be analysed and evaluated separately. It is a work plan. Schedule: A schedule is a precise time table of a series of action. A vital part of a programme or project. Budget: A budget is a document indicating amount of resources to be committed to a specific purposes of an organisation. Sales budget, production budget, capital budget and so on. Standards: A standard is a selected criterion against which actual results can be measured to evaluate performance. A standard is an integral part of control. There are four standards: quantity, quality, time and cost. Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 28 <br />A Summer Training Project Report Method: A method describes how each step of a procedure is to be performed. One best way is a standard method. Rule: A rule guides action but gives no discretion and demands strict obedience. Objectives indicate our ends or destination, policies point out what is intended; programmes, procedures, etc. describe how strategies and policies are being implemented. Standing plans ensure managerial efficiency, effective control and co-ordination. Moving from policies to rules, the standing plans become increasingly restrictive of management behaviour. IMPORTANCE OF PLANNING There are following importance of planning to Management of Business: • Planning forces on the future direction, values and sense of purpose; basic objectives tell the direction of growth. • Planning provides a unifying decision making framework and facilities integration of efforts. • Planning helps to identify potential market opportunities and threats. • Planning offers standards of performance for comparison and evaluation of actual performance. • Planning enable the organisation to tune its business with environment and establish a profitable relationship with environment. • Precise plan can achieve a correct balance among: o Corporate resources o Corporate effort and o The market potential • Planning assures effective management of change and thereby survival and growth of the enterprise. If there is anything constant, it is change. Change implies progress. Change is manageable only through conscious planning. For instance, planning can reveal future threats and uncertainties or probable changes in the national economy. Management can be prepared to face the change convert difficulty into opportunity and meet the challenge of change (resistance to change with reasonable success) • We determine our goals, policies, procedures and time bound precise action plans in advance and all activities are well coordinated and directed along predetermined channels on the target markets. Hence there is no problem of confusion or chaos, no barriers of communication and no need to grope in the dark. Thus we have an orderly and smooth journey to arrive at our destination as per plan. Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 29 <br />A Summer Training Project Report PRODUCTS Gas Cylinder: • High pressure seamless industrial cylinders. Pumps & Compressors • Centrifugal pumps • Reciprocating piston and plunger pumps • Reciprocating compressors carbonate and ammonia pumps • Sucker rod pumping units • Pumps for nuclear power station application. QUALITY ASSURANCE Backed up by metallurgical and other laboratories including standard and calibration room, the quality assurance programme confirm to international specification and requirements and aims at achieving excellence by integration quality development, quality maintenance and quality improvement effort of the various groups in the factory. Quality assurance department ensures that the products (pumps and compressors) meet the specifications of the international codes such as API and are fully guaranteed for performance on the basis of proven and most updated design Gas cylinders are manufactured as per specification of international standards as DOT, BS, BIS etc. and usage approval from recognised national/ international agencies. NEW HORIZONS BPCL is operating in hi-tech area and has established a reputation of products on which maintenance cost is least: • In recent past the company has intensified its activity in a highly sophisticated and specialised filed of nuclear pumps manufacturing order have already been executed to supply emergency core cooling pumps, moderator pumps primary system feed pumps and shut down cooling water pumps, to the country’s atomic power projects BPC ids fully geared to design manufacture and supply these pumps to nuclear power plants in order to achieve the generating capacity of 10000 MW by turn of the century. • To expand the product base organisation has undertaken manufacturing of canned motor pumps as a replacement of traditional moderator for nuclear power generation • Pursuing the policy of the government to give more thrust to agriculture areas the company has planned to take up capacity irrigation pumps for manufacturing. • Besides the company has achieved bread through to design and manufacture a high pressure air injection compressor for the in site combustion plants for the extraction of Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 30 <br />A Summer Training Project Report high viscosity crude for ONGC’s pilot plant at Balol. The other two worth mentioning break through are PACOL service compressor and hydro service compressor for linear alkyl benzene (LAB) revamp project at IPCL, Baroda and recirculation compressor for Heavy Water Project at Tuticorin. Visualising the oil crunch in coming years and unavoidable dependence on alternate resources of energy BPC is also planning to manufacture compressors and kits to be used on automobiles. A small package unit of high pressure low capacity compressors for starting aero jets and aero engines has been planned for production to meet the demand of Indian Air Force respectively. BROAD CUSTOMER PROFILE (1) PRODUCT: centrifugal pump (A) REFINERY AND PETROCHEMICAL • Indian oil corporation ltd. • Bharat petroleum corporation ltd • Cochin refineries ltd. • Indo Burma petroleum co ltd. • Mangalore refinery & petrochemicals limited. • Tamil Nadu Petri-product ltd, Bongaigaon. • Reliance petroleum. • Essar oil & refinery • Haldia petrochemicals. (B) FERTILIZERS • Fertilizer corp. of India ltd. • Hindustan fertilizer corp. ltd. • Indian farmer’s corp. ltd. • Nagarjuna fertilizer & chemicals lid, Hyderabad • Gujarat Narmada valley fertilizers co. ltd., Baroda. • Hindustan Lever ltd. • Tata chemicals limited. • National chemicals ltd. • Indian explosive ltd., Kanpur • Rashtriya chemicals& fertilizers ltd. • Krishak bharti co-operative ltd., Hazaria • Fact, cochin • Bindal Agro • Chambal fertilizers (C) OILS & GAS • Oil & natural gas corporation ltd. • Gas authority of India ltd. • Oil India ltd. (D) THERMAL POWER • National thermal power corp. • Harduaganj thermal power station • Captive power plant • Namrup thermal power station Prepared by Peush Prabhakar M.B.A.- H.I.M.C.S. 31 <br />A Summer Training Project Report • Neyveli lignite Corp. ltd. (E) <br />