AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM1.1 INTRODUCTION An organization is an entity where two or more persons work together to achieve a goal or a common purpose. If there is an organization, then there must be some people who work as a whole for a common purpose, so there must be defined purpose. If an organization does not have any purpose, it will not survive in the long run. To achieve the purpose by using people, the processes are needed. Organization is a group of people working together for achieving a common objective which is already defined by the organization. To run the organization properly without any wastage of resources a proper structure and hierarchy is to be properly defined in an organization. The organizational study was conducted at RUBCO Rubberized Coir Mattress Division, Poothukuzhi, Kottayam. It started its operation in 2001 November. The project realized with an investment of Rs.280 Millions. The manufacturing plant is among very few in the country to employ advanced Austrian Machinery, sourced from DOA, Austria. Rubber is a polymer consisting of Hydrogen and carbon and is elastic in nature. It is found in the fluid of some specific plants but it can also be produced synthetically. Naturally, rubber is produced by the process of tapping of the plant called Hevea Brasiliensis. Around 3/4th of the national rubber is produced in Kerala. So rubber has become the backbone of our economy. Due to the bad impact of globalization the overall market of rubber fell down in Kerala, that time instability in price of rubber was one of the major problem that farmers faced in the market. The farmers were not getting fair price for their effort, but this problem has come to an end since 1997, because the Kerala state rubber co-operative limited came into existence in this year for the purpose of exporting the infinite possibilities of rubber. It literally means that Kerala state rubber cultivator. RUBCO is incepted with prime objective of effectively utilizing the abundant rubber resources of Kerala. In a short span, RUBCO has successfully introduced a wide range of fast moving rubber based product. Today the RUBCO group is manufacturing rubber footwear, casual shoes, cycle tyre and tubes, two and three wheeler tyre, rubberized coir mattress process and rubber wood based furniture, block rubber (ISNR) and pale latex crepe, apart from natural rubber trading. 1 AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM 1.2 OBJECTIVES O THE STUDY To have an understanding of the profile of RUBCO Mattress division and its various activities. To acquire the knowledge regarding the functional as well as the managerial aspects of the company. To find out the problem and to put forward some suggestions. To get an idea about the organizations various departments. To familiarize with the various activities of the company. To get feel of actual working environment and to get the acquainted with it. Learn and enrich by observations and by implementation of my knowledge. To learn and maintain good relationship with the organization. 2 AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM 1.3 SCOPE OF THE STUDY This study is about the major functioning of the RUBCO Rubberized coir mattress division, Pampady. This study mainly based on the details collected from each department. Each and every activity of the department functions are studied carefully with the available data. This study is beneficial to the future mangers as they are put into real life situation. A study on allthe department can help to improve the process and there by overall improvements in the companies performance can be made. 1.4 LIMITATION OF THE STUDY The main limitations of this study are, Time limit: To understand an organization and its working the period of one month is not at all enough. So that time was the most important limiting factor in the study. Lack of data: Some of the data are treated as confidential hence the researcher could not get the details of the same. Lack of comparative data: The details of other companies related to the same business was not available to take comparative study 1.5 REASONS FOR SELECTING THE COMPANY For select this company because they are engaged in active performance in production service and marketing. The prime consideration is the study is its tremendous growth during the past few years. The major departments are Finance, marketing, Purchase, Production and planning, Maintenance, Quality control, human resource and Exports. 3 Primary Data: It refers to the first hand information which is original in character that an investigator himself collected from the respondent. Department manuals. 4 . Personal visit to plant. KOTTAYAM 1. structures. Official records. Secondary Data: The secondary data are those which have already being collected by some one else. the search for knowledge objective and systematic methods of finding solution to a problem in research”.”In short. measurement and analysis of the data. RESEACH DESIGN “A research design is the arrangement of condition for condition and analysis of data in a manner that aims to combine relevance to the research purpose with economy in procedure”.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . In fact research is an art of scientific investigation. Office manuals. the research design is the conceptual structure within which research is conducted. In fact. The advanced learner‟s dictionary of current English lays down the meaning of research as a care full investigation or inquiry especially through search for new fact in any branch of knowledge. One can also define research as a scientific and systematic search for pertinent information on a specific topic. The main source of secondary data collection is Data collected from published records and unpublished sources. A research design constitutes the blueprint of the collection. so which have already passed through the statistical process.Primary data required for the study where generated from individuals.6 RESEARCH METHODOLOGY Research in common parlance refers to search for knowledge. questionnaire and also from the discussion made with people Having formal and informal interview and discussion with managers and official staffs. AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . INDUSTRY PROFILE 5 . KOTTAYAM 2. The cotton mattress industry has a market share of 50%. through issue of government circular. health. Slowly many state Government recognized rubberized coir as “ Wealth from Waste” and advocated the use of rubberized coir mattress in various activities such as hospitals. It was in 1964 M/S bharat Motors of Chennai established its manufacturing unit. Jute fiber. Government of India recognized Rubberized coir mattress as a healthy and hygienic product. and Sunidra. As the production increased from100 cars per day to 300. This segment having more than 50% of the market share in the mattress industry. were using the horse hair as cushion filling material for their car seats. Prior to the year 1960 people hardly had any idea of this novel and high quality of product. This is priced very low. The major players of the industry are Kurlon. Of various alternatives tried like Sisal fiber. KOTTAYAM 2. In those days the world famous car manufacturer M/S Volks wagon of Germany. This was the beginning of the rubberized coir industry. The birth of rubberized coir industry is quite amusing and interesting. After nearly one decades of its introduction. This necessitated a suitable alternative products for rubberization and which could suite to their specifications. clinic etc. Other type of Mattress Cotton mattress Form mattress Spring mattress Cotton mattress: Cotton mattress mainly targets lower income groups. the coir fiber was decidedly found to be the best. Duroflex. It is nearly four decades old.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . They have more than 45 odd brands and over 200 different models.1 INDUSTRY PROFILE Rubberized coir mattress segment is a high competitive. Form mattress 6 . there was a depth of raw material. in the next 3 decades over one hundred manufacturers have entered rubberized coir field. Over the last decade. during early 60s this product got some market recognition in early 70s. KOTTAYAM Form mattress segment comes as next place after rubberized coir mattress industry. electronics etc). The major players are MM form. the brown coir sector has registered a tremendous growth. WORLD SCENARIO There are three major players in the mattress industry and are as follows. 2. sleepweell. Major players are Spring well. Simmons Bedding Company 7 . king koil has over a century of experience crafting high quality. sealy. King koil Founded in 1988. theaters and auditoriums. This industry have market share of 9 to 10% this industry mainly targets customers belonging upper income and upper middle income group.2. sealy. Texas. Spring mattress This industry targets consumers belonging to the upper income group. Today rubberized coir products are increasingly used in many industries notably in transport industry like railways and buses. hospitals.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Kurl-on. Sealy corporation: It is the major manufacturer and it got the name from the place it started. The basic raw material for Rubberized Coir industry is the brown coir fiber and the natural latex rubber. affordable bedding both the united states and through out the world. heavy engineering. Growth During Last 4 Decades From a handful manufacturers. packaging industry (pharmaceuticals. The main players are DUROFLEX DUROFLEX is the leading mattress manufacturer in India which started its operation in 1963.STATE SCENARIO In India. the coir industry has developed very well especially in Kerala where they produce „Retted Fiber‟.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Centuary is the first mattress manufacturer with ISO 9001-2000 series and ISI certification. The major players are. 2. CENTUARY MATTRESS: Centuary Fiber Plates private ltd started its rubberized coir plant at Hydrabad in 1988 under the brand name “CENTUARY”. KURL-ON LTD: Kurl-on ltd. KOTTAYAM Simmons bedding company is a major manufacturer of mattress and is one of the oldest companies in the united States.3 INDIAN SCENARIO The rubberized coir mattress market of India is estimated to be highly fragmented with little brand loyalty. It is the largest exporter of sleep and comfort products from INDIA. 2. Green husks of coconut are immersed in the salty backwaters for 10 to 1 months. DUROFLEX Duroflex is the largest exporter of sleep and comfort product from India.4 . started its operation in 1963. a Manipal group Company came into existence in 1962. 8 . for over125 years. Kurl-on Ltd is the brand leader in the mattress industry has acquired major market share in the branded mattress segment. rubberized coir and erosion control blankets are predominantly produced in larger facilities. or dust. brushes. There output is either purchased or direct export or undergoes manufacturing for twine. At the beginning of the value chain are approximately 300 fibers millers with usually less than 10 employees and an estimated 500 suppliers of coir pith. Now. which are technically more demanding or better suited for mass production. Kerala state is promoted by the government of Kerala to promote rubber industries in the part of our country.is a park of Kerala‟s renowned business conglomerate the Eastern Group of companies. KOTTAYAM EASTERN SUNIDRA Eastern mattress Pvt Ltd. rubberized coir mattress industry the competition is more and more. mats and brushes rubberized coir mattress and pots. the demand for the product is in growth stage. Its prime objective is to effectively utilizing the abundant rubber resources in Kerala. 9 . So the only the quality mattress industry can survive in the competitive World. reflecting the broad range of r aw materials and value added products involved. v. employing more persons. Future Of The Industry now in rubberized coir mattress industry the competition is more and more the demand of the product is in the growth stage. In the industry provides at least part time employment to an estimated 40000 persons. Product. RUBCO Kerala State Rubber Co-operative Ltd(RUBCO) was set up in the year 1997. geo textile and pith products. RUBCO GROUP Kerala state rubber co-operated ltd(RUBCO) situated in Kannore.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . such as high end twine. So only the quality mattress industry can survive in the competitive world. The Indian coir industry has a diversified structure. KOTTAYAM Today India enjoys 4 the position in the production of natural rubbers(NR) and the small state of Kerala contributes 92% of it‟s so it has become the backbone of our economy. 10 . (RUBCO) came into existence and here started a series of possibilities for the utilization of rubber in multifarious sphere and fields. Since its inspection in 1997. It has entered into various Rubber based industries. But this problem came into an end since 1997 as the Kerala state rubber cooperative ltd.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Due to the bad impact of globalization the overall market of rubber fills in Kerala and the instability in price of rubber was one of the major problems that the rubber farmers faced. The farmers were not getting fair price for their effort. RUBCO has travelled a long way. AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY .COMPANY PROFILE 11 . KOTTAYAM 3. Among the total production.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . The farmers were not getting fair price for their effort. Casual shoes etc. is situated in Kannur. Kerala State Rubber co-operative Ltd(RUBCO). India is promoted by the provisional Government of Kerala to promote Rubber based industries in this part of our country. Block rubber(SMR). redefined the way the co-operative movement in Kerala. Due to the bad impact of globalization the overall market of the rubber fell down in Kerala that time instability in price of rubber is one of the major problem that the farmers facing in the market. RUBCO has in short span. So the rubber has become the backbone of our economy. conventional and procured tread rubber. small state of Kerala contributes 92%. Since its inception in 1997. RUBCO adopts the best ad latest process in the production. ABOUT RUBCO Kerala State rubber co-operative Ltd(RUBCO) was set up in the year 1997. It has entered into various rubber and rubber wood based industries like Hawaii chappal with reputed Malaysian technology. for at least over 16 decade with a vision to become a Global leader in the production of natural Rubber and innovative product development. Pale Latex crepe. But their problem came into existence. Rubberized coir mattress. cycle tyres and tubes. KOTTAYAM 3. Today from a single unit company „RUBCO‟ has grown into Rs. with the objective of effectively utilizing the abundant rubber resources in Kerala. RUBCO has travelled long. In their slogan it self they had mention that “RUBCO means RUBBER and RUBBER means RUBCO” 12 .1. Today India enjoys 4th position in the production of Natural Rubber(NR) in the world. 280 crores conglomerate with well diversified operations and a market presence extending beyond boundaries of Kerala. Kerala state. In this year on the purpose of exploring the infinite possibilities of rubber. MISSION To develop brand equity and to ensure professional co-operative image through a systematic working procedure. RUBCO group has involved in a wide range of business such as. New projects for Coconut Based Products Virgin coconut oil Activated carbon Coconut spray dried milk powder Packed tender coconut water Coconut water concentrate Plant for casual/ sports shoe on progress Unit for automotive rubber components to be established RUBCO is in the process of setting up a project for the manufacture of tyres and tubes for two/ three wheelers. passenger cars. The project will be located in the proposed industrial growth center being 13 . heavy duty trucks and light commercial vehicles. Foot wear Furniture Cycle tyre and Tube Rubberized coir mattress Natural Rubber Virgin coconut oil PROJECTS IN PIPE LINE RUBCO Hawaii chappal unit introduced three models.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . KOTTAYAM VISION To ensure brand leadership in all manufactured and marketed. (RUBCO) has in short span. RUBCO was set up in the year 1997 with the objective of effectively utilizing the abundant rubber resources in Kerala. RUBCO is also a Government intervention agency towards market stabilization and has been serving the farming community directly and indirectly to get reasonable price. Maximize the capacity of utilization of the existing. sourcing from them State-of-art technology. Rubco is a major supplier of natural rubber to all leading tyre companies in India. To increase the profitability of the company and to maximize generation of surplus to enable RUBCO to finance its diversification projects. RUBCO is the largest exporter of Natural Rubber in the country today. Even in the domestic market. KOTTAYAM Organizatioanl Goals and Objectives Goal: The organizational goal of RUBCO-RCM Division is to make RUBCO a leader in the market of Rubberized coir mattress. To introduce new varieties of mattress as to increase the wide range of mattress catering to diverse segments of the market. have been RUBCO‟s products earn a reputation for quality and significant market shares.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . redefined the way the co-operative sector functions and set the pace for the co-operative movement in Kerala today. Substantial investments in modern manufacturing facilities. Natural rubber trading has being a blend of social obligation and commercial practicability led by a professional management team and ably 14 . RUBCO has also entered into technical alliances with the world leader in the respective field. To maintain and improve the existing cordial relationship between employees and the management. Objectives. HISTORY OF THE ORGANIATION Kerala State Rubber co-operative Ltd. arresting drastic fall in price during the peak production periods. coupled with well Organized market activities. Ro maximize cost reduction. To execute production on time in accordance with the market demand of the product and make available them to the distributors. To ensure strict quality control and ISI standards of products complete in the global market. RUB WOOD.Ltd The furniture manufacturing plant has a processing capacity of 40000 Metric tones per year. Japan and many other countries across the globe. with served new interactive that will take the group on a path of diversification and expansion. RUBCO Sales Inernational Ltd RUBCO sales international(RSIL) is a public limited company promoted by RUBCO to spearhead the sales and the marketing activities for RUBCO‟s entire range of product in the domestic and international market. comprises of dining tables and chairs. RUBCO Rainbow and RUBCO classic RUBCO Cycle Tyre & Tube Division The plant has an annual installed capacity of 3 Million tyre and tube.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . designer Wardrobes. RUBCO Huat Wood Pvt. Rubber holds immense potential for a wide variety of commercial uses which is yet to be fully Other Divisions Of RUBCO RUBCO Footwear Division RUBCO‟s footwear division manufactures a range of quality casual rubber footwear. RUBCO is in the process of expanding the scope of operations of this unit in line with market trends. USA. RUBCO Sreekandapuram Latex Pvt Ltd The company manufactures Block rubber (ISNR) and pale Latex Crepe(PLC). The plant manufactured under the renowned Malasian technology RUBCO‟s footwear range presently comprises of three leading brands RUBCO Hawaii. 15 . The product are being exported to UK. KOTTAYAM supported by a committed work force. RUBCO‟s range of cycle tyres & tubes has advanced features such as high non skid depth improved wet-skid resistance and traction property and more mileage and puncture resistence. RUBCO is now poisoned to enter a high growth phase. the furniture range. futons kitchen cabinets and computer and office furniture and is available in the choice of designs and finish. Jacob D Mathew 16 . Chandran Sri.Sadhasivan Sri. V. koman Nambiar Sri. CHAIRMAN: Mr. KOTTAYAM Administration and Management of RUBCO The administration and management of RUBCO vests in the Board of Directors consisting of fifteen members as follows. V. V Azeez Sri. MD: Mr.P. Narayanan He is a veteran co-operator and is holding various positions as chairman in central and state level co-operative organization. George Mathew Sri.N Vasavan Sri. E. Nine directors are elected by „n‟ class shareholders from among themselves.N.Gopi Sri. Jacob D Mathew He has more than 25 years of experience as CEO in corporate sector. S. K. Sri.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY .Manoharan Sri. K.S. M.V. Two directors elected by „B‟ class shareholders from among themselves. Other directors. Paneeri Mukhundhan Sri. AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . KOTTAYAM 4.ORGANIZATION STRUCTURE 17 . 18 . and to furnish decision making and communication networks reflecting and supporting enterprise objectives. An organization structure should be designed to clarify who is to do what tasks and who is responsible for what results.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . KOTTAYAM ORGANIZATION STRUCTURE Organization structure is the structure of the relationship among positions and the jobs created for the purpose of accomplishing the objectives of the enterprise. The organization chart shows the line of responsibility between the various departments of the company. It represents the pattern of the relationships among the components of an organization. to remove obstacles of performance caused by confusion and uncertainty of assignment. The company‟s organizational structure is diagrammatically represented by an organization chart (a diagram representative of the hierarchy of an organization‟s personnel). They are: The form of the structure The functions to be performed The human aspects This pattern of relationship governs duties and activities of persons who are depend upon each other for accomplishing the objectives of the enterprise. AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . KOTTAYAM ORGANIZATION STRUCTURE GM Quality control &Assur ance officer Administ rative cum personel officer Account Officer Purchaase Officer Mechanical Maintenance Engineer Electrical Maintenance Engineer Productio n Manager Custo mer Care Assistant Electrical Supervisor Steno Qualit y Super visor Mechanical Supervisor Accou ntant Store Keeper Sales& Shipping Officer Work Shop Technician Security Electrician Junior Clerk Shift In-Charge Production Planning Officer Supervisor Workers 19 . AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . KOTTAYAM 5.PRODUCT PROFILE 20 . 21 .AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . The range consist of Heaven A premium model that provides unmatched sleeping comfort is available in 3 inch and 4 inch thickness. Also available in customized dimensions and thickness for large quantities. PRODUCT PROFILE OF RUBCO RCM DIVISION Rubco manufacturers a wide range of mattress catering to diverse segment of the market. Heaven Plus A luxury model that is elegant as well as comfortable which is 5 inch thickness. Hitech A hitech model with an accent of finish and luxury available in 5 inch thickness. KOTTAYAM PRODUCT PROFILE I. AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Dosth Plus Safal 22 . Dosth An economy model that offers true value for money is available in 2 inch and 3 inches. KOTTAYAM Hitech Pillow Superior quality mattress finished to world class standard is available in 7 inch thickness. hospitals.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . 9. etc. Heal This quality product is suitable for uses in the hospital. tourist resort. Yathri combines superior sleeping comfort with perfect back support enabling a relaxed healthy sleep layer of rubberized coir and latex enhance the comfort which soft and elegant quilting adds a luxurious feel for use in hospitals is available in 3 and 4 inches thickness. It is available in 3 inch and 4 inches thicknes Yathri An elegant mattress mean for hotels. Dreams 50:50 23 . KOTTAYAM A regular mattress that combines comfort and durability is available in 3 inch and 4 inches.30 pm It is economy model available in 3 inch and 4 inch thickness. Renova . KOTTAYAM Relif Relif Matterss is other product it‟s thickness 4 inch and density 3. Product Category: Rubco Sleeping System Thickness: 6” Material: Rubberized Coir Blocks Density: 3.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY .10mm 13 density PU Foam pasted at the bottom side 24 . 90 kg/m2.5” 90 Kg/M3 Upholstery: 100 Density 1” Rebonded PU foam sheet pasted on the bare block.5 inch. KOTTAYAM Traveler Traveller matters is 51 mm thickness material: Ruberized coir material Density: 60 kg/m2 Upholstery : 5mm 9 density p u foam pasted both sides.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Cushions Mats Eco soft pillow Pillow cover Rexin Pillow Soft Touch Pillow 25 . Other product from factory. Cotton cloth pasted over border side. AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . KOTTAYAM 6.GENERAL MANAGEMENT PRACTICES 26 . KOTTAYAM A. WORK SCHEDULE FOR BAG ORDER. WORK ORDER NO. Q UALITY. PRODUCTION PLANNING AS PER THE REQUIREMENT (DEMAND). ITEM. THE PLANNING PROCESS 1. LABOUR PLANNING I NCENTIVES ACCOMMODATION TRANSPORTATION F OOD PROVIDENT FUND MEDICAL I NSURANCE HEALTH INSPECTION . FINANCIAL PLANNING CAPITAL INVESTMENT BY BOARD OF DIRECTORS LOAN FROM BANK I NITIAL WORKING CAPITAL FOR RAW MATERIALS . 2. MAINLY MENTIONED THE FOLLOWING DETAILS . COMPLETION DATE . LABOR SALARY & OTHER EXPENSES LIKE ELECTRICITY . 27 . MATERIAL SCHEDULING BY INCREASING THE SIZE OF THE RING USED IN THE LOOM . SERIAL NO.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . DISPATCH DATE . (P ERIODICALLY ) 3. PLANNING OF PURCHASING RAW MATERIALS FOR THE MONTH JULY WILL BE TAKEN ON J UNE. o T OTAL MATERIAL USED FOR PRODUCTION. TAPE PLANT o RAW MATERIALS USED PER DAY. o WASTAGE HAPPENS IN PRODUCTION. AND ALSO DISCUSS THE VARIATIONS IN THE RATE OF THE MATERIALS PURCHASING. DURING NIGHT HOURS ) o AND IF ANY MAINTENANCE IS ORIGINATED. F. DECISION-MAKING PROCESS DECISIONS TAKEN BY BOARD OF DIRECTORS . C .G. ORGANIASATION MANUAL A well equipped advanced manufacturing technology under one roof controlled by ERP system throughout all departments.INFORMATION SYSTEMS RAW MAINLY INFORMATION GETTING THROUGH TENDERS & E -MAIL. GENERAL STRATEGIES OBEY ALL INSTRUCTIONS OF ORGANIZATION D UTIES & RESPONSIBILITIES . TAKING ORDER THROUGH E-MAIL. o I NTER COMMUNICATION . D. KOTTAYAM B. THAT SHOULD ALSO INFORM IMMEDIATELY . o PUNCHING SYSTEM o REPORTING THE TOP MANAGEMENT AT ANY EMERGENCY CIRCUMSTANCES .AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . 28 . VARIATIONS IN RAW MATERIAL PRICES SHOULD PASSED THROUGH EMAIL . (E. (EACH SECTION WISE ) E. o DIRECT COMMUNICATION. CONTROL SYSTEM o SECURITY o CCTV (CLOSED CIRCUIT TV) G. o LETTER o I NFORMATION REGISTERS . COMMUNICATION SYSTEM o GROUP MOBILE SYSTEM . MAINLY DECISIONS TAKEN FOR RAW MATERIALS PURCHASING. ENSURE THAT PROPER ACCOUNTING PRACTICES ARE FOLLOWED. MAINTAIN SALARY RECORDS. ENSURE THAT ALL PURCHASES ARE DONE ON TIME AND ECONOMICALLY . 3. EMPLOYEE ‟S WELFARE AND SAFETY IS ENSURED. ENSURE THAT ALL TAXES ARE PAID ON TIME AND AS PER LAW . ORGANIZE BOARD MEETINGS . ENSURE THAT PROPER LIAISON WITH VARIOUS CLIENTS AND GOVERNMENT AUTHORITIES ARE DONE AS REQUIRED BY CONCERNED MANAGERS . MANAGE CANTEEN ACTIVITIES AND LABOR ACCOMMODATION. SENIOR MANAGER CO-ORDINATION WITH ALL THE MANAGERS AND MD/DIRECTORS . ENSURE THAT PROPER RECORDS ARE MAINTAINED REGARDING EMPLOYEE WELFARE .AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . ENSURE THAT ALL DELIVERIES ARE DONE AS PER CLIENT REQUIREMENT AND AS PER SCHEDULE . 2. ENSURE THAT QUALITY OF MATERIALS AS PER PURCHASE ORDER . ENSURE THE COLLECTION ESPECIALLY FROM THE CORPORATE ORDERS . I N-CHARGE OF COMPANY SECURITY. LIAISE WITH LOCAL AUTHORITIES AND POLITICAL PARTIES. ENSURE THAT PRODUCTION TARGETS ARE MET . FINANCE MANAGER S UPERVISE ALL ACCOUNTS FUNCTIONS . KOTTAYAM H. HUMAN RESOURCE MANAGER MANAGE ALL MAN POWER RELATED ACTIVITIES . F OLLOW UP ON PAYMENTS FROM CLIENTS . LIAISE WITH AUDITORS AND BANK. PREPARE MONTHLY PRODUCTION PLANNING AND TARGETS. DUTIES & RESPONSIBLITES OF THE TOP MANAGEMENT: 1. PROPER SALES TAX AND EXCISE DUTY RECORDS SHALL BE MAINTAINED . 29 . UPDATE THE COSTING OF PRODUCT AND INFORM THE CONCERNED IMMEDIATELY . ENSURE THAT ALL FUNCTIONS OF BRMSCO ARE PROGRESSED AS PLANNED AND AS REQUIRED BY THE DIRECTORS . MARKET THE PRODUCT AND OBTAIN SALES ORDERS. F OLLOW UP WITH CLIENTS FOR PAYMENTS AND SALES PROMOTION ENSURE THAT GOOD WORKING RELATIONS ARE MAINTAINED WITH CLIENTS . KOTTAYAM COLLECTION AND ISSUE OF C FORMS. MAINTENANCE AND OFFICE. PREPARE SALES TARGETS AND ENSURE THAT SALES TARGETS ARE ACHIEVED. ENSURE THAT COST ESCALATION CLAUSES OF ALL CONTRACTS ARE PROPERLY FOLLOWED UP . PREPARE MANAGEMENT REPORT ON CASH FLOW . 5. STOCK CONTROL TO BE CHECKED WITH PRODUCTION MANAGER AND INVENTORY TO BE MAINTAINED . 30 . 4. ENSURE THAT PAYMENTS ARE DONE AS PER THE TERMS OF THE PURCHASE ORDER AND CHECKING OF GRN. ENSURE THAT PRODUCT QUALITY IS MAINTAINED BY PRODUCTION AS PER CLIENTS ORDERS . ENSURE THAT ALL RAW MATERIALS ARE PURCHASED ON TIME AS PER THE REQUISITIONS RAISED BY PRODUCTION . SALES MANAGER PREPARATION OF TENDERS FOR SALES. PREPARE MONTHLY INCOME AND EXPENDITURE STATEMENT WITH SEPARATE HEAD WISE . ENSURE THE PURCHASES ARE DONE ON A COMPETITIVE BID BASIS AND MOST ECONOMICALLY AT THE OPTIMUM PRICE . MONTHLY OUTSTANDING COLLECTION STATEMENT TO BE PREPARED AND INFORM /CONTACT THE CLIENT FOR PENDING PAYMENT . DAILY MONITOR THE STOCK AND ORDERS . ENSURE THAT PRODUCTION WORK ORDERS ARE ISSUED AND DELIVERY DATES ARE MET . PURCHASE MANAGER CARRY ALL PURCHASE ACTIVITIES OF THE COMPANY. ENSURE THAT ALL STATIONARY ITEMS ARE PURCHASED AS REQUIRED . ENSURE THAT BANK PAYMENTS ARE DONE ON TIME AND WITHOUT INCURRING PENALTIES . I NVENTORY CONTROL ENSURE THAT ALL REQUISITIONS AND PURCHASES ARE THROUGH ERP AND PROPER APPROVALS ARE OBTAINED .AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . ENSURE THAT ALL TENDERS FOR PP BAGS FOLLOWED UP AND RESPONDED. ERECTION AND COMMISSIONING (LOOMS ) AND OTHER MACHINERIES AS AND WHEN REQUIRED .AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . ENSURE THE QUALITY ASSURANCE. MAINTENANCE REPORT TO BE PREPARED AND SUBMIT THE SAME DAILY TO THE MANAGEMENT . DAILY FABRIC AND BOBBIN STOCK CHECKING . DAILY UPS OVERLOAD CHECKING . MAN POWER ALLOTMENT AS PER THE REQUIREMENT. PRODUCTION MANAGER T O ENSURE OPTIMUM MACHINE UTILIZATION SO AS TO ATTAIN PRODUCTION TARGET . MANAGER MAINTENANCE DAILY MONITOR POWER FACTOR. T O ENSURE ALL THE MACHINERIES ARE ON WORKING CONDITION . ENERGY UNIT . TROUBLE SHOOTING AND RECTIFICATION . DG AND DIESEL CONSUMPTION CHECKING. T O ATTEND THE ENTIRE BREAK DOWNS AT THE EARLIEST WITHOUT AFFECTING THE PRODUCTION . T O CHECK ALL THE RUNNING MACHINERIES . T O ENSURE PLACEMENT OF INTENT FOR SPARE PARTS IN ADVANCE . ENSURE STATISTICAL QUALITY WORK. 7. KOTTAYAM 6. WORK ORDER ANALYZE BEFORE THE EXECUTION . CONTRACT EMPLOYEE ‟S WAGES REPORT . T O ENSURE ALL THE MACHINES ARE ENGAGED AS DAILY MAINTENANCE . MONTHLY MAINTENANCE AND PREVENTIVE MAINTENANCE . WORK EXECUTION AS PER THE REQUIREMENTS OF THE CLIENTS . 31 . MACHINE WISE LOAD CHECKING. KOTTAYAM 7.DEPARTMENT PROFILE 32 .AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . iii. KOTTAYAM FUNCTIONAL DEPARTMENTS Departmentalization is the method of arranging activities to facilitate the accomplishment of organizational objectives. The organizational process of determining how activities are to be grouped is called departments. Production (main plant) Production (furnishing) Production development Production planning and control Lab and quality department Engineering department 4. Administration cum personnel department 2. vi. v. These departments show the horizontal differentiation in an organization. iv. ii.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . The main departments are 1. Marketing department 33 . Stores department Purchase department 3. Finance and accounts departments i. ii. Production department i. counseling. The department comes under administrative cum personnel officer 34 . motivating them to the higher level of performance and ensuring that they continue to maintain commitment to the organization are essential to achieve organizational objectives. KOTTAYAM A. The main functions are: Conducting job analysis Planning about needs and recruiting job candidates Selecting job candidates Conducting orientation and training program for new employees Managing wage and salaries Providing incentives and benefits Appraising the performance Communication with employee (interviewing. education. health and safety and fairness concern. out of which permanent are alone will come up to 147. business. compensating employees and attending to their labor relations. discipline) Training and developing managers Building employee commitment Human resource is the greatest of all resources RCM division have the total strength of employee and staff of Rubco RCM factory is 218. appraising.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . developing their skills. It is a high to manage this large resources. For that efficient functioning of administrative cum personnel department needs special mention. training. ADMINISTRATIVE CUM PESONNEL DEPARTMENT Human Resource Management HRM is the process of acquiring. Since every organization is made up of people. acquiring their services. government. In other words HRM is the people concern dimension in management. health. This is true regardless of the type of the organization. recreation and social action. KOTTAYAM STRUCTURE OF HR DEPARTMENT . e. training compensation. Hr manager is responsible for formulating HR policies and interpretation of different labor laws. f. The HR manager is responsible for preparation of wage and salary bill and passing to finance department for disbursement. He is responsible for providing advices and guidance or assistance to the officers and staff working in the unit of control of General Manager in the matter connected with performance appraisal discipline harmonious relation training optimum use of human resources achieving the targeted production. package. b. HR manger shall be responsible for complying with various labor legislation. c. optimum use of HR achieving the targeted production etc. performance appraisal maintaining. HR manager is responsible for the creation of posts pay scale and other required sanctions from managing director chairman for filling up manpower requirements from time to time. 35 .P. selection. discipline harmonious relation training.O STENOGRAPHER Jr. A.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . The human resource manager is responsible for the manpower planning recruitment. d. Clerk TIME OFFICER SECURITY WING RECEPTION RESPONSIBILITIES OF HUMAN RESOURCE MANAGER a. Monitoring the daily inwards and outwards dispatch. All the internal and external mail. Security A well equipped security forced is provided for safeguarding everything inside the factory complex. Correspondence with various government and non-government organization. The Functions of Administrative cum Personnel Department The functions of administrative cum personnel department can be divided into two heads. letter and memo. Administrative function Personnel function ADMINSTRATIVE FUNCTION Liaoning with government and local bodies. registered item handled by this department. KOTTAYAM . MANPOWER PLANNING PROCESS Following are the steps involved in manpower planning at RUBCO RCM division o Analysis of current system o Forecasting the time horizon of the plan o Reconciliation of action plan 36 . PERSONNEL FUNCTION MANPOWER PLANNING The main object of manpower planning in Rubco RCM division To ensure optimum use of human resource employed.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . To determine further recruitment level To forecast further skill requirements that will serve as a basis for training and development programmers.A(i). The area follows: To define the responsibilities of the job To review the organization structure and distribution of duties with the organization for a the job evaluation. Selection is a negative in its applicants as it‟s seeks to eliminate as many unqualified applicants as possible in order to identify the right candidate. They are: Skilled workers Semi skilled workers Un skilled works JOB DESCRIPTION Job description is preparing for a number of different purposes in an organization. RECRUITMENT Recruitment is the process of searching right persons and stimulating them to apply for job in the organization. The workman are divided into 3 levels based on their skills. In RUBCO RCM division selection of employees are done at two levels at the workers level are at managerial level. KOTTAYAM JOB ANALYSIS Job analysis is the procedure through which a HR manager has to determine the duties of the positions and characteristics of the people to hire for them. INDUCTION The main function of induction process at RUBCO RCM is to make the worker understand the relevance of his or he in the overall organization in the set up. Only recruitment of casual workers is directly done by RCMs division in itself SELECTION Selection is the process of differentiating between applicants in order to identify and those with a greater likely hood of success in a job selection is concerned with picking the right candidates from a poll of applicants. To provide information about a post to be filled recruitment or selection purpose.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . apart from the general orientation programmed concerning all aspect of the company 37 . Rubco RCM division follows a centralized system of recruitment at head office level. External agencies include personnel from worker educational centers as well as from professional training agencies. KOTTAYAM operation given by personal department specific induction programmed are also conducted depending upon necessity EMPLOYEE REMUNARATION AND COMPANSATION At RUBCO RCM employees are remunerated well considering its year of inception was just 3 years back. TRAINING AND DEVELOPMENT Training is a learning activity. which is directed towards the acquisition of specific knowledge and skills for the purpose of an occupation or task. Internal training includes both in house training and on the job training. Development can be considered as any learning activity. Evaluation of training program is conducted through internal assessment. evaluation is based on measuring the performance of employees before and after training periods. EVALUATION OF TRAINING PROGRAM Evaluation is done to determine whether or not the objectives and content of the training courses are consistent with the aim and current needs of the company and whether these objectives being reached in the most effective and economical manner. The factory rigorously follows its training and employee developing activities focusing on up its training and employee development activities focusing on up gradation of technical and behavioral skill. The development programmers for top manage are done by head office which is mostky external.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . 38 . The wage is given on a monthly basis. The average wage of permanent workers is more than 150per day allowances. The employee compensation for accidents happening in the factory is also handled by personnel department. The training officers of concerned programs include both internal as well as external training personnel. which is concerned more with career growth than immediate performance. Health is wealth for employees as well as for managers. Precautions are taken to avoid dust in factory complex. b) Determining training needs for further improvement s in performance. Drinking water Latrines and urinals. RUBCO RCM division has a very good safety policy in which it was envisaged to make it an accident free organization. The company has identified the probable area of accidents and the worker working over there are given extra training and proper caution boards displayed at accident prone areas. The performance appraisal in RCM division of RUBCO is normally conducted for: a) Identifying employees for further increment in salary or position. First aid facilities are provided in the factory for all employees.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . d) WELFARE EMPLOYEES All employees in the organization are covered under the employee‟s state insurance scheme.company is very much aware of the safety needs of the worker. RUBCO RCM division has done enough measures to ensure mental as well as physical health of employees. Festival advances are given to the employees on the occasion of notified festivals. 39 . Canteen Transportation HEALTH AND SAFETY Safety. KOTTAYAM PERFORMANCE APPRAISAL Performance appraisal is a systematic and objective way of judging the relative worth or ability of an employee in performance his job. Annual bonus/incentives are paid out to the employees as per the company rule. c) Motivating employees by indicating their performance level. Health. The union is lead by C. If the employee still feel aggrieved. An employee ha s full freedom to take up any grievance with his immediate supervisor. ABSENTEEISM Absenteeism rate in RUBCO is normal only. EMPLOYEE RETENTION Most of the employees are young who are gaining experience at RUBCO.I. So after going enough experience they may opt for other companies. In the factory there exists a good and healthy relationship between management and trade union. then he can take up the a matter with the next higher authority up to the level of administrative cum personnel officer. TRADE UNION The trade union in RUBCO RCM division is Rubco union. The department gives updated reports on the labor situation to the head office time to time. GRIEVANCE REDRESSAL A very grievance redressal system is there in the factory. KOTTAYAM INDUSTRIAL RELATION Administrative cum personnel department looks after the key area of union and management relationship. 40 .U. Management has initiated many steps as the absenteeism in coming down. who tries to solve it to the extend possible. So in order to retain them and build loyalty towards the organization administrative cum personnel department has drawn clear cut plan and are working towards the plan by implementing it on a step by step basis. The department has set in place on effective system to speedy sort out any difference and disputes. More than 94% attendance are maintained.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY .T. AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM FINANCE AND ACCOUNTS DEPARTMENT B. FINANCE AND ACCOUNTS DEPARTMENT I. Financial management Financial management, also to as corporate finance or managerial finance, emerged as a distinct field of study at the turn of 20th century. Finance theory in general, rests on the premise that the goal of financial management should be to maximize the wealth of shareholders. Finance is the lifeblood of the business of the entire organization. Accounts department at RUBCO RCM division is responsible for all financial decision in the division, which involve decision regarding financing, investment and working capital. All financial activities in the division routed through the accounts department. The accounts department RUBCO RCM gets fund from financial department of head quarters. The stores and purchase department also comes under this department. II. Finance Management Department Finance refers to the application of skills in the manipulation is the use and control of money. The finance in the modern business world is the life blood of the business economy. We cannot imagine a business without finance because it is a central point at all business activities. Responsibilities of financial manager III. Financial planning Raising of necessary funds Disposition of profits Tax planning Internal audit Profit planning Financial Functions Passing and settlement of all miscellaneous advances. Perform all works connected with insurance coverage of fixed asset. Keeping personnel file of employees relating to salary computation and annual increment. 41 AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM Prepare profitability trend reports and wage analysis. Quarterly and yearly financial report preparation. Making bank statement. Preparation assisting the coordination at all works connected with finalization of accounts. Assisting statutory/ vigilance/ auditors from head quarters. Make internal and external purchase. STRUCTURE OF FINANCE DEPARTMENT FINANCE MANAGER ACCOUNTS STORE KEEPER PUECHASE OFFICER JR. CLERK JR. CLERK JR. CLERK IV. FUNCTIONS OF FINANCE DEPARTMENT Exercise control over cash Passing and settlement of all miscellaneous advances Performing all work connected with insurance of fixed assets Settlement of telephone and electricity bill Keeping personnel files of employees relating to salary computation and annual increment. Preparation and maintain of accounts and book up-to-date, that are required under different acts Preparation of financial statements Over view of internal and external purchase Preparation of profitability trend report and wage analysis 42 AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY , KOTTAYAM Preparation of monthly profit and loss account and cash flow statement and present them monthly to top level managers meeting of whole RUBCO Group at RUBCO headquarters. BANKERS OF RUBCO RUBCO RCM bankers are: District Co-operative Bank, Kottayam State Bank of Travancore PROFITS 2003-2004 2004-2005 2005-2006 2006-2007 2007-2008 2008-2009 - 100 lakh - 145 lakh - 100 lakh - 10 - 50 lakh lakh - 58 lakh Financial highlights of the organization Current assts Drs Finished goods Cash Raw material WIP Total 2004-05 25 20 25 80 65 215 2005-06 60 60 10 40 60 260 2006-07 40 40 8 40 60 188 2006-07 50 30 5 50 40 175 2007-08 40 100 2 70 35 247 2008-09 50 110 6 70 40 276 43 Cash is the common denominator to which all current assets can be reduced because that other major liquid asst receivable and inventory get eventually converted in to cash. It focuses on accuracy of data and takes the user into confidence. organizing data discrimination of data and storage of data. These data will be used for managerial analysis and control. CASH MANAGEMENT Cash management system is one of the key areas in any business. CAPITAL BUDGETING Capital budgeting is done at the beginning of the year itself. FIXED ASSETS Fixed assets are the major working of any company. A set of computer based system and procedure implemented to help managers in their crucial job at decision making. If the requirement is seen as on important one of them approve of the capital is sanctioned. KOTTAYAM MANAGEMENT INFORMATION SYSTEM It is computer based system that provides flexible and speedy access to accurate data. If any other requirement of capital is faced then proper justification has to be made. A company grants credit to protect it sales from the competitors and to attract the potential customers to buy its product at favorable terms. The actual process involved collecting data. Depreciation of fixed assets is charged on diminishing balance method. Apart from the fact it is the most liquid current asset can be reduced. The requirement of capital will be specified clearly for the approval during the budgeted year.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Credit period allowed is 44 . Credit control system A trade credit arises when a company sells its product or services on credit and does not receive cash immediately. It can be extended to 180 days. The company will always have a comparison of budgets and actual. The collection of credit will be handled over to the factory manager. If the company has submitted the cheque or person for the credit due and the cheque has bounces or dehorned the company can be take legal action against the person or the company. Trade creditors receivable which the company is expected to collect in the near future. Stock in store Stores department is an auxiliary department of financial department. This is the estimation done by the observation over the physical activities of the company. Cost control The costs are controlled in row material and reduction to expenses as there is limitation of utilization of funds. Recording of transaction Each and every transaction that takes place in the company has to be recorded properly for the purpose of having better control over the funds.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . The company will give the creditors on further extension on one month legal action will be taken against the person or company. The major purpose of this department is to be having row material from suppliers to different 45 . All the transaction are recorded in journal and then posted to the ledgers. Allocation of funds Providing at funds to proper place at proper time is also an important task to be done by financial manager studies the cash requirements of each department and then funds are distributed. KOTTAYAM 60 days to 90 days. Planning Funds Planning funds is a careful estimate made by the manager about the total finds required. losses and unauthorized uses etc. Maintenance of accounts. Rejected material requirements. Timely intimation to proper authorities regarding out of stock conditions. KOTTAYAM departments and there after verify the bill/invoice to ensure of incoming material and confirm the quality and value with purchase order. 46 . STORES DEPARTMENT Stores department is an auxiliary department. Prevention of damages. Sales return management. It functions under accounts officer. Efficient and orderly record keeping of all material storage.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Issue of material against written authority. STRUCTURE OF STORES DEPARTMENT STORES DEPARTMENT STORES KEEPER STORES CLERK SEMISKILLED LABOUR Functions of Stores department Receipt of incoming material. Stores of material in safe and conventional location. Such products are sold out as separate sale items.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Classification of materials Raw materials Latex Coir Chemicals Cloths Fabrics General Engineering Materials Electrical items Mechanical items Capital item tool etc Statutory Items and Furniture Furniture Paper Bill books 47 . KOTTAYAM Material documents of this department are produced in coordination with the production department. There is a separate section for rejected products. Such products are inspected before and after by the quality control department. Rejected products are stored in stores department itself. Monthly check and other periodical checks are done to certify the actual inventory value in quantities. STRUCTURE OF PURCHASE DEPARTMENT PURCHASE OFFICER JR. Source selection Source selection involves selecting the best supplier from different suppliers. price. KOTTAYAM PURCHASE DEPARTMENT This is the department. So this department can be said as the backbone of Rubco. The main function of purchasing department is to ensure uninterrupted flow of production. he will inform it to the accounts officer and he will pass on the information to the general manager. Vendor rating 48 . which purchases the required raw material for the production of mattress. The store keeper verifies the material and if it goes beyond minimum required level. CLERK Purchase Functions: Source identification Source identification involves the identification of suppliers from which purchase are to be made.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . service etc. The general manager then doe‟s further action to buy the required raw materials. CLERK JR. which is based on desired quality. paper and bill books. Receipt of materials Materials are collected by the receipt store and the details will be given to the section for inspection. Mechanical items. rejected and the reason for rejection if any will be specified.e. GENERAL ENGINEERING ITEMS Electrical items. PU forms and threads. cloths and qualified fabrics. The original will be retained by the receipt store. KOTTAYAM This responsibility lies with RUBCO head office. CLASSIFICATION OF MATERIAL The materials used in RUBCO RCM division are broadly classified as: RAW MATERIALS Latex. cleaning products PURCHASE PROCEDURE Requisition The power of approving material requisition is with Rubco head quarters. delivery schedule and terms of payment will be mentioned. Receipts store will then prepare materials receipt report and then send it to the concerned section i.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . price of the materials and the reports from the production department in case of latex or chemicals. 49 . Purchase proposals After the purchase requisition has been approved by the head office. coir rubber chemicals. Purchase order After fixing the right supplier. The order rate. purchase and accounts. Vendor rating is done on the basis of the product. STATIONARY ITEM AND FURNITURE Office requirements. quantity. purchase order is prepared and placed with proposed party. Number of item passed. the order is placed. spare parts and capital item tools. AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . KOTTAYAM Vendor rating The responsibility lies wit the RUBCO head office. Receipt store will then prepare materials receipt report to be send to the concerned srction. Original copy will be retained by the receipt store. Vendor rating is done on the basis of product. price of the material and reports from the production department in the case of Latex or chemicals. Number of items passed and reason for rejection if any will be specified. Receipt of material Materials are collected by the receipt store and the details will be given to the section for inspection. 50 . Production department is equipped with managers and supervisors. The machine used in the production department are of high cost and mainly imported from foreign countries like U. KOTTAYAM PRODUCTION DEPARTMENT C. it is the largest functional department in RUBCO RCM division. The whole production department comes under factory manager.K. Structure of production department PRODUCTION MANANGER Production plant Production furnishing Product development Lab and quality department Production Planning Control Engineering Department Raw materials used The main raw materials used for the production of bare mattress are Latex & chemicals Curled coir 51 .AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY .A and U. PRODUCTION DEPARTMENT RUBCO RCM division ha progressively recorded high productivity and profitability.S. where specific temperature is maintained. Number of workers of this department The skilled workers at this department comes to 33.(i). 52 . To eliminate this moisture content it is kept in the coir drier machine & and by using steam from boiler it is heated for three days. which is purchased as bundles (140 bundles= 1 load). KOTTAYAM The chemical used with latex are Sulphur Zink oxide Zmbt ZDC Dispersal F China clay B-rods TDQ Final product from this department The final product from this department is bare rectangle shaped rubberized coir block. This moisture content in coir is brought down allowable limit of 5% or below. production (main plant) Processing of coir Coir is one of the major raw material for the rubberized coir mattress.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Casual workers will come to 42. This purchased bundle may contain moisture in them. The production process of RUBCO RCM division consist of following stages: C. There are 46 semi skilled and 35 unskilled workers. Rubberized coir block is resilient and because of resilient of the curled fiber. Temporary workers are 12 in number. The purpose of rubber latex is to bond the resilient coir fibers together and impart shape of the product. Then these sheets and the hand sprayed in a 53 . The second sheet former takes the fiber over and pragmatically produces sheet with partly vertical fiber orientation adjustable width and surface weight. There is three ceramic ball milling machine of Rubco RCM factory. SHEETFORMING SATGE The production of rubberized fiber sheets are done by the computer controlled sheet forming machine. After drying in its first passage. The 7 crores investment machine generally called DOA is imported from Austria. The sheet is sprayed with compounded latex from the top in the automatic spraying section called spraying gun. o o o o Untwisted unit Distributor and first spraying section Drier and second spraying section Cutting table Here completely dried and tempered rope are fed into the untwisted unit were the untwisted unit were the ropes are opened up to make it coir fiber and curled coir fiber are thrown by a „cyclone‟ into a feeding conveyor. KOTTAYAM PROCESSING OF LATEX ( COMPOUNDING SECTION) The raw latex processing consist of two steps: Ceramic Ball milling Ceramic ball milling a process in which chemical required for the compounding is grinded with ceramic balls to make it dispersion.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Compounding In this stage the above model chemical dispersion is mixed with latex stirrer machines. PRESSING STAGE The sheet from DOA machine are piled up and progressed in a continuous roller press to get the desire weight. The sheet is then dried in its passage through the tunnel drier. the sheet is automatically turned over and sprayed with compounded latex on the other side. This section has under it. Sufficient quantity of stabilizers also added into the above mixture at this stage. After the final drying the sheets are cut to the required size in automatic cutting machine. Fibers are opened further with air from compressors and supplied to a sheet former. VULCANIZING STAGE The pressed parts are then loaded in a trolley and further processed in a Vulcanize to give the desire resilience to the product. 54 . KOTTAYAM spraying booth compounded latex these progressed parts are in a hydraulic hot press to active the required dimensional stability. FINAL INSPECTION After final inspection and checking this bare block are given the furnishing department to further processing. On vulcanization properties such as tensile strength.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . heat resistance and resistance to ageing of rubberized coir are improved TRIMMING After vulcanization the bare blocks are cut in machine called band saw to form rectangular bed like a block of desired length and width. KOTTAYAM STRUCTURE OF PRODUCTION PLANT Production Department Coir Ropes Cenex and Dislodged Latex Coir Drier Compounding(latex mixed with chemicals Untwisting machine Sheeting plant Conveyer Drier Pre-press Pilling and weighing Cutting machine Surface spraying Hot press vulcanize Inspection Trimming Sending to furnishing department dispatch Quality control 55 .AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Final inspection of mattress.(ii). The major machinery in furnishing department is all are imported one. Functions of furnishing department Furnishing at different models of mattress. packing and dispatching mattress and cushion. At furnishing department the „bare‟ mattress from production-plant is brought to furnishing department and it is fabricated with Rexene and cloths and packaged and made ready to dispatch. Preparation of furnishing material. Dispatch – dispatch of mattress. cushions. According to work order only labor is deployed every day. pillows and other bedding accessories.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Furnishing process steps Corner cutting Adding Feeding Stitching Quality checking and inspection Labeling 56 . cushion and pillows as per planning department instruction. Furnishing department works as per the daily work order given by planning department. cushions and pillows as per the set standards. Labeling. Production (furnishing) Furnishing department comes under factory manager. Reworking of rejected mattress after referring the condition. KOTTAYAM C. This machine is fully computerized and imported from UK. Relief. Heaven plus. KOTTAYAM MAJOR MACHINES USED IN FURNISHING DEPARTMENT OUILTING MACHINE This machine produces over covering PU from ponds for Heaven. Hi-Tech pillow top. OTHER MACHINES Corner Cutting Machine Sewing machine Fabric cutting machine Sealing machine Handle stitching machine 57 . which stitches on the sides. It is capable of producing thousands of variety of design. HiTech.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . TAPE EDGE MACHINE Quilted tapster with the boarders kept on rubberized coir pad is feed in to the machine. BOARDER STICHING MACHINE PU form together with the upholstery is feed to this machine where the machine stitches the boarders in which are rolled and passed to the stitching section. and mattress are now ready for packing. AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Product development The product development carried out is concerned with the identification of the most economically feasible method for applying the principle through research. C(iv). human skills and other inputs into finished goods. KOTTAYAM STRUCTURE OF FURNISHING DEPARTMENT SHIFT IN CHARGE PRODUCTION SUPERVISOR PRODUCTION PRODUCTION HIGHLY SKILLED WORKERS SKILLED WORKERS UNSKILLED WORKERS SEMISKILLED WORKERS C. Operation planning involves the organization of an overall manufacturing operating system to produce a product. Objective of production planning is to provide a physical system together with a set of operating guidelines for efficient conversation of raw materials. Production planning and control It is done on the basis of specification or orders placed by RUBCO sales international and based on domestic order placed by authorized distributors. The purpose is to ensure that it meets the requirement and quality slandered. Product development essentially involves developing product to suit their customers needs and conditions. The required quality and quantity is specified through production planning and the production is done according to this planning. 58 . It involves design.(iii). This is applicable to all product modification of the existing company. redesign and fabrication of new or modified product and testing it to find its usefulness. The design and implementation of an organization‟s quality management system is influenced by varying needs. Ensure the quality of finished products. This department comes directly under factory manager. particularly the objectives the products provide to sustain an dwin products acceptability in the market. KOTTAYAM C(v). Carry out research and development activities with product development department. Assure quality of packing and selling. lab and Quality Control Development RUBCO‟s product have domestic and international acceptance due to stringent quality maintenance. Assure quality of transport. Ensure the quality online process of production.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Laboratory functions and Quality Assurance Department 59 . The functions of Lab and Quality Assurance department They are classified into two: Quality assurance function Laboratory function Quality Assurance Function Strive to achieve international quality standards to the products through various quality inspection models. Supervise the production process at various stages to make sure that quality policy of Rubco is strictly maintained throughout the manufacturing process. The adoption of quality management system should be a strategic decision of an organization. A well equipped lab functions at RUBCO RCM division to assure the quality maintenance produced here. Ensure quality of raw materials purchased. AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . and assistance according to the need. QUALITY TEST FOR RAW MATERIALS TEST FOR COIR Moisture content test: The purchase-curled coir may contain moisture from atmosphere. Effluent treatment plant. The permitted level of moisture in coir is 5% of below. Shift-in-charge (lab &Q. PU foam cotton.A) quality supervisor lab and a clerk are the permanent staff. The effluent treatment functions also come under lab Testing of sub-contract material Testing of packing and selling Customer relation management Here lab works in tandem with marketing department Vendor analysis Effluent Treatment Plant At the effluent treatment plant rubber and latex is separated from the effluents and this water is used for irrigation purpose in the garden at RUBCO RCM factory compound. Personnel in Lab Only shift-in-charge (lab & Q. are all temporary employees. The rest of lab technicians. furnishing materials like cloth. blanket. KOTTAYAM Testing of material this include testing and analysis work of raw materials like Latex and Coir. threat etc and finished product. To detect this moisture content test is carried out. 60 . lab assistance etc.A) is at freedom to appointment these technicians. o At atmosphere condition o In hot air oven(70%) Aging Test This test is done to test the durability performance of the mattress. PH Test 61 . various quality control procedures and tests are adopted in the lab. KOTTAYAM TEST FOR LATEX To measure whether the quality of purchased latex meets with the specific standards following test are conducted: Dry rubber content test Total solids test Test for ammonia Volatile fatty acid content test Mechanical stability test QUALITY CONTROL PROCEDURE To maintain the quality policy of RUBCO and assure the quality of bare mattress block as well as raw material. They are: Indentation Hardness Test This test is conducted using indentation hardness apparatus. It si kept in for 22 hours. 3 hours after the release of the load reading is noted from the compression test apparatus under the following conditions. Flexing Test This test is done to check the internal hardness of bare mattress. The bare mattress block is kept in flexing apparatus and subjected to 250000 times of flexing to check the hardness. A 10cm x 10cm sample block is taken fro the bare mattress and this block is compressed to 40% of its original thickness by applying a load of 500gm per minute. Compression Test This test is also done to check the hardness of bare mattress.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Sulphate Test To estimate the sulphate content the extract of rubberized coir sheet.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . STRUCTURE OF THE QUALITY ASSURENCE DEPARTMNET Shift in charge Quality supervisor Production supervisor workers workers ENGINEERING DEPARTMENT Functions of engineering department: Instrumentation Electrical maintenance Maintenance and utility 62 . KOTTAYAM PH test is conducted to analyze the durability performance of the mattress. Its efficient and effective marketing strategies helped the organization to build up a very strong brand name.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Within a short span of its inception. Functions of Marketing Department The functions of marketing department are given below. MARKETING DEPARTMENTS Marketing is the foremost function that gives the management hopes for their integrated task through making profits. 63 . Conducting consumer survey for the purpose of collecting information from customers for the product development and evaluation of existing position of product in market. Product development is based on the feedback from customers and retailers. Formation of effective marketing competition increase market share launching of new product entering into a new market with different product formulation of sales strategies in order to achieve the target turnover. Orientation given to leader and distributors to make awareness about the quality of products. Marketing of RUBCO mattress is done by Rubco sales International ltd (RSIL) at H. retailers. RSIL could effectively develop a competent network domestically as well as globally and undertaken the su ccessful launch of Rubco‟s product. Formulation of sales strategies in order to achieve the target turnover. It is a social and managerial process by which individuals and groups obtain what they need want through creating and exchanging products and value with others. Conducting seminar/ exhibition for the purpose of launching new product to the market and also make the people aware of their existing products. KOTTAYAM D. Conducting retailers meet for the purpose maintain cordial relationship between management and distributors dealers. Rubco sales International ltd (RSIL) is a public limited company promoted by Rubco to spear head the sales and marketing activities for Rubco‟s entire range of products in the domestic and international markets. D(i). Kannur.O. AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY .e. place and promotion. i. Expansion of existing market into other geographical areas. Through better and effective distributors network expansion as well maintains it ensures improved product availability at reduced cost. product.(ii). Planning for introducing new products into market and entering untapped segment is their innovative strategy. MARKETING STRATEGIES Rubco mattress attained wide market coverage in Kerala within a short period of it being established. price.e. 64 . KOTTAYAM STRUCTURE OF MARKETING DEPARTMENT Highly skilled workers Highly skilled workers Highly skilled workers D. It is classified as the 4 the P‟s of marketing i. Marketing Mix Marketing mix is the set of marketing tools that RUBCO RCM division uses to pursue its marketing objective the target. Now Kerala market is dominated by Rubco mattress industry. now Rubco is the market leader in Kerala mattress industry and they are about to expand their market all over South India in order to attain their target turnover. The effective marketing strategy that they have adopted is the reason behind this explosive growth of Rubco. FUNCTIONS OF RSIL Gather market information Monitoring of supply chain system Nurturing and sustaining excellent customer relation Helps to achieve product innovation and modification by way of conducting marketing R&D and customer survey. RSIL is a separate Department to spear head the marketing activities of Rubberized Coir Mattress product at its factory in Pambady.(RCM) include two Jr. The sales personnel of Rubco Marketing Department. the current year‟s sales figures may even go up further. the marketing Department (RCM) had done an excellent job in making the Rubco almost a market leader in the state within a short span of 3 years. In the highly competitive sector of rubberized coir mattress where there are almost 120 odd as well as half a dozen organized sector players are existing. With the aggressive market expansion plans and the domestic sales turnover of RUBCO Rubberized Coir Mattress are all poised to doubles. Sales Officer and 6 sales executives. 65 . KOTTAYAM To help the production units to better and improve the quality of output. As Rubco has entered in to expert deal with some with the European Unions nations and the shipment already flagged off. RUBCO mattress has also entered Tamil Nadu with setting up of distribution channel in Chennai and Erode.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . D Company secretary (administrative officer of RSIL) GM (RSIL) Cost accountant (accounts officer of RSIL) Mktig sales mgr (RCM) Mktig sales mgr (F&P) Mktig sales mgr (F&C) Advt sales promotion dept Area managers Jr. KOTTAYAM ORGANIZATIONAL STRUCTURE OF RSIL Chair man M. sales officer Sales Executives 66 .AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . The pricing policies of RUBCO RCM also include The price quoted is inclusive of transportation charges. Rubco charges the price as per Duroflex price.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . The retailer are at freedom to sell below MRP 2. Packing is the covering given to a product to a product for protecting it. 67 . publicity and sales promotion. 3. an advertisement agency. The margin of distributor is 11% on transfer price and margin for retailer in 20% on MRP in Tamil Nadu. KOTTAYAM NEW MARKETING INITIATIVES The marketing initiatives other than maker expansion include the function of new innovative products like. Packing strongly affect the purchase decision. Packing Packing of the product plays vital role in success or failure of a product. Rubco‟s pricing strategy on its mattress is largely competitor based(going rate price). Advertising The advertising of Rubco rubberized mattress is done through „Maabozell communication Ltd‟ Ernakulum. 4. On the plastic covering of Rubco mattress contain information regarding its unique 3-D technology. Budget matters Foldable matters Mattress protector (comforter) Hi-tech pillow top mattress with 7 inches thickness Latex pillows 1. Pricing The price denotes the value of a product or service expressed in money. Promotion To win the battle of competition every manufacturer has to choose a number of promotion tools which can be classified as advertising. Lanka. Exports Exports is not a function of Marketing Department (RCM) at Kannur. STRUCTURE OF SALES NETWORK RUBCO (manufacturer) DISTRIBUTOR RETAILER CUSTOMERS 68 .AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . Rubco RCM divisions also receives enquiries from Sri. As Rubco RCM decision strictly follows its quality and product satisfaction of the customer the exports opportunities are plenty.and other middle east centers.S. KOTTAYAM 5. This year Rubco has started exporting of its mattress to some European Union Countries. U.A. This function is done by RCM factory Pambady itself. AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . KOTTAYAM 8.SWOT ANALYSIS 69 . AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . goodwill. 3) Opportunities ● Rubco rubberised coir mattress shold plan to enter into foreign markets ● Rubco rcm division is notyet fully tapped their 100% utilization of existing machine 70 . Lack of promotional activities abroad Transportation facilities are available but not to the extend as desired. wide range of products are manufactured which is capable to challenge variable environment condition. wide network. Products with high quality. marketing intelligence. and interaction with customers. Good financial management system that exist in the organization. Effective managerial system is on of their strength. Relationship between employee and top level management and among dealers and distributors is in harmony. opportunities and threats is called SWOT 1) Strength Rubco mattress division wide range of different mattress in different range. Through effective marketing Rubco products could have acquired wide market acceptance and customer within a short period of being time established. 2) Weakness Higher rice compared to their competitors. technical advice. Company should conduct more training and development programs to the employees and the workers. and customer service. KOTTAYAM SWOT ANALYSIS – RUBCO MATTRESS The evaluation of company‟s strength. weakness. Leadership style that company following is through dedication and coordination. That encourages employees of the organization to work towards their organizational goals. 71 . 4) Threats Fluctuating price of raw materials Lack of raw material Increasing competition Taste of customers varies Product differentiation For the past several years company is facing severe competition RUBCO ensure high quality products due to which the price of the product is comparatively high compared to its competitors. ● Opportunity of identifying the regions where introducing more and more quality products. So there is possibility that customer can switch to competitors.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . So that structure can withstands the different regional environment. KOTTAYAM capacity so opportunities lies there. ● The factory can undertake new projects regarding projects diversifications. KOTTAYAM 9.FINDINGS AND SUGGESTIONS 72 .AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . More automation should be done so as to reduce the number of workers. A good co-ordination exists between different departments. Trade union play a vital role as bargaining agents. 4. 2. cousions and furniture upholstery. 5. SUGGESTIONS 1. Increase promotional activities could enhance building brand image. KOTTAYAM FINDINGS 1. 3. Workers health and safety are given prime importance. The company has to make strengthen their supply chain in other states. The company has to engage in production of variety products. 73 . That way it can acquire a strong reputation in the single field. 4. 3. Increased production for increased profits. RUBCO should adopt a strategy that would result in lowering the production and distribution cost than of its competitors to win the market. Presence of good industrial relations with local unions and there is greater co-operation management and employees. Labor turnover is very low. It has to add new product line thus widening its product mix ie. Wages system is fair in RUBCO. 6. 6. 5. 7. in order to tap the target market. The company has to engage in production of variety products. 2.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . KOTTAYAM CONCLUSION 74 .AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . which spend huge amounts of money for advertisement and other promotional activity. mattress market has become one of the most competitive markets in India. They are mainly giving attention to provide customized product. The internship study is helped to make a valuable conclusion through the analysis of different functional departments of the RUBCO. RUBCO is a major player in this industry. At present. There are number of mattress manufactures in the market who are struggling hard to make an impact in the mind of customers. The core competencies of the organization can listed as below: Professional management Effective Leadership Cordial relationship between employees and top level management.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . 75 . who cannot afford to branded mattress at comparatively high price. Presently it is ranked at the top with consideration to quality. The company has well established network in industry with sound manufacturing and marketing experience. unbranded ones are concentrated on the local market. KOTTAYAM CONCLUSION The rubberized coir mattress industry has a great market in India. The company had adequate resources available for expansion. Branded and unbranded mattresses are there in the market. KOTTAYAM BIBLIOGRAPHY 76 .AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . KOTTAYAM BIBLIOGRAPHY www.com www.17.AN ORGANIZATION STUDY AT RUBCO COIR MATTRESS FACTORY . aug2010 77 .rubcogroup.rubcorcm.com www.com www.rubcomattress.com Journal : Rubber AIS vol .rubcoindustry.