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PLANT LAYOUT
A STUDY CONDUCTED AT
Guided by
Shri. KIRAN NAIK MBA
Director
Bharatesh College of Business Administration,
Belgaum.
2010 - 11
BETS
ACKNOWLEDGEMENTS
The successful completion of any task would be incomplete without the mention of
people who made it possible, whose constant guidance and encouragement crown all efforts with
success.
First of all I would like to thank the HARSHDRUV PRRO PACKAGING,
Belgaum Company for giving me the approval to do this project in the organization. I grateful
thankful to Mr. Bipinchandra N Patel (Managing Director) who has given this opportunity to
study the organization in totality, which provided me with the immense managerial, and
production knowledge, which is used by their organization for the moral support, encouragement
and generous assistance.
I am thankful to Mr. Sujit Dhuma (General Production Manager) who has guided me to
take up this project and for all the hospitality that he has given me which has enabled to complete
my project on time.
I also thank the staff and workers who have co-operated with me in successfully
completing my project by providing valuable information and knowledge about the functioning
of the organization.
Business Administration Belgaum, for the support and encouragement to finish this report. I
thank my faculty guide Mr. Kiran. Naik for coordinating the project work and giving me the
guidance. I am thankful to many individuals in the company for the encouragement and
professional assistance.
MARTIN. C
P.A JAIN Bharatesh College Business Administration
DECLARATION
I hereby declare that this project work is the result of my original work. The findings and
conclusion is based on the information collected by me during the study. I am solely responsible
for any errors in the work.
Place: Belgaum
TABLE OF CONTENT
SL.NO
CONTENT
Acknowledgement
Declaration
Abstract
Company profile
Methodology
Sample size
10
Interpretation
11
12
Findings
13
Conclusion
14
Suggestions
15
Annexures
PAGE
NO.
Bibliography
Abstract
This project is based on problem solving. As a part of course requirement the
students Bachelor of business administration has to take up a project for a month.
The basic purpose of the project is to enable the students to expose the working of
any organization and manager, to relate the concept learned by the students to the working of the
organization, to understand the practical aspect of working of organization.
It aimed to diagnose the cause of companys problems and to formulate programs for
improvement.
This project is on the study of Harshdruv Prro Packaging. Plot No. 59, KIADB,
Honaga, Industrial Area, Honaga, Belgaum. The project is done based on the information,
manuals etc, given by the Harshdruv Prro Packaging .
The report initiates with brief introduction of company it covers many aspects of
Harshdruv Prro Packaging like Company profiles, scope, limitations etc. Finally this project
report on Problem solving on PLANT LAYOUT of Harshdruv Prro Packaging ends
suggestions and conclusion.
Company profile
:
:
Constitution
The Partners
Activities
Nature of ownership
M/s. Harshdruv Prro Packaging is a partnership firm. There are 2 partners
1. Mr. Bipinchandra Patel
2. Mr. Jitendra Patel
P.A JAIN Bharatesh College Business Administration
Number of employees
There are 60 employees working in the organization. It is a horizontal as well as
vertical type of organization structure which they follow. All the employees are divided in
different departments as per the requirements.
Office staff 9
Helping Laborers 30
Operators 21
The same number of employees is employed for the second shift.
Organization Structure
This is the organizational structure which is followed in Harshdruv Prro Packaging. The
organizational structure which they follow is very simple. The top level management discusses
and gives order to the middle level management in the organization. The middle level
management has many departments in it they are Production Department which has 20
Operators. And this department is directly connected with the middle level management that is
the production manager. The other department is Stores Department which has 1 Stores Manager
among the 20 operators. The stores department is connected to the top level management and to
the lower level management and the Accounts department and is also connected to the top level
management. The Accounts Department has 1 account manager among the office staff itself.
And is connected to the Sales department. The last department is the Human Resource
Department which has a HR manager and it is directly in touch with the top level management.
Organization Chart
Managing Director
General Manager
Office Manager
Factory Manager
Finance Department
Production Department
Marketing Department
H.R. Department
R & D Department
Maintenance Department
Designing Department
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Production department
Production department deals with the manufacturing of the product that is from
raw materials to finished goods. Mr. Sujit Dhuma looks after the production department and
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Production Process
1. Corrugation Machine:
2. Cutting Machine
Here the corrugated sheets are cut according to the particular size and order. The
gears are set to cut the paper and corrugated sheet according to the length required.
Man power required: 1 operator and 1 helper for each machine. Number of machines - 2.
3. Printing Machine
4. Pasting Machine
The liners are pasted on each other according to the required ply by the customers.
To get 3-ply a single paper is pasted on a liner, to get 5-ply a single paper is pasted on 2 liners
and so on. Here for the pasting process white glue is used which comes in powder and is mixed
with water.
Man power required: 3 operator and 2 helpers for each machine. Number of machines - 2.
5. Scrolling Machine
P.A JAIN Bharatesh College Business Administration
6. Slotting Machine
This machine helps in separating the flaps (the part which is folded to cover the box) of
the box. It cuts a small line and allows the flap to fold according to the given shape/requirement.
Man power required: 1 operator and 2 helpers. Number of machines - 1.
8. Stitching Machine
Stapling of the box is done through this machine. There is a roll of steel wire which
the machine cuts it self and staples the box.
Man power required: 1 operator and 1 helper for each machine. Number of machines 4.
HR strategies
Since the factory is located 20 kms away from the city, taking educated and hard working,
account and clerical staff was a big task and the management knowing this limitation took steps
2 months in advance by keeping in touch with placement services, local contacts and newspaper
advertisements. The large team of employees is seen working hard in all segments that is
accounts, marketing, dispatch, production supervision, machine operators and casual laborers.
When personally contacted there came to know about future plan as follows:
They also plan to have categorized work uniform for permanent skill labors and
operators, a different one for supervisors, section in-charge, production manager and
administrative accounts and other senior staff.
Performance based incentives and bonus will be provided.
Training Policy:
P.A JAIN Bharatesh College Business Administration
4. Finance Department
The finance department consists of 1 finance/Account Manager Ms. Shilpa Sungar is
in charge of the financial department. She looks after all the transactions and the accounts. The
accounts department is connected to sales department and the dealers and the purchase
department. This department also maintains the records of salary and the wages of the
employees. Its transfers their salary to their respective accounts. It also maintains the receipts of
purchase and sales department
Responsibility
Reconciliation to the bank account,
To control & minimize the expanses of the company,
To maintain & record of all transaction involve.
To prepare the balance sheet and trading and P&L a/c every year,
Book keeping.
Preparation of invoice and vouchers.
2, 70,000/-
Electricity
1, 00,000/-
Transportation
2, 00,000/-
15,000/-
Quality
Pricing
Delivery
Reliability
6. MAINTAINENCE DEPATRMENT
This department is very important in the organization. This department has to look
after everything like machinery, furnitures, computers, electrical etc. The process of
maintenance department is as follows: 1. If the problem occurs they have to write a complaint in the register, which is provided to
them.
2. Technician will look after the problem and gives the report.
3. If part is not available then give the requisition of the same.
7. DESIGNING DEPARTMENT
Design department looks after designing of new products. The marketing team gives
them the theme. According to the theme the design team designs the boxes. There are 2 designers
in the Harshdruv Prro packaging designing department. The department head is Mr. Maruti B
Patil. He has completed his certified designing course from IMAGE IDT Limited, Mumbai.
Corrugated Pallets
Mono Cartons
Partitions
Interior Packaging
Storage Bins
Ring Flaps
Methodology
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Primary data: I had visited the project workplace and studies the various aspect in
management systems by personal observation, discussion with the head of the departments and
in formal chat with employees of all the departments.
Secondary data: the relevant information for secondary data was collected from various
sources like various records maintained, through the companys different manuals and
procedures & through the survey.
Pie chart
Doughnut graph
Interpretation
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Values
Percentage
Satisfied
22.22
Neutral
22.22
Dissatisfied
55.56
Total
100
22.22
22.22
55.56
Interpretation:
The above chart shows that the 55.56% of the machine operators are not satisfied with the
present layout of the company. Therefore the company needs to take the decision for new plant
layout.
Table no.2: Machines need to be serviced?
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Percentage
Twice a month
22.22
6 month
33.33
1 year
44.45
Total
100
44.45
22.22
100
Interpretation:
The above chart tells us about the servicing of the machine that it is done twice year and 44.44
machine workers have answered this. So they need to look after this and take important decision.
Percentage
Yes
77.78
No
22.22
Total
100
44.45
22.22
Interpretation:
The above chart defines about the new layout of the company that is which is in U shape and
77.78% workers have agreed to the new layout. So there should be change in plant layout of the
company
Percentage
Excellent
33.33
Good
44.45
Fair
22.22
Total
100
33.33
44.45
22.22
Interpretation:
The above diagram tells about the work of the machine that is quality of the product it produces
according to survey the machine need not to be changed as the percentage itself tells us that its
quality is best .
Values
Percentage
Yes
66.67
No
33.33
Total
100
66.67
33.33
Interpretation:
The above chart tells about the time consumed by the each machine and there after taking
the product for drying where in lots of time is wasted .And the company wont be able to
make the high production.
Values
Percentage
Yes
44.44
No
55.56
Total
100
66.67
33.33
Interpretation:
The above graph explains about the investment in money, space, and labour. according to survey
the investment in money ,space and labour is not the problem.
Percentage
Yes
66.67
No
33.33
Total
100
Graph no.8: Do you think the present layout creates more damages to product while
carrying for drying?
66.67
33.33
Interpretation:
The above picture tells about the damages occurred by the present layout of the company and
according to survey 66.67% of workers have said yes to it. So there should be change in the plant
layout at it will help the company to increases its sales, production, and there will be no damages
to the product and there is no need of labours also.
Cutting Machine
Drying
Transport
Printing Machine
Problems faced
Pasting Machine
Scrolling Machine
Slotting Machine
1. Damages.
2. Time consuming.
3. Huge investment required for
labour (more labour).
4. Wastage of floor area.
5. Low productivity.
6. Lower efficiency.
7. Higher cost of production.
8. More expenses on labour
(wages).
Punching Machine
Stitching Machine
1. Damages:
As the plant layout is in a straight i.e the process starts from one point
and ends at another point in this process the problem faced by the product which is
not finished product as it needs to be dry after the last stage of production and as the
exit point is where it started so to carry the product from the last machine to exist or
to carry them for drying purpose it gets damage.
2. Time consuming:
The process is straight line so to carry out the whole process and to
carry the products from one end to another end it consumed time which inturn is
waste of time which could be used for productive use.
5. Low productivity:
Any process where time consumption is more or is wasted or it is low
productive unit as it cannot produce more because it would invoved high
investment.
6. Low efficiency:
The efficiency turns out to be low as it cannot make bes use of raw
material available and the highly invested labours as the time consumption and
damages involved is high.
8. More wages:
Where the unit invests more labour its wages are high which addes to the
expenses which effects on cost of production.
Raw materials
Corrugation
Machine
Transport
Cutting Machine
Stitching Machine
Printing Machine
Punching Machine
Pasting Machine
Slotting Machine
Scrolling Machine
Less damages.
Reduces production time.
Less labour required.
Optimums utilization of floor.
Lower cost of production.
Less expenses of labour.
Note: - No capital (money) is required to change into this process because machines are
moveable.
1) Less damages:
As we suggest the plant layout in U shape i.e the process starts from one
point & end at same point due to this it consumes time & finished product does not
damage while taking to the drying .
2) Reduce time :
After the implementation of new plant layout the time taken is less as the
layout is in U shape it ends where it starts as entrance & exit are same & after last stage
it needs to be dried so it reduce carrying time.
Note: - No capital (money) is required to change into this process because machines are
moveable.
Limitations of study
As the project work has been confined to 1 month, the project work could not be taken up in
detail. However the necessary data required for the project has been collected to have
understanding of the problem.
FINDINGS
There is discipline followed in HARSHDRUV PRRO PACKAGING
by all
Conclusion
The project work has given me ample of scope in studying the practical aspects of business. I
thank everybody for helping me in conducting project on problem solving. Any size of the
organization can succeed in its business venture provided the organization works on the principle
of the business management.
Benefits of changing the process layout.
1.
2.
3.
4.
5.
6.
Less damages.
Reduces production time.
Less labour required.
Optimums utilization of floor.
Lower cost of production.
Less expenses of labour.
Mr. Bipinchandra Patel who has been a key factor in the success of Harshdruv Prro Packaging
has led Harshdruv Packaging.
Suggestions
The company can increase its labour strength to carry out the product for drying.
The company can form the machines in U shape as the machines are movable and form a
layout.
The company can increases their machines and form a new plant layout in empty space
left.
The company should get new 4 wheel cart to carry the product for drying and to place the
ready products in godown.
Annexures
Questionnaire
DATE: ____/____/_____
DESIGNATION:
DEPARTMENT:
( ) neutral
( ) Dissatisfied
( ) 6 months
( ) 1 year
( ) neutral
( ) Dissatisfied
( ) good
( ) fair
( ) neutral
( ) Dissatisfied
6. Time consuming?
( ) Yes
( ) No
( ) Yes
( ) No
8. Do you think the present layout creates more damages to product while carrying for
drying?
( ) Yes
( ) No
BIBLIOGRAPHY
www.google.co.in
www.harshdruv.com