A PROJECT REPORT

ON
MANPOWER SKILLS AND FLEXIBILITY
MAPPING
AT

(FAG Bearings India Limited)

A REPORT SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT
OF MBA PROGRAM OF

M.S. PATEL INSTITUTE OF MANAGEMENT STUDIES

FACULTY OF MANAGEMENT STUDIES (FMS-BARODA)
THE MAHARAJA SAYAJIRAO UNIVERSITY OF BARODA
PREPARED BY:
DEEPESH J. GAVLI
MBA PROGRAM (2015-2017)
1

ORGANIZATION

Bearings India Limited

(Part of SCHAEFFLER GROUP)

UNDER THE GUIDANCE OF:

Mr. Gopalakrishnan Sathyanarayanan
Plant Manager-FAG Vadodara Plant

SUBMITTED BY:
Deepesh J. Gavli
M.B.A. Program (2015-2017)
Faculty of Management Studies, M.S.U. Baroda

DECLARATION

I, Deepesh J Gavli hereby declare that this report is prepared on the basis
of training taken at 'FAG Bearings India Ltd.' for the period of 09-05-2016
to 09-07-2016. I ensure about the authentication of the material and give
guarantee that there will not be any misuse of the data. Data used will only be
taken for the academic purpose and will not be used for commercial or any
other purpose. Views mentioned in the report are of my own, which are based
on my observation and it may or may not be accepted to the company.

Deepesh J. Gavli
Faculty of Management Studies
M.S. University of Baroda
Date: 14/07/2016
Place: Vadodara

ACKNOWLEDGEMENT
I sincerely thank Professor (Dr.) Jayrajsinh Jadeja (Dean, Faculty of Management
Studies, M.S. University, Baroda) and Prof. Smita Trivedi (Placement Co-ordinator,
Faculty of Management Studies, M.S.U, Baroda) for giving me this wonderful opportunity
of practical studies in the form of summer internship scheduled for 8 weeks.
My extended & sincere thanks to Mr. G. Sathyanarayanan (Plant Manager, FAG
Bearings India Ltd.) without his support and guidance this project would not have been
possible. Also sincere thanks to Mr. Rajesh Mandan (G.M. Plant & Operations, FAG
Bearings India Ltd.) for providing me this opportunity to undergo summer training at FAG.
I would like to thank all the segment heads, managers, employees and executives of the Plant
Productions who supported me and guided me during the period of my internship.
My most sincere thanks to everyone associated with MOVE department for their help and
cooperation in carrying out this project.
I would also like to thank Mr. J.P. Nair (Dy. Manager, Learning And Development, FAG
Bearings India Ltd.), for giving me opportunity to undergo the Summer Training at FAG
Bearings India Ltd., Vadodara.
Thank you all for making this internship a success and helping me to enrich my practical
knowledge about the real working of a company.
Deepesh J. Gavli

INDEX
SR. NO.

PARTICULARS

PAGE NO

DECLARATION

ACKNOWLEDGEMENT

INDEX

PREFACE

ABOUT FAG BEARINGS INDIA LTD.

FAG PLANT LAYOUT

ABOUT THE PROJECT

10

LIMITATIONS AND FURTHER SCOPE

12

MACHINE AND MAKE LIST

10

MATRICES FOR ALL PRODUCTION LINES

PREFACE
Internship is the one step of a MBA student's academic career. For a student of the
Department of MBA, industrial training is essential for the complete understanding of the
concepts learned from formal education. There remains a huge gap between academic
learning and the implementation of that theoretical knowledge in the practical world of
modern business and commerce. Internship can balance this wide gap as it brings
opportunities for a student to understand the main trends of business activities.
It is said "Knowledge is Power". But it is partly correct as "Applied Knowledge Is Power".
Hence, the opportunity to get the practical training in an organization has fulfilled the above
condition and has enabled me to learn how most of the theory concepts are implemented in
the organization. It helps to fill the gap between the classroom study and practical scenario.
In compiling this report I have intended to provide a combination of theoretical approaches
and methods of implementing them in the world of business. I have tried to learn the
relationship between theoretical and practical type of knowledge. During the entire course of
our academic study we remain busy in theoretical learning where the primary objective is
academic success.
With these objectives, I have made all possible efforts and the necessary study to submit this
project report in a progressive form in a very short time. I have tried my level best to
eliminate errors from the project report. As I had to complete my internship within a short
period of time so the study admits its limitations.
I have done my project in FAG Bearings India Limited, PO. Maneja, Vadodara, as a part of
the internship program starting from 09 May 2016 to 09 July 2016.
Sincerely,
(Deepesh J. Gavli)
MBA Student (Production & Operations)
M.S. Patel Institute of Management Studies
The Maharaja Sayajirao University of Baroda

About- FAG BEARINGS INDIA LIMITED:

FAG Bearings India Limited was incorporated in 1962. Since January 2002 FAG has been
integrated into a strong network because that is when FAG, together with INA and LuK
formed the Schaeffler Group. INA and FAG became the worlds second largest rolling
bearing manufacturers.
FAG Indias headquarter and manufacturing facilities are located in Vadodara, Gujarat, India.
Quality management at FAG India is a dynamic process that is operating on daily basis to
ensure that continuous improvements are made. The Indian plant is certified as per ISO 9001
and TS 16949. Active environmental protection is an integral part of all areas of their
business. They are convinced that positive environmental management helps to secure the
progress and success of their Company. The FAG India plant has been certified to ISO 14001.
FAG India has its presence in automotive and across all core industrial segments.
Indian automotive industry has rapidly progressed in the last decade. FAG India has been a
proud partner in this technical progress providing Indian industry with bearings of
contemporary technology and global quality standards. FAGs advanced system solutions for
wheels and engine accessories support the automotive industrys need for higher levels of
integration, increased safety, driving comfort and environment protection. No wonder, FAG is
No.1 supplier of hub bearings to the Indian Passenger Car Industry.
Since inception of FAG India, the Indian Railways has been an important customer and
FAG India is recognized as the most reliable source for critical applications viz.
Traction Motors, General Roller Bearings, Transmission, Auxiliary Motors, etc. Just on
track with the Indian Railways.
FAG India caters to all major industry segments including:
Construction Machinery, Electrical Engineering, Fluid Technology, Conveying
equipment, Industrial Gears, Mining & Cement, Power Generation, Agricultural
Engineering, Steel plants, Motorcycles, Textile Machinery, Machine tools, Wind power,
Pulp and Paper and so on.
Recent times have seen the Indian manufacturing industry metamorphose into a global force
to reckon with. FAG India has been an integral part of this industrial revolution providing
innovative bearing systems for a wide range of applications. Proximity to the customer and
intimate knowledge of individual requirements has enabled FAG India to provide innovative
solutions on time and within budgets.
FAG bearings from the Indian plant are exported to Europe, US and Asia. International
customers using FAG India products include: Daimler, Chrysler, Volvo, Volkswagen,
Renault, Otis and General Electric.

Home to five manufacturing halls, the plant area houses manufacturing & finishing facilities
for all the components of a bearings-inner rings & outer rings, rolling elements & cage as
well as the assembly of the bearing.
FAGs finance department report directly to Germany, works wonders on matters of crucial
improvements such as controlling costs, investing smartly, tax control & capitalizing on
techniques to ease working-capital pressures & debt collection.
FAG believes in employee focus & has to its credit a thoughtful HR Policy & a brilliant team
of HR Personnel who ensure that the employees are to be cared for and rewarded for their
dedication to the organization whether it is because of the high salary or because of the
numerous welfare schemes or because of the progressive performance appraisal system or
because of the strenuous training programs. FAG Indias employees are being happily
managed a lot.
Working with a transparent unambiguous co-operative management style that involves all the
employees in decision making FAG moves steady fast towards its vision which is strongly
characterized by the motto "Together We Move The World". Everything that moves with
the assistance of bearings & FAG serves as a reliable partner to every industry associated
with movement to achieve their mutually complementary goals.

ABOUT THE PROJECT:

The main objective of the project is to prepare skills matrix for the operators working on the
production lines. The project involves mapping of the operators against the workstations or
the machines and their competency in each workstation as per the defined criteria for skill
mapping. The flexibility indices are also developed which enables to identify the operational
as well as the set up flexibility of an operator in a particular production line and also other
production lines within the segment and other segments.
The purpose of preparing such a skill matrix format is to visually recognise varying levels of
ability in a structured way. It can also help the management to develop focused training plans
to maximise flexibility and to enhance the development of every individual.
What is a skills matrix?

It is an integral part of our Visual Management System (VMS)

It is a simple visual tool to aid in the management, control & monitoring of skill

levels.
It displays all tasks & skills required to work in an area or team.
It displays all current team members.
For each team member it displays current competency/ability levels for each task.
It is a simple tool to aid resource planning.

How do we quantify the skill levels?

Level
0

2
3

Description
Cannot do

Criteria
Symbol
Insufficient knowledge or
experience to perform to
standard.
Learner-Able to operate with Has
fully
reviewed
directions.
instructions and is familiar
with the tools of the job.
Practitioner-Able
without directions.

to

operate Can perform activity as per

standard job requirement.

Proficient- Able to set as well as

operate
and
solve
minor
problems.
Expert- Able to set, operate,
maintain and train others.

Can set up and perform

abnormality judgement during
operations.
Can
provide
operational
guidance in respective job to
others and do problem
solving.
10

What is a skills matrix used for?

It highlights training needs for our most important resource.our employees.

To monitor & control training effectiveness.
To increase flexibility by allowing people to master a broad range of skills.
To drive improvements as part of a Visual Management System (VMS).
To increase the effectiveness of an area and the entire business.

Flexibility mapping:
Along with a skills matrix, flexibility index is also incorporated in the same format
which enables to identify the operational and set up flexibilities of every workstation
and every operator.
In operational flexibility mapping a minimum level of 2 is taken into consideration
whereas in set up flexibility mapping a minimum level of 3 is taken into
consideration.
Workstations or machines with their machine type or make are identified and
frequency of similar machines within the segment and outside the given segment is
also indicated in the format prepared for particular production line.

11

LIMITATIONS AND FURTHER SCOPE:

Time is the most important constraint in carrying out this project.

The busy schedule of operators and supervisors is also a limitation.
More accurate and efficient skill matrix can be developed by taking time method
study into consideration.

12

SEGMENT 02
CRB 170

13

SEGMENT 04
DGBB62

14

SEGMENT 05
DGBB140

15

SEGMENT 06
WHEEL BEARING

16

SEGMENT 08
SRB/CRB-320

17

FACE AND OD

18

HEAT TREATMENT

19