`

GOVT.POLYTECHNIC
COLLEGE
PALAKKAD

2014-2017

INDUSTRIAL TRAINING REPORT

S5 MECHANICAL STUDENTS

DEPARTMENT OF MECHANICAL
ENGINEERING

ACKNOWLEDGMENT
We express our gratitude to all staff of our MECHANICAL
ENGINEERING DEPARTMENT. First we thank our Principal K N
SEEMA TEACHER, GPTC, PALAKKAD, for providing necessary
provisions & encouragement. We would like to thank our HOD
SIR for permitting us to undergo this industrial training at South
Indian metal Company Shornur who gave us the support and
advice to complete training successfully.
We would like to profound our sincere thanks and express our
gratitude to Sri

managing partner SOUTH INDIAN

METAL COMPANY Shornur for giving us an opportunity to practice

in the company under their management for One week in
connection with the industrial training program. We would like to
take this opportunity to express our sincere thanks to Sri.KM
PARAMESWARAN, office manager and Sri. JITHESH.T Maintenance
in charge and other persons for giving us helpful advice and
direction for completing program, inspire of their busy job
schedule and engagements.

DECLARATION
We are pursuing our DIPLOMA IN MECHANICAL ENGINEERING in
GOVT.POLYTECHNIC COLLEGE PALAKKAD hereby declare that
this is a record of in planned
Training conducted by us at
SOUTH INDIA METAL COMPANY (SIMCO) SHORNUR KERALA. The
study was under taken in partial fulfillment of the requirement for
the award of the Diploma in Mechanical Engineering under
Technical Education Kerala.
We further declare that this is not wholly submitted for
any other purpose and the date included in the report was
collected from various sources and are true to best of our
knowledge.

GROUPMEMBERS
AGHIL.T
ARAFATH M

YASAR

AJITH.C
M.L

LIGNESH

AMALCHANDRAN K.C
SUDHEESH K.S
ARUN.A

AJITH P.M

KISHOR K.R
MANESH K.P
PRAMOD T
SANDHEEP P.V
SHYAMKRISHNA P
SREEJITH P.R

CONTENTS

1. Introduction
2. Objectives of study
3. Location & Site
4. Company profile
5. Plant Lay out
6. Machine Lay out
7. Organization chart
8. Safety measures
9. Products list
10.
Photos of products
11.
Different products process & The Machine involved
12.
Flow diagrams
13.
Various departments
14.
Machines & its uses in various sections
15.
Swat analysis
16.
Conclusion

INTRODUCTION

The SOUTH INDIAN METAL COMPANY (SIMCO) was established in

the year 1936 under the ownership of Purayannur industries as a
private Company. Later a partnership firm as Purayannur
Industries purchased the company from Abdul Samed in the year
1947 and registered under the Indian Partnership Act in the same
year itself SIMCO properly known for its product brand name
LION hand its production and the sales from the year 1947.But
now it is a registered partnership firm with effects from 1947.
It is a manufacturing unit engaged in the
production of agricultural implements. Garden tools, Hand tools
etcThese products are made out of iron metal. The products of
this manufacturing firm are famous in inside and outside Kerala
because of its quality. The firm has got an award in the World
Agricultural fare in the year 1964.The agricultural products of this
firm is selected as the best one in the world agricultural fare
besides the firm has own the National Quality Award in the year
1984.T he firm got an award for one of its special product named
SECATEURS. This is used for gardening.

OBJECTIVES OF STUDY
The following are the objectives of study
1.
2.
3.
4.
5.
6.

To study the operational unit aspect of the unit.

To study the production process in the firm.
Identity the various tasks assigned by each department.
Examine the various functions of departments of the firm.
To study the Machine details and its Utilization.
Analyze the various problems faced by the firm

REASONS
COMPANY

FOR

SELECTING

THE

The main reason for selecting the company is, it is one among the
best agriculture implements manufactured industries in Kerala
and maintaining the quality in the products and they are ethical in
their manufacturing industry and to the customer

LOCATION AND SITE

SIMCO has 3 Acres of Land situated at kulappully, Two kilometers
away from Shornur town. Shornur is an important railway junction
in Kerala. There are a large number of branches of nationalized
and scheduled bank operating nearby Shornur. Most of the
dealings of this company are though Punjab National Bank
kulappully.

WORKING CAPITAL OF SIMCO

The Company invities deposits in the form of unsecured loans

from the partners for its day to day activities it also invities
deposits from outsiders their deposits are are used for meeting
the companys working capital requirement it also the banking
facilities such as over drafts.

COMPANY PROFILE
Registered Name

:- South Indian Metal Company

Registed office

:- Purayannur Industries
Shornur 679122

Established

:- 1947

Registered Number

:- 07P/09/7/88

Founder

:- PMC Namboodiripad

Managing Partners

:- P. Divakaran
P. Valsala

Office Manager

:- K M Parameswran

Maintenance Supervisor

:- T Jithesh

Bankers
Punjab
National
Bank,Kulappully
Thrissur
SBI Shornur
Palakkad Dist. Co-op Bank, Shornur 1
Canara Bank Kulappully Branch
Canara Bank, Shornur 1
Trade Name

:- SIMCO

Brand symbol

:- LION

Workers

:- 71

&

Website
Nature of ownership
Phone No

:- [email protected]
:- Partnership firm
:- 0466-2220408

HISTORY OF SOUTH INDIAN METAL

COMPANY
The SouthIndia Metal Company are Pioneers in the
manufacturing field of Agricultural and Horticultural implements,
Garden Tools and Hand tools
All equipments are manufactured under strict quality control
measures.We were conferred with the
NATIONAL QUALITY
AWARD in the year 1986.
South India metal company was established in 1936. The business
was taken over by sri. P.M.C Divakaran namboothiripad and his
brothers in march 1947. He was the managing partner till his
death on 18th January1999.
The company is one of the Pioneers in Manufacturing various
kinds of Agricultural implements, Garden tools and Estate tools
worked by hand. The company was able to successfully develop
many of the implements like digging forks which were imported
from Sheffield , Englend before independence. Thus it was able
to contribuite to import substitution and agrarian revolution in the
country after independence. Its SIMCO brandimplemends and
tools are well known for quality among Agriculturists, Estates and
handware dealers throughout South india.
The company has received various awards including a first prize
in the World Agricultural Fair at New Delhi in 1961 for secateurs

11

and

second

prize

in

the

Nationalquality.

13

WORKING TIME
Office Time

:- 8 AM to 12 NOON
1 PM to5 PM

Power forging section

:- 6AM to 6 PM
1 PM to 6 PM

Other workers

:- 8 AM to 12 NOON
1 PM to 5 PM

TOILET

PLANT LAYOUT

OFFICE

GO
DOWN GG G

RAIL
CUTTI

MACHINE SHOP
REST ROOMOM

CUTTIPOWER FORGING
NG

HAND FORGING

FUEL

GODOWN
FU
EL
ST
OR
E

WELDING

TEMPERING

RAW MATERIAL
STORE

GENERATO
R ROOM

GRINDING&POLISHING

GO DOWN

PAINTING

CUTLERY

PACKING SECTION

CARPENTRY

FINISHED GOODS
T
OI

OFFICE

15

RAI
L
ST
OC

MACHINE LAYOUT

RAIL CUTTING
PH

PCM

CUTTING STORE
F

HAND FORGING
F
F
HP

C
MACHIN
G
ESHOP
D

POWER FORGING
F
PH

F
F

FUEL
CUTTI
NG
(COAL
)

FUEL
STORE

F
WL

G
F

GRINDING

OQ
H

BP

PAINTING

PD
M

F
W

BPM
G

PACKAGING
RHN

POLISHING

DM
G

WELDING
WM

OQ

DM

PH

P
P

S
L

GC

OFFICE

CUTLERY
G

G
M

L-LATHE
OQ-OIL QUENCHING
HG-HAND GRINDER
WC-WATER COOLING
PDM-PEDESTAL DRILLING MACHINE
PB- POLISHING BELT
C-CUTTER
WL-WOODEN LATHE
BPM-BELT POLISHING MACHINE
GC-GAS CUTTING
GM-GENERATOR ROOM
PCM-PLASMA CUTTING MACHINE
PHR-POWER HACKSAW
CT-CUTTING MACHINE
HP HAND PRESS
WM WELDING MACHINE
G- GRINDER
DM-DRILLING MACHINE
S- SHAPER
RD- RADIAL DRILLING MACHINE

ORGANISATION CHART
PURAYANNUR INDUSTRIES

MANAGING PARTNER
17

TECHNICAL
MANAGER

RAW MATERIAL
PURCHASE &
STORES
DEPARTMENT

FOREMAN

CHARGE MAN

WORKERS

OFFICE MANAGER

PRODUCTION
&
MAINTANENCE

MAINTANENC
E IN CHARGE

WORKERS

FINISHED
GOODS
&SALES
DEPARTMEN
T

SALES
MANAGER

STORE
KEEPER

ACCOUNTIN
G & SALES
DEPARTME
NT

PURCHA
SE

*SALES CLERK
*WAGE CLERK
*DESPACH
*CLERK
*COMPUTER
OPERATOR

STORE
KEEPER

PURCHASE
MANAGER

STORE
ASSISTANT

PRODUCT LIST
SIMCO is providing variety of products under its brand name LION. They
are available at different types ,models and weightings.some of them are listed
below

1. Digging
2. KodaliFork
3. Mammatty Mysore Short Neck
4. Mammatty West cost pattern
5. Mammatty Nadan
6. Mammatty Irinjalakuda
7. Mammetty Half Size
8. Mammatty manappuram
9. Mammetty Swan Neck
10.
Neck
11.
Head
12.
Tanged
13.
weeding Hoe
14.
15.
16.
17.
18.
a
19.
Head
20.
21.
22.
23.
24.
25.
26.
spade
27.
28.
29.
30.
splitting
31.
32.
pattern

19

Mammetty Long
Mammetty Button
Mammatty
Halfmoon
Weeding Hoe
Potato Hoe
Trenching Hoe
Sledge Hammer
KottayamThoomb
Quintany Button
Pick Axe
Mattock
Garden Shear
Tin cutter
Mammatty Fork
Hand Fork
Alavangoe flat
Garden Rake
Secateurs
Kodali Tamilnadu
Wedges for wood
Felling Knife
Kodali Ceylon

33.
pattern
34.
35.
Spade
36.
37.
Knife

Kodali Malabar
Pruning knife
Alavangoe Spoon
Pruning Saw
Grass Cutting

SIMCO PRODUCTS

Mammattyhalf size

Mammatty swan neck

Mammatty button head

Quintany button head

21

Mammattynadan

Mammatty tirur/ponnani

Hand fork 3 forged prongs

MammattyIrinjalakkuda

Mammatty mysoore patten

Mammatty fork

Alavangoe

Digging fork

Kodali fork

Hand trowel

Pruning saw

Tin cutter

23

Grubbing mattock

Axe tamilnadu pattern

Potato shoe

Trenching hoe with handle.

Felling knife

Pick Axe

Splitting Axe

Axe Ceylon pattern

Sledge Hammer

25

DIFFERENT PROCESSES &THE MACHINES

INVOLVED
RAIL CUTTING
The first stage in the production process is rail cutting. Rail is
divided into three parts. Head, Flange, Center. Generally head is
used for making Hammers, center is used for making Fork,
Mammattyetc.Billets are used for make Sledge Hammers[big]and
other products which need high carbon content.
Things learned
There are three type of rails used,namely
1,90R
2,105R
3,120R
They are differentiated by the weight per metre that they
possess.
For 90R rails 1 metre carries roughly 44 kg
105 rails - 1 metre carries roughly 52 kg
120 kg

- 1 metre carries roughly 60 kg

It can also identified by the breadth of the flange which we found

to be quite difficult at first.

27

USES OF EACH CUTTINGS

CENTRE
1,Alavangoe[ both flat and spoon type of varying cross sections]
2,Felling knife
3,Hand fork 3 prongs forged
4, kodali fork
5,Trenching hoe
7,weeding rake3 prongs
8,Garden shear
9,Tin cutter
10,Pruning knife
11,D/F strap
12, mammatty [ half bend,half straight]
FLANGE
1,Mammatty[tirur,ponnani,swan neck,mysore,irinjalakkuda etc]
HEAD
1,Pick Axe
2,DiggingFork
3,Kodali
4,Splitting Axe
5,Grubbing mattock
6,Mammatty Fork

The weight of a mammatty using a flange piece of weight 1.8 kg

will be 1.4 kg which means a loss of 400 gms have taken place
during processes such as heating, hammering, shaping etc.
The weight of individual pieces can vary within arrange of +80 or
-80gms from the required weight[approx +5 or -5%]

COMPOSITION OF RAIL STEEL

Carbon content maximum of 0.82%
Manganese maximum of 1.7%

COMPOSITION OF HELICAL SPRING

Chrome vanadium / chrome molybdenum steel

MACHINES
1,Plasma cutting machine
2, Power hacksaw
3, Single stage double cylinder compressor

29

PLASMA CUTTING PROCESS

Plasma cutting is a process that cuts through electrically
conductive materials by means of an accelerated jet of hot
plasma. Typical materials cut by this process include steel,
aluminum, brass and copper though other conductive metals may
be cut as well. Plasma cutting is often used in fabrication and
welding shops, automotive repair and restoration, industrial
construction, salvage and scrapping operations. Due to the high
speed, precision cuts, combined with low cost of operation,
plasma cutting sees a widespread usage from large scale
industrial CNC applications down to small hobbyist shopsPlasma
cutting is the most common process used for cutting thick
stainless steel, Aluminum, Copper and host of other alloys of
steel. The cut quality is very sharp and most economical even for
ferrous materials such as mild steel. Plasma cutting process is fast
replacing the commonly used oxy fuel cutting for thicknesses in
the range of 0.5mm to 50mm thicknesses.
Plasma is fourth state of matter, others being solid, liquid and
gas. Plasma is ionized form of gas. Application of external energy
such as heat or electrical on gas leads to eviction of electrons
from the orbit creating free electrons and ions. This makes the
gas conductive .Plasma cutting machines make use of this Plasma
for cutting of steel and other metals.

Plasma Cutting Machine

Plasma Cutting is process

by which all types of conducting materials can be cut. This is an
economic commonly used process for steelcutting in the industry
today. Plasma arc is generated in a device called Plasma Torch.
Compressed air, Argon, Nitrogen , Argon + Hydrogen ( 65%+35%)
gas is used as plasma gas based on metals and quality
requirements. Pilot arc is generated in the torch which oozes out
of the nozzle and is thrown on to the job to be cut. Plasma arc is
established between the cathode in the torch and the job which is
anode through constricted hole in the nozzle. Plasma arc
temperature is quite high ( in the range of 11000 degree C to
300000 degree C). The metal under cutting melts instantaneously
and is thrown down by the kinetic energy of the Plasma arc.
Electrical capacity of the power source decides the max. Cutting
capacity.
Plasma cutting is the most common process used for cutting thick
stainless steel, Aluminum, Copper and host of other alloys of
steel. The cut quality is very sharp and most economical even for
ferrous materials such as mild steel. Plasma cutting process is fast

31

replacing the commonly used oxy fuel cutting for thicknesses in

the range of 0.5mm to 50mm thicknesses.

PRINCIPLE
When the gaseous state of a substance is heated

to high

temperature the gas will become ionized and hence conductive. A

plasma cutter uses this electrically conductive gas to transfer
energy from an external power supply material resulting in

clear and faster cutting process.

WORKING
Gases such as oxygen, nitrogen,Argon etc are forced through a
nozzle orifice inside a part called the plasma torch
When the electrical arc produced due to the externaql power
supply is introduced to this high pressured gas flow, it results in
the formation of plasma jet which easily reachestemperature upto
40,000 F , which will enable us to easily pierce through the molten
material.

Some

plasma cutters

have the

electrodes and

nozzles

in contact with

each

other, where

nozzle is

the cathode and

electrode is the

anode.

POWER HACKSAW

Power hacksaws are used to cut large

sizes (sections) of metals such as steel. Cutting diameters of more
than 10/15mm is very hard work with a normal hand held
hacksaw. Therefore power hacksaws have been developed to

33

carry out the difficult and time consuming work.The heavy arm
moves backwards and forwards, cutting on the backwards stroke.
The metal to be cut is held in a machine vice which is an integral
part of the base. Turning the handle tightens or loosens the vice.
The vice is very powerful and locks the metal in position.When
cutting is taking place, the metal and especially the blade heats
up quickly. Coolant should be fed onto the blade, cooling it down
and lubricating it as it cuts through the metal.Without the use of
coolant the blade will over heat and break/snap. This can be
dangerous as the blade can break with powerful force, shattering.
When the metal is placed and fixed in the vice, the blade is
lowered onto its top surface. The diagram below shows the arm
being lowered with the adjusting handle.Blades of power
hacksaws are graded according to the material they are made
from and the number of teeth per inch. Top quality blades are
manufactured from High Speed Steel. although there are cheaper
alternatives such as carbon steel blades In general the number of
teeth per inch (TPI) range from 14 to 24. The more teeth per inch
- the smoother the cut.

DOUBLE STAGE COMPRESSOR

During the downstroke of the piston of a two stage compressor,

air is drawn through an intake valve in the head of the
compressor into the low pressure cylinder and compressed during
the upstroke of the piston.
The compressed air is then released through a discharge valve in
the head of the compressor to an intercooler (usually finned
tubing) where the heat resulting from compression is allowed to
dissipate. The cooler compressed air is then drawn into a second
compression cylinder, the high pressure cylinder, for compression
to final pressure.From there the compressed air is released
through a discharge valve to an air receiver tank or directly to a
network of compressed air supply lines. In one revolution of the
crankshaft a compression cycle is completed.

35

POWER FORGING
It is known as rough forging. There are 8 hammers used in this
section. One Hammer is kept idle to use at the time of breakdown
of another Machine.
These
PowerHammers have horse power ranging from 10 to
25. When the charge man is informed of the required production
for the coming hours be issues an intent with a storekeeper for
semi finished goods. After heating rail up to red from furnace it is
passed to power hammer to give through shape of products.

PNEUMATIC POWER HAMMER

Pneumatic power hammers are mechanical hammers that use a

non- muscular power source to raise the hammer preparately to
striking and accelerate it onto the work being hammered. Also
called Open Die power Forging Hammers. They have been used
by blaksmiths, blade smiths, metal workers and manufacturers
since the late 1880s,having replaced trip hammers.
Atypical pneumatic power hammer consist of a frame, anvil and a
reciprocating ram holding hammer head or die. The work piece is
replaced on the lower anvil or die and the head or upper die

strikes the workpiece. The pneumatic power hammer is a direct

descendant of the trip hammer, differing in that the pneumatic
power hammer stores potential energy in an arrangement of
mechanical linkages and springs,in compressed air and by the
fact that it accelerates the ram on the downward stroke. This
provides more force than simply allowing the weight to fall.Earlier
designs like trim hammer, stream drop hammers, board or strap
hammers use the power source to raise the ram. But let its fall
be propelled solely by gravity.

37

HYDRAULIC PRESS
A hydraulic press is a device using a hydraulic cylinder to
generate a compressive force

The power press is a

powerful sheet metal machine. It is mainly used for cutting,
bending, pressing, forming and stamping sheet metal into
different shapes and sizes. This highly precise and versatile
machine deforms and cuts metal by pressing it between two
heavy pressure plates. The various types are classified as
mechanical, electrical, pneumatic and hydraulic; including the
pillar type and C type unit. They are readily available in different
specifications and have numerous features in order to fulfill the
diverse requirements of several industrial segments.They are
corrosion resistant, very silent and vibration free; and can be
continuously operated at a relatively faster speed to deliver

higher output. These are commonly used in a wide range of

industrial segments such as automobile, plastic, metal, rubber,
wood, textile, etc. The other applications include sheet metal
machining and engineering tasks, in light as well as heavy
industries

PASCALS LAW:-

Pressure on a confined fluid is transmitted

undiminished and acts with equal force on equal areas and at 90
degrees to the container wall...

WELDING
Any defects in the products like scratch, blowholes, linings
etc.these are finished by welding. It is the process of joining
similar metals with the application of heat or pressure.

HAND FORGING
The rough shape of the product is passed to hand forging section.
Products like garden shears head fork knife and secateurs need
not enter the power forging section. The semi finished goods are

39

GRINDING
The work is done through grinding machine. The machine has a
grinding wheel. The grinding machine is used for sharpening the
products.

PEDESTAL GRINDING MACHINE

Grinding is the process of removing material by the cutting action

of the countless hard and sharp abrasive particles of a revolving
grinding wheel as they come in contact with the surface to be
ground . Grinding machines are made in a variety of types and
sizes., depending upon the class of work for which they are to be
used. Pedestal grinders are used to sharpen high-speed steel
cutting tools used on the lathes and milling machines, deburr, or
used to remove surface imperfections and to work extremely hard
materials.

TEMPERING
The sharpened products are passed to the tempering section, oil
& water are used for tempering. Some products are tempered in
oil and some other in water.
Tempering is a process of heat treating, which is used to increase
the toughness of iron-based alloys. Tempering is usually
performed after hardening, to reduce some of the excess
hardness, and is done by heating the metal to some temperature
below the critical point for a certain period of time, then allowing
it to cool in still air. The exact temperature determines the
amount of hardness removed, and depends on both the specific
composition of the alloy and on the desired properties in the
finished product. For instance, very hard tools are often tempered
at low temperatures, while springs are tempered to much higher
temperatures.

ROCKWELL HARDNESS TESTING MACHINE

41

These Rockwell scale is a

hardness scale based on
indentation hardness of a
material. The Rockness test
determines the hardness by
measuring
the
depth
penetration of an indenter
under a large load compaired
to the penetration made by a
preload. The result is a
dimensionless number noted
as HRA,HRB,HRC,etc.. where
the
last
letter
is
the
respective
Rockwell
scale.This important relation
permits
economicall
important
nondestructive
testing
of
bulk
metal
deliveries with lightweight, even portable equipment.

POLISHING
Polishing is done for giving an attraction to the products. After
tempering the products, it moves to the section for job.

BELT GRINDER

A belt grinder is a grinder used in shaping and finishing wood and

other materials. It consist of an electric motor that turns a pair of
drums on which a continuous loop of sandpaper is mounted. Belt
grinders may be handled and moved over the material, or
stationary (fixed), where the material is moved to the sanding
belt.Stationary belt grinders are sometimes mounted on work
bench,in which case they are called bench grinders. Stationary
belt grinders are often combined with a disc grinder.
Belt grinders can have a very agressive action on wood and are
normally used only for the beginning stages of the sanding
process, or used to rapidly remove material. Sometimes they are
also used for removing paints or finishes from wood. Fitted with
fine grit sand paper, abelt grinder can be used to achive a
completely smooth surface.

43

HAND GRINDING MACHINE

These grinding machines are used to remove chips in the holes of
the products, and for finishing and polishing the holes, angles
etc

CARPENTRY
The main job of the carpentry works is making handles to the
product such as digging fork , mammatty fork. The company had
lathe machine to make handles speedly.

MACHINES USED IN CARPENTRY

DRILLING MACHINE

CARPENTERS LATHE

PAINTING
After fulfillment the carpentry works the products is sent to the
painting section.Paints are used in the the iron parts of the
products and varnish is used in the iron parts. Usually red and
black colour is used for painting.

PACKAGING
After painting the goods are sent to the finished goods store. All
products are packed in prescribed number of orders demanted.

45

DIFFERENT PRODUCTION FLOW

DIAGRAMS
FLOW DIAGRAMS FOR SLEDGE HAMMER
FOR SMALL SLEDGE HAMMER
RAW MATERIAL
RAIL YARD
FUEL
STORE

RAW MATERIAL CUTTING

AND SPLITTING

RAIL CUTTING STORE

LAM COCK
+AIR

HEATING &FORGING

VISUAL INSPECTION
HEATING
COAL+ AIR

GRINDING

TEMPERING

POLISHING

VARNISHING

PACKING

FINISHED GOODS STORE

TO BUYER

FOR BIG SLEDGE HAMMER

RAIL YARD

RAW MATERIALS CUTTING

AND SPLITING

FUEL STORE

RAIL CUTTING STORE

LAM COCK+AIR

HEATING& FORGING

VISUAL INSPECTION &SOUND

INSPECTION

WELDING

GRINDING

TEMPERING
BY
HEATING
COAL+AIR
OR OIL
FURNACE

POLISHING

HARDNESS TESTING MACHINE

PAINTING

PACKAGING OF FINISHED

47

TO BUYER

FOR PREPARATION OF MAMMATTIES

RAIL YARD (RAW
MATERIAL)
FUEL
STOR

RAIL CUTTING AND

RAIL CUTTING STORE

LAM
COKE
+AIR

HEATING AND ROUGH

HEATING AND FLATING

LAM COKE
+ AIR

INSPECTION
WELDING
HAND FORGING
CUTTING AND BENDING

LAM
COKE
+ AIR

WELDING
GRINDING

FINISHING,WEIGHING,AN
D STAMPING

PAINTING

PACKING

FINISHED GOODS STORE

TO BUYER

VARIOUS DEPARTMENTS
FUNCTIONAL DEPARTMENT
There are several departments in simco the working of company
states from the raw material purchase and stores department.The
production department converts the raw materials into finished
goods through various processes. The sales department makes
necessary arrangements for the distribution of finished goods.
Human resource department aimed at recruiting capable, flexible
and committer pupil,managing and recording their performance
and developing key competencies and so on. The accounting and
finance department consists of accounts, jerks, wage
jerks,dispatch jerks,computer operators etc. all there departments
together constitute the successful company.

PRODUCTION DEPARTMENT
Production is the process of converting raw materials into finished
goods. SIMCO produces more than 330 items.
1,Garden implements Mammatties, Thooba, etc
2,Garden tools Garden hand forks etc.
3,Horticultural implements- secateurs etc
The successful conversion process of raw materials into finished
goods is known as production. The head of the department is
known as production manager. The success and growth of every
organization depends upon planning and contact of production or

49

operations. SIMCO produces different agricultural implements,

estate tools and hand tools etc
SIMCO holds monopoly in production and sale of digging. The
works manager is the top of the production department and
controls the production smoothly and efficiently. There are
maintenance engineer with the maintenance work in SIMCO.

TECHNICAL MANAGER

FOREMAN

CHARGE MAN
(Power forging section)

WORKERS

CHARGE MAN
(power forging)

WORKERS

CHARGE MAN
(cutting of carpentry)

WORKERS

CHARGEMAN
(railcutting )

WORKERS

The entire department is divided into three sections. They are as

follows

1. Rail cutting section

2. Forging
3. Cutlery and carpentry

PRODUCTION AND PROCEDURE

1.Receiving metals
2.Preparation of intend of semi finished goods
3.Receiving the list production requirement
4.Preparation of finished receipt data
5.Preparation of outturn sheet

PURCHASE DEPARTMENT
The pearson in charge of purchase department is the purchase
manager. This department has two sections,purchasing section
and storing section.The important function of this department is
purchasing
the
required
quantity
ofraw
materials
,
storing,issuing,them as and when required to
ensure
uninterrupted flow of the same time reduce final stock of finished
goods. The purchase manager make purchase order only after he
receives the purchase requirement requisitions
The
important
purchase
of
raw
materials
such
as
iron,fuel,charcoal,coke,tire oils and spare parts machineries. The
raw materials such as second class rails had bought from the
suppliers who are participating the action held by railway.
Similarity other items are purchased from lignite corporation
throught authorized dealers, charcoal is purchased from open
market.

PURCHASING PROCEDURE
1.Inviting the quotation through tenders
2.comparing various quotatations and selecting the best
one.

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3.Receiving and purchasing order showing deatails of goods

through stores receipt note.
The order made through a purchase order form.

MATERIAL STORE
After receiving the material the store keeper stores it on proper
place .the store is situated near the plant in order to reduce
further loss of time and transportance. The store keeper has to
manage the stored materials and concerned negotiations sent by
the supplier when the material reaches the employer ,the checks
materials with purchase order. Then they are entered in general
store by store keeper. All the materials except rails and fuels are
stored in the raw material store. The rail which does not need
much care and they are kept inyards.The store value of material
is calculated by adding the tax,duties forward charges and will be
valued.

SALES DEPARTMENT
The sales manager with the help of sales clerk under taken the
sales activities on receiving orders from agents the sales product
delivers its price etc in a book known as delivery order book for
orders worth Rs 6000/- on more at time 20%discounts will be
allowed for all items it also provided credit sales at a limit rate .
Negotiations are made through the bank or directly generally
invoices of the company. It interest place the company makes
door to door delivery in case freight is paid by the company

MAINTENANCE DEPARTMENT
The maintenance action should be taken to prevent a device
component from falling to repair normal equipment degradation
experienced with the operation of the device to keep it in proper
working under maintenance section is a part of production. This
section helps to make the product smoothlyand effectively.

The main functions of this department are,

1. To provide spare parts to machine
2. To repair machine
3. To maintain the machine properly
4. Provide directions and instructions to handle the machines
and equipments properly
The departments keep two records namely
1. Mechanical maintenance record
2. Electrical maintenance record

MARKETING DEPARTMENT
Marketing is the management process responsible for identifying
satisfying consumerss requirements profitability. Sales manager
is in charge of this section . He keeps all the records and accounts
in connection with sales His functions includes formatting a
marketing plan implementing and evaluating the marketing plan.
Procedure planning product, diversificationstrategy and new
product planning and also the following importance functions.

PRICING
The most considerable factor of price is cost of production. The
company can only increased the price in accordance with the
agreement by All Kerala AgriculturalImplements Manufacturing
Associations[ in which all the major manufactures of agricultural
implements are members of association. All the members are
charges a uniform price. Taxes and duties will be charge extra
form their price.

ADVERTISEMENT
All companies in the industry are alive in the case of
advertisements strategies. SIMCO are giving advertisements in
dailies,magazines,etc.. They also have sigh boards, dealers and
directories. To know more about the company, SIMCO have its
own websites,
www.simcoindia.com
and the email id

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[email protected] from these SIMCOwill alone sell its

products other ads and efforts play little.

COMPETITION
The main competitors toSIMCOin the field are TATA,AGRICO, etc.
The manufactures belongs to Palakkad district are the members
of Agricultural Implement Manufactures Association.This avoids
price was it is done unilaterally.

DISTRIBUTION
Kerala ,Tamilnadu, Andra Pradesh,and Karnataka are the major
marketers for simco products.An efficient distribution network
formulated by the company ensures the right products are the
right place at the right time.

HUMAN RESOURCE DEPARTMENT

The main purpose of department is to establish and maintain the
sound personal relation at all levels of organization and effective
are of personal by ensuring good condition of employment. There
are 100 employees in the company. Among them 53 permanent
workers ,21 staff including 3 security staffs who works in the
company . Among them 53 permanent workers, 21 staff including
3 security staffs who works in two shifts.

LIST OF MACHINES AND ITS USE IN

VARIOUS SECTIONS
SECTIONS AND
MACHINE
Rail cutting section
a.Air plasma cutting machine
b.Power Hacksaw
Power hammering section
a. 250Kg pneumatic power
hammer(1)
b.200Kg pneumatic power
hammer(1)
c.100Kg pneumatic power
Hammer(2)
d.Furnaces(4)
Hand forging section
a.Spring hammer(3)
b.Hydraulic press(2)
c.Furnaces(4)

Tempering section
a.Oil furnace(1)
b.Furnace(1)
WORKERS

Grinding section
a.pedestal wheel grinder(4)
Polishing section
a. Belt polishing
machine
b. Pedestal puffing
machine
Welding section
a.welding machine

PURPOSE OF
MACHINES

NUMBER OF SHIFT

For rail splitting

For billet cutting

1 shift
1shift

For power forging pick axe ,big

sledge hammers other hand
forging item
For power hammering
(forging)mammatties
One for power forging small
sledge hammers another for
flattening the mammatties
For heating the work pieces

3 shift

For all hand forging works

except mammatties
For hand forging work of
mammatties
(Training and bending)
For heating the work pieces

3shift

3shift
3shift

3shift

3shift
3shift

For tempering big sledge

hammer
1shift
For tempering small sledge
STORE
hammer and mammatties.
KEEPER
For grinding all items(including
1 shift
cutlery)
For polishing big sledge
1shift
hammers
1shift
For polishing small sledge STORE
hammer
ASSISTANT
For welding the pipe handles
of mammatties repair welding
1shift
works and other fabrication

55

PURCHASE
MANAGER

works
Machine shop section
a.Lathe (light)
b.Shaper
c.Lathe(heavy)
d.Radial drilling
machine(2)
Carpentry section
a.wooden lathe(2)
b.circular saw
c.Drilling machine
(Flat belt)
Finished good sections
a. Rockwell hardness
testing machine

For turning , threading and facing

works of small work pieces
For machining of pallets dyes and
all other machine pieces
For turning, threading and facing
works of big work pieces

1shift

For drilling and boring works

1shift

For turning the wooden handle of

the product
For cutting and shaping the wood
pieces
Drilling works in the wooden
handle
It is used for checking hardness of
the product

1shift
1shift

1shift
1shift
1shift

SWOT ANALYSIS
*The company is having good market share.
*The company is having good percentage of skilled workers.
*The company has good products of variety.
*The sufficient availability of raw materials.
*Since the company comes under small scale industries , the
government is providing lot of help.
Especially via Tax benefits.
*All means of transport is available in this area.

WEAKNESS
*Lack of advertising.
*The company is not having sufficient fund for employees welfare.
*Latest technologies are not using.
*The company is having Acres of land , but they are not using it
completely.

WASTAGE
*The furnaces are not working continuously. They are turned off
one shift to another. High wastage of fuel is there.
*The grinding machines are not using properly.
*Some kind of machines are not working.
*Material handling is complicated.

OPPORTUNITIES
*The products of the company are high demand.

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*The products have good market in rural area.

FINDINGS
*Absenteeism is one main problem of the company.
*There is a good employee employer relationship in SIMCO.
*SIMCO had not faced strike for last 10 years. This clears the
efficiency of firm.
*scarcity of experienced workers is another problem.

SUGGESSTIONS
*Adopt necessary precautions to decrease the level
absenteeism of the firm provide good working conditions.

of

*Give necessary safety equipments to employees who are

working in more risky areas.

CHALLENGING FEATURES IN THIS FIELD

*The capital cost is high
*It needs large area which is free from homes and any kind of
other populated
area
*Working noise and vibrations are very harmful
*High risk of safety
*Workers are not satisfied in their wages
*New generation are not interested in this work because of high
risk and low
wages
*Material wastage is high
*Need good and confident employee employeer relationship
*Raw material cost is high

59

CONCLUSION
Inplant training at SIMCO has given firsthand experience
about various process parameters of agricultural
implements manufacturing,their measurement,
monitoring andcontrol.this inplant training helped us to
know various machines like power hammer,plasmacutting
machine etc.&their working principle.We also got an over
view about industrial management&also familiarized with
various techniques related to sales.

REFERENCE
1.INDUSTRIAL INSTRUMENTS :

S K SINGH

2.INDUSTRIAL MANAGEMENT AND SAFETY

WEBSITES
1.www.google.co.in
2.www.wikipedia.com
3.www.simcoindia.com
4.www.wikianswers.com

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