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Safety Measures for employees PROJECT REPORT MBA HR

VIEWS: 378 PAGES: 66

									          FLOWSERVE MICROFINISH VALVES PVT LTD




                            EXECUTIVE SUMMURY

The Flowserve Microfinish valves pvt ltd was established in 1997 at hubli.we started our
project with the organization study of the particular organization, we passed through the
various departments of the organization like sales and shipping, accounts and
administration, quality assurance and production departments, then after the organization
study through observation then selected the research topic as       Safety Measures for
employees in Flow Serve Micro Finish Valves Pvt, Ltd.

       Then we carried on our research through the descriptive research methodology in
which prepared structured questionnaire with 12 questions and surveyed employees,the
results and findings of the survey are given below:

       In our survey we found that very few accidents are met, then all the employees are
aware of the safety measures and the safety measure policies provided to them, overall
opinion is that all employees are satisfied by the safety tools provided to them by the
organization.




BABASAB PATIL                                                                          1
          FLOWSERVE MICROFINISH VALVES PVT LTD



                                 INTRODUCTION

Flow serve Micro finish is one of the 100% EOU [Export Oriented Unit]         in the
city of Hubli. The Flow serve Micro finish group of companies consist of two units
namely Flow serve Micro finish Valves Pvt Ltd [FMVPL] and Flow serve Micro
finish Pumps Pvt Ltd [FMPPL].

       Flow serve Micro finish Valves Private Limited (Here in after referred to as
the company) was established in 1997 to manufacture Industrial valves, plug valves
and valve components. The company is located in the Industrial Area, Hubli which
is one of the Biggest Industrial centers in the state of Karnataka, India. Hubli is
situated midway between Poona and Bangalore on the NH – 4 Highway and is
connected by Road , Rail, and Air. The company’s manufacturing unit has a 15,000
Sq .ft of built up area to house the facility.

       The Company is catering the major needs of industries in the field of
petrochemicals, refineries, fertilizers, fine- chemicals, pharmaceuticals, food &
beverages and other general chemical industries.

FLOWERSERVE PVT LTD., USA:

       Flow serve Pvt Ltd. is a U.S.A company which was set up in early 1920.
Flow serve Pvt Ltd produces engineered and process pumps, precision mechanical
seals, automated and manual quarter-turn valves, control valves and valve actuators,
and provides a range of related flow management services, primarily for the process
industries. Flow serve engineers products and provides services to meet the needs of
the global flow management industry. Flow serve serves the flow management
industry worldwide. More than 40% of the Company's 2006 sales of $3 billion were
outside the United States.

       Flow serve Pvt Ltd is having its business more than 30 countries to name
few are Canada, Belgium, Australia, India, Argentina, Mexico, Germany, etc. Flow

serve Pvt Ltd of U.S.A. found a Indian market for its expanding its business and
came to India by the way of joint venture.




BABASAB PATIL                                                                      2
           FLOWSERVE MICROFINISH VALVES PVT LTD

                               INDUSTRY PROFILE

Heavy Engineering Industry is one of the largest segments of Industrial production. It
occupies a whole range of industries such as Heavy Electricity Machinery. Turbines,
Generators, Transformers, Switchgears, Textile Machinery etc. The Index of Industrial
Production figures of 8 of the 16 major industry groups show substantial growth with the
rates ranging from 6% to 28%.

       Thought there was some signs of recovery in the third quarter of 2002-2003 the
stimuli seems to have dissipated quickly. The problem with the cotton textile sector has
also continued to perform badly in the last two years. The only positive development is
the measures announced for the textile industry in the recent budget.

       Trends across major sectors show that growth in the two lead sectors-capital
goods and ./lk,.l,.mmmmm,xzccCconsumer non-durable goods-have decelerated but still
remain at the double-digit levels. This has, however, been compensated by the strong
recovery in the intermediate goods segment. A major concern is the lackluster
performance of the consumer durable goods segment over the last year with production
declining for the first time since themed-nineties.




BABASAB PATIL                                                                         3
            FLOWSERVE MICROFINISH VALVES PVT LTD

                            VALVE & PUMPS INDUSTRY

A valve is a device that regulates the flow of fluids (either gases, fluidized solids, liquids)
by opening, closing, or partially obstructing, various passageways. Valves are used in a
variety of applications including industrial, military, commercial, residential,
transportation, etc

        They are mainly used for safety purposes in steam engines and domestic heating or
cooking appliances. Others are used in a controlled way in Otto cycle engines driven by a
camshaft, and they have a major part in engine cycle control.

     A Pump is a device that manages the needs of fluids (either gases, fluidized solids,
slurries or liquids) by pumping . Pumps are used in a variety of applications including
industrial, military, commercial, residential, transportation, etc.



AN ORIGIN OF THE INDUSTRY

The development of control and instrumentation sector has undergone
transformation in phases. Earl y processes were relativel y simple and plant
size small. Measuring instruments were mounted directl y on the process
lines. Monitoring and recording of measured values were performed by
plant

         Operators. As the plant size and process complexit y increased, the
number of critical parameters that needed to be meas ured and monitored
also increased. This led to the requirement for a centralized monitoring of
process     variables,      and     the   introduction     of     signal   transmitters   and
transmission          techniques.      The     first     system     employed       pneumatic
transmitters of the forced balanc e t ype. Manual control gave way
subsequentl y         to   automatic      control      implemented     through     pneumatic
controllers. Later electronic controllers began to gain ground.




BABASAB PATIL                                                                                 4
            FLOWSERVE MICROFINISH VALVES PVT LTD

GROWTH & DEVELOPMENT OF THE INDUSTRY

       The domain of primary sensing elements comprises of measu rement
of flow, level, temperature, pressure, vibration, electrical parameters and
anal yzers. Development in flow elements is targeted towards reducing
pressure loss and increasing accuracy.

    The demand for the valve business is going to increase by 30 -40%
       and pump business would increase proportionatel y.

    Pumps & Valve Manufacturing Industry in India is growing at the
       rate of 10 -12% per annum. 500 large, medium & small -scale
       manufacturers in India manufacture approximatel y 6,000 pumps &
       20,000 valves per da y in India.

      All core sectors of industry namel y power, oil & gas, water &
infrastructure      projects,   metal   and   mining,    chemicals,   drugs   &
pharmaceuticals & food and beverages require various t ypes of pumps &
valves and each of these industries are growing a t a exorbitant rate today
in India.

PRESENT STATUS OF THE INDUSTRY

Indian Scenario

       Following industrialization India has established over the years
reasonabl y sound technological base in many industries including process
oriented industries like steel, pow er, cement, fertilizers, petrochemicals
and   refineries.     In   developing    these   needs   for   process   control
instrumentation was apparent.




BABASAB PATIL                                                                  5
             FLOWSERVE MICROFINISH VALVES PVT LTD

BUSINESS ENVIRONEMENT OF THE INDUSTRY

Indian market for Industrial Pumps and Systems has been a mature market
since years. India has been a reliable, technicall y competent, competitive
and enterprising outsourcing option for many multinational companies in
the field of Industrial Pumps and S ystems for outsourcing to countries
such    as    USA,       Germany,         Holland     etc       .for:- Pumps, Systems, Pump
Components        and    sub-assemblies -cast             and    machined,   fabricated   and
finished, molded, customized and/or mass -produced- Basic and Applied
research and anal ysis employing also CFD techniques .

        A Valves & Pumps industry deals with the Business Marketing . They
are    widel y    used     in    Chemical         &       Process   industries,   Refineries,
Petrochemicals & Fertilizer plants, Pharmaceuticals, Oil Exploration,
Thermal       &   Nuclear       plants,    Food       &    Beverage    industries,   Effluent
Treatment & Sewerage plants, Water Treatment, Cooling Water & Water
Suppl y plants, mining industries etc.



FUTURE OF THE INDUSTRY

Valves & Pumps are tremendous growth opportunity in the areas of Chemical & Process
industries, Refineries, Petrochemicals & Fertilizer plants, Pharmaceuticals, Oil
Exploration, Thermal & Nuclear plants, Food & Beverage industries, Effluent Treatment
& Sewerage plants, Water Treatment, Cooling Water & Water Supply plants, mining
industries etc.




BABASAB PATIL                                                                               6
           FLOWSERVE MICROFINISH VALVES PVT LTD



                               COMPANY PROFILE
BACKGROUND AND INCEPTION OF THE COMPANY:

Flow serve micro finish group of companies having two units namely Flow serve Micro
finish Valves Pvt. Ltd.., and Flow serve Micro finish Pumps Pvt. Ltd., was established in
1997 to manufacture Industrial Valves viz. Ball Valves and Plug Valves and Industrial
Pumps viz. ISO Pumps and ANSI Pumps. The Group of Companies is located in
Industrial Area, Hubli, which is one of the biggest Industrial Center in the State of
Karnataka, India. Hubli is situated midway between Pune and Bangalore on the NH4
Highway and is well connected by road and rail. Valves and Pumps manufacturing
i.e...Mifs have a 15,000 Sq. feet and 10,000 Sq. feet of built-up area to house the facilities
respectively. Both divisions have an open space of 10,000 Sq. feet and 15,000 Sq. feet
respectively for further expansion.

       The two units have excellent machining testing facilities, consisting of CNC's,
center lathes, milling, drilling, grinding machines, SPM’s etc. supported by adequate
gauging, measuring instruments. Dedicated Staff &, workers strive &, ensure that quality
objectives are achieved.

       The units are catering to the needs of major Industries in the field of
Petrochemicals, Refiners, Fertilizers, Fine chemicals, Pharmaceuticals, Food and
Beverages and other general Chemical industries.

       Flow serve Micro finish Valves Pvt. Ltd., and Flow serve Micro finish Pumps Pvt.
Ltd., has a documented Quality System to meet the requirements of ISO 9001: 2000
requirements to ensure that its orders are processed; products are manufactured to meet
the requirements of the customer. Flow serve Micro finish. Valves Pvt. Ltd., in addition
meets requirement of PED 97/23/EC.




BABASAB PATIL                                                                               7
           FLOWSERVE MICROFINISH VALVES PVT LTD


VISION :

       Vision is to manufacture quality valve products for the process          industry
worldwide. We embrace the concept of total quality and people involvement to enhance
“Total quality satisfaction” and commit to maintain this standard of   excellent through
continual improve and use of quality management system.



MISSION:

       Mission is to manufacture quality valve products for the process industry
worldwide. We embrace the concept of total quality and people involvement to enhance
“Total Customer Satisfaction” and commit to maintain this standard of excellence
through continual improvements and use of quality management system.




BABASAB PATIL                                                                         8
         FLOWSERVE MICROFINISH VALVES PVT LTD




                     PRODUCT PROFILE:

Ball Valve               38 series Ball Valve




Ball Valve                      Flanged Ball Valve




BABASAB PATIL                                        9
      FLOWSERVE MICROFINISH VALVES PVT LTD




BABASAB PATIL                                10
           FLOWSERVE MICROFINISH VALVES PVT LTD

Plug Valve




VALVES

       valves are mechanical devices specifically designed to direct, stop, mix or regulate
the flow, pressure or temperature of a process fluid. Valves can be designed to handle
either liquid or gas application.

       By nature of their design, functions and applications, valves come in a wide
variety of styles, sizes and pressure classes.



BASIC FUNCTIONS OF VALVES:

       Starting and stopping flow.

       Regulating flow volume (frequently called throttling).

       Preventing reserve flow (called anti-back down).

       Changing flow direction.

       Limiting fluid pressure




BABASAB PATIL                                                                           11
          FLOWSERVE MICROFINISH VALVES PVT LTD

The application of valves is done in every imaginable field. There are ranges of
valves we encounter in our everyday life; from the valves inside our body such as
the heart valve to the valves inside the automobiles we drive, to the water faucet we
turn ON and OFF. It is hard to realize how many there are and how we come to
depend on them.



             Sl.No. Product       Size    Max Pr. Rating Material of C

             1       Ball Valve   15-200 # 300             CS / SS

                                  15-50   # 800            CS / SS

             2       Plug Valve 15-300 # 150               CS / SS

                                  15-300 # 300             CS / SS




BABASAB PATIL                                                                     12
          FLOWSERVE MICROFINISH VALVES PVT LTD

AREA OF OPERATION:

FLOWSEREVE MICROFINISH LTD:

Micro finish was set up in the year 1978. The Micro finish is manufacturing an industrial
pumps and valves. Micro finish is known for its quality product and has got certificate of
ISO 9002. In 1998 Flow serve Pvt Ltd of USA came to India by entering into a joint
venture with a Micro finish of Hubli. As Micro finish is known for its quality product
world wide, the Flow serve Corporation made a technical collaboration with the Micro
finish valves. Flow serve Pvt Ltd came to India and gave technical and management
training to the employees of the Micro finish in the year 1996 and commercialized its
business in the year 1998. The training they give was of high standard and then later
Micro finish of Hubli was able to produce spare parts of high quality. When Flow serve
Pvt Ltd inspected the spare parts which came out to be more than their expectation. Later
Micro finish started its separate 100% exporting unit and came to be known as a Flow
serve Micro finish Pvt Ltd. Hubli. Now the Flow serve Micro finish ltd. exports to more
than 15 countries to name few,

1. USA                5. SOUTH AFRICA               9. AUSTRALIA

2. U.K                6. TIWAN                      10. HONGKNOG

3. GERMANY            7. BELGIUM                    11.KOREA

4. BRAZIL             8. MEXICO                     12. SINGAPORE




BABASAB PATIL                                                                          13
           FLOWSERVE MICROFINISH VALVES PVT LTD

HISTORY AND NATURE OF THE COMPANY:

As mentioned earlier, Flow serve Micro finish [FMVPL & FMPPL] was established
in the year 1997 to manufacture Valves viz Ball valves and Plug valves and
Industrial Pumps viz ISO pumps and ANSI pumps. The company is formed as a
result of joint venture between Micro finish and Flow serve Corporation USA, with
Flow serve as the major shareholder.

       Valves and Pumps manufacturing units have a 15,000 Sq. ft and 10,000 of
built up area to house the facilities respectively. Both the divisions have an open
space of 10,000 and 13,000 Sq. ft respectively for further expansion.

       In addition, the two units have excellent machining testing facilities
consisting of CNC’s, Centre Lather, Milling, Drilling, Grinding machin es SPM’s etc
supported by adequate gauging measuring instruments. Dedicated staff and workers
strive to ensure that the company’s quality objectives are achieved.

       The company is having a documented Quality system to meet the
requirements of ISO 9001 – 2001 to ensure that its orders processed, products
manufactured meet the requirements of the customer. Further the company is also
certified for CE – Marking.



ACHIEVEMENTS

          The company is an ISO 9000 - 2001        recognition.

          The company is also certified for CE-    Marking

          As per the Safety Related Audit conducted by Flow serve US, the

          company is certified as the ‘Safest Entity’ scoring 99%, beating even

          the Singapore and Bangalore Units.

          It has also bagged the ‘Best Garden’ award ensuring to get even the

          ‘Best Flower’ award.




BABASAB PATIL                                                                      14
            FLOWSERVE MICROFINISH VALVES PVT LTD

    FLOWSERVE MICROFINISH GROUP OF COMPANIES PVT. LTD.,


 Name & Address of The Industry         Flow serve Micro finish Group Of Companies pvt. Ltd.,
                                        568/1, Industrial Area, Gokul Road, Hubli – 580 030. India.


 Status of Organization                 Private Limited (100% EOU).

 Certificates                           ISO 9001, ISO 2000 and PED97/ 23 / EC.


 Date of Registration                   19 th April 1996

 Date of Commencement                   1 st June 1998

 Availability     of    communication   Telephone, Fax, Internet, Printer, Hard copy, P.O.
 facility

 Cost of Project(Initial Investment)    3 Crores

 Exporting Capacity                     20,000 valves

 Turn Over Per Year                     20 Crores

 Applicable Act                         1) Factory Act:
                                        2) Provident fund:
                                        3) ESI( Employee State Insurance)
                                        4) Bonus Act
                                        5) Payment of Gratuity:
                                        6) Product Processing order:

 Bank                                   1) Canara Bank
                                        2) Bank of India.

 Email                                  admin@flowservemicrofinish.com
                                        dispatch@flowservemicrofinish.com

 Factory Area                           3 ½ Acres ,
                                        Built Up area : 15000 Sq. Ft.

 Manpower                               76

 Branches                               Pumps Pvt Ltd., and Valves Pvt Ltd.,

 Agencies                               Foreign System Pvt. Ltd – Germany
                                        Panel Kena – South Africa
                                        Uniworld Logistics – US.
                                        Export Freight – Singapore.

 Tel & Fax No.                          2233202, 2332301 / Fax – 0836-2333205




BABASAB PATIL                                                                                         15
      FLOWSERVE MICROFINISH VALVES PVT LTD




                    Certificates




BABASAB PATIL                                16
      FLOWSERVE MICROFINISH VALVES PVT LTD

                WORK FLOW




BABASAB PATIL                                17
           FLOWSERVE MICROFINISH VALVES PVT LTD

                   STRUCTURE: ORGANISATION CHART

                                   BOARD OF
                                   DIRECTOR



                                   MANAGING
                                   DIRECTOR
                                    TILAK K



ADMINISTRATION        PLANNING                 PRODUCTION              QUALITY
AND ACCOUNTS        AND PURCHASE              AND ASSEMBLY            ASSURANCE
  V.M.NAYAK                                    PRASHANT V.            ARAVIND A.
                                                                       NATEKAR

             PERSONAL           SALES AND                  SHIFT I              RECEIVING
              OFFICER        SHIPPING OFFICER            INCHARGE              QUALITY ENG.
           POOJA ANGADI       UMESH ANGADI                UMESH G                MANOJ N.


            ASSISTANT        PLANNING AND                  SHIFT II             INPROCESS
           ACCOUNTANT        PURCHASE ASST               INCHARGE              QUALITY ENG
           NARAYAN H.           MAYUR                    MOHAN M.                 DANIEL


                                                       MAINTAINANCE           FINAL PRODUCT
                              STORE OFFICER I            INCHARGE                ENGINEER
                             SHIVASHANKAR T             NARAYAN PAI             M. M. ROOGI


                                                         ASSEMBLY              DEVELOPMENT
                             STORE OFFICER II           SUPERVISOR               ENGINEER
                                                       KUMAR KATKAR           MAHESH CHILLAL


                                 LOCAL
                               PURCHASER




  BABASAB PATIL                                                                      18
             FLOWSERVE MICROFINISH VALVES PVT LTD

             DIFFERENT FUNCTIONAL DEPARTMENT CHARTS:

          ADMINISTRATION AND ACCOUNTS DEPARTMENT:


               ADMINISTRATION
                           AND
                        ACCOUNTS
                        INCHARGE




                                          PERSONAL
                                                        OFFICER
                                              [FACTORY & PERSONAL SAFETY]




                                          ACCOUNT
                                                      ASSISTANT




FUNCTIONS OF ADMINISTRATION DEPARTMENT (H.R)

 Training

 Recruitment

 Safety

 House Keeping

1. TRAINING

Objective:

        To provide appropriate training to the personnel of various departments who
perform the quality control activities.

Responsibility:

Administration and Accounts (A & A) In-charge through personnel officer is overall
responsible to ensure that the training needs of personnel of all the departments are
fulfilled.




BABASAB PATIL                                                                     19
           FLOWSERVE MICROFINISH VALVES PVT LTD

  Personnel officer is responsible for identifying the proper trainer in consultation and
contact with the top level management for arranging the training.

. Training is given for employees once or twice in a month depending on the need. In
training the following aspects and topics are covered:

Product Application, Instrument Knowledge, Industrial Safety and First Aid, Basic
Computer Knowledge, Statistical Quality Control, ISO Awareness Leadership Quality,
Manpower Handling, Communication Skills, and Material Handling.

2. RECRUITMENT

       Personnel officer is responsible for recruiting The right person for the right job at
the right time, He takes into consideration the knowledge, skill and work experience of
the person .

3. SAFETY

Objective: To ensure safe and healthy environment for personnel

Responsibility:
Administration and Accounts in charge through personnel officer is responsible for safety
related activities in the company.

Procedure:
  Safety committee meeting is conducted every quarter i.e once in 4 months. Safety
related training for staff and workers is conducted once in two months such as Fire
Extinguisher, Chemical Hazardous, Personal Hygiene etc and first-aid facility is also
provided for workers.

   Safety round-up is carried out by the personnel officer accompanied by H.O.D and two
workmen\staff of different department.

4. HOUSE KEEPING

Objective: To ensure good, healthy, clean, neat and safe work environment.

Responsibility:

While the activities are co-ordinate by the personnel officer, each and every individual in
the organization is responsible for the implementation.

BABASAB PATIL                                                                            20
            FLOWSERVE MICROFINISH VALVES PVT LTD

Procedure:

For effective implementation of the system, the entire premises of the company are
divided into sub-zones as Production and Assembly division, Quality Assurance division,
Administration and Accounts division etc. Each sub-zone is headed by a team leader and
supported by co-ordinates, supervisory staff and workers.

PRODUCTION AND ASSEMBLY DEPARTMENT:


                               PRODUCTION
                                   AND
                                ASSEMBLY
                                INCHARGE
                               DEPARTMENT

     SHIFT          MAINTENANCE           ASSEMBLY               SHIFT II

        I

  MACHINE            MAINTENANCE            FILTERS             MACHINE
 OPERATION            ASSISTANT                                OPERATION



              HELPERS                                                       HELPERS




PRODUCTION:

       The production department ensures that the production process is identified,
planned and carried out under the controlled conditions in accordance with monthly
manufacturing plan. The objective of this department is to improve the productivity, to
reduce the cost of production without any compromise on quality and to manufacture non
defective quality products by training the people in right manner and effective way.

OBJECTIVES:

1. Productivity improvement.

2. To reduce the cost without compromise on quality.

3. To manufacture “non defective product” by training the people.




BABASAB PATIL                                                                          21
            FLOWSERVE MICROFINISH VALVES PVT LTD

PRODUCTION PLANNING AND PROCESS:

 Upon the receipt or the work order copy, bill of material, monthly manufacturing plan
etc, the department head instructs the production planning personnel to determine the
material availability with reference to bill of material.

      If there is any shortage of material the production and planning personnel will place
the material shortage list to planning and purchase dept. There by they will refer to the
production and plan and collect the material from stores through material requisition note.
If material intended and received is in excess, then the production personnel will return
these material back to the stores, with material return note.

       The Head of department will then prepare daily production schedule through
which he schedules the production and machine loading for the day. The cell in charge
prepares and provides relevant document and instruction for processed and other tolling
in charge through his personnel ensures the production facilities like machines, tools,
fixtures etc, are available for production when required.

      The cell in charge will load the machine and provide instruction to the machine
operators by means of job cards. The operator himself will instruct the components at
each stage of manufacturing and identifies the confirming, components by inspection
colour code. The products are either processed for standard or non-standard product. The
design for the certain products are standardized and kept in the production dept and for
non-standardized products are obtained from the design and development dept. The shift
in charge will collect the drawings from the draftsman for the processing. In consultation
with the production and assembly in charge, shift in charge will allocate material for sub-
contracting for machining through the stores officer.

      When required for assembly the customer supplied products are collected from
stores against a written requisition ensuring that products has been issued for a particular
work order for which it is meant. Proper care is taken while handling these products for
assembly.

      The P&A in charge schedules the assembly and prepare the assembly schedule and
ensure that the same is carried out through the shift in charges that prepare the assembly
job card and give instructions to the operators. After assembling the products are handed




BABASAB PATIL                                                                            22
          FLOWSERVE MICROFINISH VALVES PVT LTD

over to the final inspection and testing section along with the valve assembly and testing
status formal and assembly job card.

      After clearance from Quality Assurance dept the shift in charge will send the
assemblies to dispatch section and finished valve completion note is given to the stores.

There are two types of machines which are used in the production department:

1. Conventional machines

2. CNC machines

1.   Conventional machines: All the operations in this types of machines are done
manually work the cost of such machines are cheaper & the capacity is very less as it can
handle only 1 operation at a there are conventional machines of ac the 4 types of
operations it maintains of such machines & it is less safe than CNC machines.

2.    CNC machines: Computerized numerical control machines. This machines are
operated automatically i.e. a program is written for its function which is in assembly level
language i.e. economic codes which are not understood by human beings. In this type of
machine there are 2 types,

a) X&Y side (2 dimensional)

b) x,y,z side (3 dimensional)




BABASAB PATIL                                                                            23
          FLOWSERVE MICROFINISH VALVES PVT LTD

             PLANNING AND PURCHASE DEPARTMENT:



                                     PLANNING
                                        AND
                                     PURCHASE
                                     INCHARGE




 SALES AND
  SHIPPING                             STORE             STORE          LOCAL
                   PLANNING
  OFFICER                             OFFICER           OFFICER       PURCHASE
                                         I                 II             R


PLANNING:
Planning is the backbone of any organization. Success of any organization depends on
how well things are planned.

TYPES OF PLAN:

   1. TENTATIVE PLAN: It is a plan for a particular which is drawn five weeks prior
       to a month. It can be modified amended.

   2. FINAL PLAN: It is a plan which is issued one week earlier to the particular
       month. It can be modified, if required on the basis of information from other
       departments.

OBJECTIVES:

   For usage of resources to meet the delivery commitments.

SCOPE:
   Applicable to all work orders and related activity of departments with respect to
monthly manufacturing plan.




BABASAB PATIL                                                                    24
          FLOWSERVE MICROFINISH VALVES PVT LTD

RESPONSIBILITY:

1. Planning and Purchase in charge is responsible for drawing tentative and final
“monthly manufacturing plan” through planning assistant.

2. Production and Assembly in charge is responsible for modifying to meet urgent
customer requirements.

PROCEDURE:
1. Plan is drawn to approximate 90% of capacity and 10% of capacity is reserved to meet
URGENT amendments.

2. Tentative plan is modified /amended if required on the basis of feedback information
from other departments.

3. Final plan is issued one month earlier to the particular month.

4. Final plan is amended, if require on the basis of feedback from P&A department.

5. Valves which are planned to be manufactured in a particular month but could not be
manufactured are re-planned in consultation with P&A department.

6. Cause of not meeting the plan is discussed with P&A department.



PURCHASING DEPARTMENT

OBJECTIVES:
   To ensure that all the purchase/ processed items and services meet the specified
requirements.

SCOPE:

   Applicable to all raw materials, bought out items, sub contracted items, capital goods,
consumable and services to be produced.

DEFINITIONS:

SUB CONTRACTOR:

   He is one who carries out processing on material / components supplied by FMVPL.




BABASAB PATIL                                                                          25
          FLOWSERVE MICROFINISH VALVES PVT LTD

VENDOR:

   He is one who supplies some specific components.

SUPPLIER:

   All vendor’s & sub contractors are considered as suppliers.

RESPONSIBILITY:

1 P&P in charge is responsible for approval of supplier.

2 P&P in charge is responsible for approval of purchase order.

3 Planning assistant in co-ordination with quality assurance department is responsible for
evaluation of supplier and submit the report to P&P in charge for review and approval.

SALES & SHIPPING DEPARTMENT

RESPONSIBILITIES:

       1. HEAD OF THE DEPARTMENT :

                  The supervisor should look after to the product requirement, the order
                   acceptance, document approval etc.

                  He is the only person responsible for solving the customer complaints,
                   identifications of training needs and maintenance of quality records
                   under his/her guidance.

       2. SALES ENGINEER (Tender Reviews: TR) :

                  Engineer himself is responsible for tender/ enquiry review, and follow
                   up and also for amendments review.

                  He is responsible in preparation of cancellation note, maintenance of
                   concerned quality records & attending the customer during their visit.

       3. SALES ENGINEER (Order Review: OR) :

                  He is responsible for order acceptance.

       4. SHIPPING OFFICER:

                  He is responsible for handling, storage, packing and delivery, dispatch
                   follow up, providing delivery status and allocation of stock.

BABASAB PATIL                                                                            26
           FLOWSERVE MICROFINISH VALVES PVT LTD

PROCEDURE:

a) Sales & Shipping officer will study the packing slip thoroughly with respect to W.O.

b) Size of the box will be decided the S&SO depending on the quantity.

c) S&SO will collect the value remember from Q.A.dept against packing slip



1. STRUCTURE
2. STYLE:

   The style of management in the organization is very much similar to TOP DOWN
    MANAGEMENT. The Director from USA who is at the top most level takes strategic
    decisions and is passed on to the Managing Director of HUBLI of the respective
    company.

   Short term decisions are decentralized in FMVPL and Micro Finish Valves Pvt Ltd as
    the number of employees is more and it would be impractical for the MD to take
    regular decisions.

   Though the decision making is concerned only with the top management, the
    company also emphasizes on PARTICIPATIVE FEEDBACK from the employees
    and helpers on a regular basis to enhance thinking capacity of the employees.

   This is generally done by the Respective department incharge.

3. STRATEGY

    To establish themselves as a global company with strong technology capabilities
FMVPL, has laid increased emphasis on devising its business strategy on aggressive top
line growth, a de-risked business model, increased operational efficiencies and CPI
programme adopted to improve the productivity. The company emphasizes on two key
elements that form the cornerstone of the company’s growth strategy:

       Developing a global product strategy

       Creating an integrated organization with world class quality valve to produce and
        full service supply capability

4. SYSTEM:

    MERIT RATING SYSTEM:

BABASAB PATIL                                                                         27
           FLOWSERVE MICROFINISH VALVES PVT LTD

    OBJECTIVES:
    `To ensure the performance of the supplier with regards to Quality, Delivery, &
    Service.


    SCOPE:
       These ratings are applicable to all the Suppliers, like sub-contractors, vendors,
    traders & suppliers.


RESPONSIBILITY:


          Planning & Purchase Incharge Planning Assistant is responsible rating to
           supplier.
          Planning & Purchase Incharge is responsible to carry out the supplier rating
           with assistance of planning assistant.


REFERENCE:
          Goods received inspection
          Purchase order
          Statistical welding reports
          Rejection notes
          QA department work instruction.


5. STAFF

      Number and types of personnel within the organization.

      Number of employees: Above 70.

      The company considers the employees as one of the major resource. The skills of
       the employees are constantly improved through various training programmes.

      The company organizes regular Departmental meetings MR meeting with the
       members wherein the suggestions and feedbacks of the members are discussed.

6. SHARED VALUE

       Guiding concepts, fundamental ideas around which a business is built – It is
generally simple, usually stated at abstract level, have great meaning inside the
organization even though outsiders may not see or understand them


BABASAB PATIL                                                                        28
            FLOWSERVE MICROFINISH VALVES PVT LTD

7. SKILL:


         Skills refer to the fact that employees have the skills needed to carryout the
company's strategy. Training and Development - ensuring people know how to do their
jobs and stay up to date with the latest techniques.




BABASAB PATIL                                                                       29
           FLOWSERVE MICROFINISH VALVES PVT LTD

                   QUALITY ASSURANCE DEPARTMENT



                                    QUALITY
                                   ASSURANCE
                                    INCHARGE




      RECEIVING                     INPROCESS                 FINAL
       QUALITY                       QUALITY                 PRODUCT




       WORKERS                                  COMPONENT
                                                                          TESTING




High Temperature Test             Fire Safe Test              Cryogenic Test




QUALITY:

        Quality refers to the degree of perfection as perceived by the user of a product. At
Flow serve Micro finish , the objective of the Quality Assurance department is to
maintain a consistent appraisal of the quality of the product at all stages of manufacturing
till the product is dispatched.




BABASAB PATIL                                                                            30
            FLOWSERVE MICROFINISH VALVES PVT LTD

FUNCTIONS OF QUALITY ASSURANCE DEPARTMENT

    Incoming Material Inspection

    In-process Inspection

    Final Inspection

1) Incoming Material Inspection

           All materials are purchased out door such as castings, bars, and bought items-
nuts, bolts and pickings and sub-contract items are inspected as per the drawings or
according to the applicable work instructions

    Receiving Quality Engineer is responsible to ensure that the quality of incoming
components\raw materials\products is in accordance with the established methods and the
quality of all accepted items are conforming to the specified requirements.

    He is only responsible for identification of items, reviewing non-conforming
products\component, sub-contractor rating and for maintaining quality records.

He is also responsible for inspection of castings, bought out items and machined
components, which are received as samples and test the sample material as per the Work
Instruction.

2) In process Inspection

    Components taken for further process are also inspected. Machines that are used in the
manufacturing process are also inspected periodically.

    In process Quality Engineer is responsible to ensure that the in process components\raw
materials\products is in accordance with the established methods and the quality of all
accepted items are conforming to the specified requirements.

In process Quality Engineer is also responsible for identification of items, reviewing non-
conforming products\component and for maintaining quality records and testing and
maintaining hydro shell testing reports of casing and cover.

    In process Quality Engineer is also responsible for ensuring that the special processes
are in accordance with the established methods. (Calibration of inspection and
maintaining calibration records)



BABASAB PATIL                                                                           31
           FLOWSERVE MICROFINISH VALVES PVT LTD

Special process carried out by in process quality Engineer is as follows:

a) Welding:

        In process Quality Engineer is responsible for continuously monitoring the
welding process so as to ensure that it is in compliance with documented procedure. All
the welding process parameters are listed in welding process specification and are carried
out by a qualified welder.

b) Painting:

Painting is carried out as per work instruction of painting specification and the painters
have been qualified based on the past experience.

3) Final Inspection:

          This inspection is mainly to check if any of the lapses that may have occurred in
the above stages.

  Final Product Engineer is responsible to ensure that the products are in accordance with
the established methods and the quality of all accepted items is conforming to the
specified requirements.

  Final Product Engineer is also responsible for identification of items, reviewing non-
conforming products\component and for maintaining quality records and to ensure that all
assembled products\components are identified with regard to inspection and test results.

  Final Product Engineer is also responsible for issuing test certificates, material
certificates, compliance and warranty certificates as against requirement of Work Order
for closing all positive recall loops.

  Final Product Engineer is also responsible for inspection of painted product\
components as per specification.

  Final Product Engineer is responsible to ensure that all outgoing components\ products
are subjected to dispatch inspection. He verifies the components\products material of
construction, size, class, special requirements and metal tags etc with W.O. and ensures
that the sample tested valves are packed with identified box and note down the box
identification and then the inspection and testing results are noted down in the ‘Dispatch
Inspection Report’.

BABASAB PATIL                                                                           32
          FLOWSERVE MICROFINISH VALVES PVT LTD

Inspection colors codes used by the Q .A. Department

Green     :   Conforming

Black     :   Accepted on Deviation

Yellow:       Rework

Red       :   Reject

Dark Blue:    Hold




BABASAB PATIL                                          33
          FLOWSERVE MICROFINISH VALVES PVT LTD



                         RESEARCH METHODOLOGY

       The methodology is the method used in the collecting the information, which
assists for the research problem.

The research design is in the descriptive in nature & for the data collection simple
random sampling method is used.



Statement of the Problem:

Safety Measures for employees in Flow Serve Micro Finish Valves Pvt Ltd



Objectives

      To find out the causes for manual accidents and remedies.

      To study the usage of personnel protective equipments.

      To identify the awareness of workers regarding safety.

      To study the overall effectiveness of the safety.



DATA SOURCES

A) primary data
The primary data collected through survey, by preparing questionnaire and meeting
respondents personally and interviews them and gathering information from them. Like
this primary data was collected. Hence the questionnaire is main source of primary data.


B) Secondary data

The secondary data collected from the company manuals, check lists and through
company web site




BABASAB PATIL                                                                          34
           FLOWSERVE MICROFINISH VALVES PVT LTD

SAMPLING DESIGN AND PROCEDURE

1)The population

       The populations for my project study which I have considered are the Flowserve
Micrifinish pvt ltd



Scope of study:
The scope of the study is, to study about the safety measures of the FSMFV Pvt Ltd. It
undertakes the all employees and all safety facilities which are available at company and
knowing about how they are using.




BABASAB PATIL                                                                         35
            FLOWSERVE MICROFINISH VALVES PVT LTD

SWOT ANALYSIS:


STRENGTHS:

   The company has excellent network, which provide good quality product with
    minimum time

   ISO standard helps to marketing in International Level.

   The good HR system is their like - Motivation, Training, to new employee etc.

   Feed-back information is provided to all employees

   The company has unity of team work, good salary to workers.

   Regular medical checkup & help to employees.

WEAKNESSES:

           It is not having a separate marketing dept.

           No direct exporting.

           No international recognition by its own name

OPPORTUNITIES:

       Potential market for spare parts is growing high.

       Export order received is greater than what they are able to produce, so opportunity to
    increase production capacity for which ready market is available

       Whatever is produced is exported.

       Opportunity to enter plug valve market.

       International Customers shows more interest to buy Flowserve Microfinish products.

       Company has an out bond logistic management and documentation.

THREATS:

No threat in the sense, no competitors for it because it is not a independent firm but has
got JV with Flowserve USA. So threat may be any action of Flow serve USA on Micro
finish like taking back shares invested in Micro finish or can stop giving export order to
Flow serve Micro finish


BABASAB PATIL                                                                                36
          FLOWSERVE MICROFINISH VALVES PVT LTD



                THEROTICAL ASPECTS TO THE STUDAY
INTRODUCTION :-


The Factories Act 1948 is a comprehensive piece of legislation all the aspects regarding
the factories. Under the rule making power practically all the states have framed their and
regulations thereby ensuring maximum advantages In order to trace history of legislation
which resulted in legislation the factories act 1948 we to go back to the last decade of the
19th century. Till the end of 19th century there was no control of the state over the
conditions of employment and the employees did according to their liking and advantage.
After great objections by the employers the Indian factories act 1881 was passed which
gave a limited measure of       protection to children provisions for fencing of some
dangerous parts of machinery were also there. In 1980 government of India appointed a
factories commission and on their recommendation the act of 1981 was passed. In 1911
another act was passed after taking into account the reports of Freer smith committee and
factory labour commission.



Object of the Act

It is clear from the preamble that the factories act was engaged to consolidate and amend
the law regulating labor in factories. It is probably true that all legislation in a welfare
state is enacted with the object of promoting general welfare but certain type of
enactments are more responsible of some urgent social demands and also more immediate
and visible impact on social vices by operating more directly to achieve social reform.




BABASAB PATIL                                                                             37
           FLOWSERVE MICROFINISH VALVES PVT LTD

SAFETY


Meaning:


Safety is a basic and ordinary requirement in a factory. Unless body, mind life of workers
is secured smooth and proper working cannot be ensured in any factory. As indicated
earlier the object of these legislation was to ameliorate working conditions and to provide
with effective measures of safety of the workers from accidents causing partial or total
disablement and sudden misfortunes affecting the victims and their dependants. The
factories act 1948 deals with such security and safety measures under its chapter iv
containing sections 21 to 41. There have been made significant amendment in the
provisions dealing with safety so as to make the measures more effective and appropriate.
It would be desirable to discuss these safety measures.



Fencing of Machinery:- sec 21(1) contains the provisions regarding the safety by fencing
of machinery. The sec lays down that the following shall be security fenced by safeguards
of substantial construction which shall be kept in position when the parts of machinery
are in motion or in use.



   i)      The head race and tailrace of every water wheel and turbine

   ii)     Any part of a stock bar which projects beyond the headstock of a lathe



Speed not to exceed: The speeds so indicated in the notice shall not be exceed and in
every factory effective measures shall be taken to ensure that the safe working peripheral
speed of every revolving vessels, cage, basket, flywheel, pulley disc or similar appliance
driven by power is not exceeded.




BABASAB PATIL                                                                           38
             FLOWSERVE MICROFINISH VALVES PVT LTD



   Employment of young person on dangerous machines:- Section 23 lays down the
   general rule that no young person shall work at any machine to which this sec applies
   i.e any dangerous machine so prescribed under sub sec (2) of sec 23 by the state
   government. However they can be allowed to work if,



          1. They have been fully instructed as to dangers arising out of in connection with
             the machine and the machine and the precautions to be observed, and

          2. Has received sufficient training in work at the machine or is under adequate
             supervision by a person who has a thorough knowledge and experience of the
             machine.



 Precautions against the use of portable electric light: - section 36A provides that in
any Factory,

   a) No portable electric light or any other electric appliance of voltage exceeding 24
          volts shall be permitted for use inside any chamber ,tank, vat, pivot, pipe, flue, or
          other confined space.

   b) if any inflammable gas ,fume or dust is lightly to beset in such chamber ,tank, vat,
          pit, pipe, flue or confined space no lamp or light other than the that of flame proof
          construction shall be permitted to be used their in.



 Precautions in case of fire:-

   Section 38 of the act for the precaution of fire in the factory. The general precaution in
   this     Aspect in that every factory shall be provided with such means to escape incase
   of fire as may be Prescribed, The following other precautions against fire shall also be
   taken,



   a) Exit doors of room shall not be locked so that they can’t be easily opened and all
   such doors unless they are sliding type shall be constructed to open outwards.


BABASAB PATIL                                                                               39
            FLOWSERVE MICROFINISH VALVES PVT LTD

   b) Every window door or other exit affording a means of escape in case of fire other
than ordinary exit shall be distinctively marked in the language of the majority of the
employed persons in red letters of adequate size or by same other effective and clearly
understandable sign etc.

Safety of building and machinery:-

    Section 40 provides the measures for the safety of any building or machinery or
ways, if it appears to the inspector that any building or part there of part of ways or
machinery or plant is in such a condition which is dangerous to human life or safety he
may serve on the occupier or manager or both of factory an order in writing specifying
the measures to be taken and requiring them to be carried out before a date specified in
the order. In the same way if it appears to the inspector that the use of any of the above
mentioned



    Things involves imminent danger to human life or safety he may serve on the
occupier or manager or both on order in writing prohibiting its use until it has been
properly repaired or altered.



No woman or young person be allowed to clean and lubricant etc

Sub section (2) of section 22 lays down that no woman or young person shall
transmission machinery while it is in motion or to clean, lubricate or adjust any part of
any machine if in doing so the women or young person would be exposed to rise of injury
from any moving part either that machine or any adjacent machinery. The state
government may prohibit by notification in the official gazette, in any specified   Factory
or class or description of factories the cleaning, lubricant or adjusting by any person of
specified parts of machinery when those parts are in motion. Section 41 provides that the
state government may make rules requiring the provisions in any Factory or in any class
or description of factories of such further device and measures is so of securing the safety
of persons employed there in as it may deem necessary.




BABASAB PATIL                                                                            40
            FLOWSERVE MICROFINISH VALVES PVT LTD

          Safety measures at Flow Serve Micro Finish valves pvt ltd
Introduction:-
         The Flow serve Corporation of dollars, Texas USA and the micro finifsh group of
companies Hubli, Karnataka, India. Set up to manufacturing plants with joint ventures in
Hubli in 1997. The inauguration of both manufacturing plants occurred on November 1st
1997. Production activities at both plants were initiated immediately after the
inauguration.

         The flow serve micro finish valves pvt ltd engaged in the manufacturing ball
valves, plug valves and other miscellaneous valves products. Adjacent to this plant is the
flow serve valves pvt ltd.

         The manual on safety, health and environmental affairs is intended to customize
the flow serve corporate policy on these affairs in the Indian environment. Hubli is
considered relatively small industrial area of the Karnataka state. Therefore, many
policies prevented on the other major industrial areas of India e.g. Bangalore, Mumbai etc
may not be applicable at hubli location.


SAFETY, HEALTH AND ENVIRONMENTAL POLICY


Introduction
Scope:
    This policy applies to both manufacturing units located in Hubli, Karnataka, India.
Purposes:


      1. To provide safe working environment for all production and staff workers
           including visitors.

      2. To become leader in the community by creating “safe working conditions” for
           employees.

      3. To follow the flow serve and microfinish companies policy on safety, health
           and    environment

      4. To exceed all the governmental, local, state and national rules, policies and
           regulation.


BABASAB PATIL                                                                             41
           FLOWSERVE MICROFINISH VALVES PVT LTD

  Responsibilities:
          The chief operating officers of these units will be responsible for
           implementation, Monitoring and compliance of policy.

          The M.D. will oversee that policy is followed with good intent. The enclosed
           pages cover the various policies, which are deemed appropriate at this Time,
           as government regulations are revised and / or the Flow serve corporate
           policies are updated. This policy will be revised and kept unto to date.



EMERGENCY PROCEDURES


The COO will have the responsibility for coordinating all emergency response measures.
The coordinators will be either on the facilities or on the call (i.e.) available to respond to
emergency by reaching the facility within the short period of time at all times at all times.
The coordinator should be thoroughly familiar with all aspects of the emergency plans,
the operation and activities at this facility involving hazardous materials and the facility
layout. The coordinator will have full authority to commit the resources to needed to
carry out this Plans. Whenever there is an immediate or an actual emergency situation,
the emergency coordinator Shall immediately, active internal facility alarms or
communication system if not activates Automatically to notify or affected personnel. In
the event of discharge fire exposure the coordinator shall immediately identify the
character, Sources amount and content of any discharge material. He/she may do this by
observations and/ Or review facility records of manifests and if necessary by chemical
analysis. Concurrently the Coordinator shall immediately assess the possible hazards to
the human health as environment That may result the discharge, fire or explosion. This
assessment shall consider both direct and indirect assets of discharge fire or explosion. Is
the assessment indicates that evaluation of local areas be advisable. He /she shall
immediately notify the appropriate official is making decision whether local areas should
be evaluated and he will make a report to individual.




BABASAB PATIL                                                                               42
           FLOWSERVE MICROFINISH VALVES PVT LTD



1. Name and phone no or reporters.

2. Name and address of facility.

3. Time and type of accident.

4. Name and quality of materials involved.

5. The extent of injuries, if any

6. The possible hazards to human health or the environment outside the facility.

During an emergency the coordinators shall take all the responsible measure necessary to
insure fires, explosions and discharge do not occur reoccur more spread to other.
Hazardous materials at the facility. These measures shall include where applicable,
stopping, process and operations collecting and containing discharge waste and removing
or isolating container. If facility stops operation in response to a discharge, fire and
explosion the coordinate shall monitor leaks, pressure build up gas generation, or rupture
in valves, pipes or other equipments, whatever this is appropriate.

        Immediately after emergency the coordinate will provide for the treating, storing
or disposing of Recovered waste, contaminated soil, surface waste or any other material
that result from a discharge, fire or explosion at the facility. The coordinators will in
affected areas of the facility that the following items be followed,


        A. No waste that may be incompatible with the discharge material is treated,
stored or disposed of unit cleanup procedures are completed.


       B. All emergency equipment is cleaned and fit for its intended use before
operation is resumed.


EMERGENCY EQUIPMENT


Fire extinguishers and red colored bucket with sand (marked fire) are placed in the
facility.


CONTINGENCY EMERGENCY PLAN




BABASAB PATIL                                                                          43
          FLOWSERVE MICROFINISH VALVES PVT LTD

Spill containment:


1. All containers with hazardous. Waste materials shall be kept in the appropriate storage
Area. Containers shall be handled in such way and with the proper equipment, as to avoid
Damage and possible spill.


2. If a spill occurs out side of the normal storage area immediately connected the
emergency
Coordinator clean up procedure of containment of spill shall be accomplished as follows,


a) Providing adequate ventilation and obtain protective clothing.


b) Utilizing sand spread sufficient amount of the spill to correct the materials.


c) Sweep or reside into containers and properly label prepare for the disposal.



FIRE PREVENTION PLAN


The fire extinguishers shall usually inspected monthly and annually certified. All heat
producing equipment shall be inspected at least annually during the month of October
and at the any other time that maintenance is bring performed in the equipment to
prevent accidentally ignition of combustible materials a list of heat producing equipment
shall include, but is not limited to,


a) Generator – Flow serve Micro finish Valves pvt ltd.
b) Generator – Flow serve Micro finish pumps pvt ltd.
c) Electrical Sub-station area.




BABASAB PATIL                                                                           44
          FLOWSERVE MICROFINISH VALVES PVT LTD

FLOWSERVE MICROFINISH: SAFETY CHECKLIST


  1. Safety records keeping
     a) Verification of records.
     b) Verification of reports.


  2. Employees Protection
     a) Safety glasses
     b) Safety shoes
     c) First aid kit
         No empty bottles / tubes
         No expired date of bottles / tubes
         Trained employees names
         First aid kit list outside the cabinet


  3. Machines, Equipment etc
     a) Machine chip guards
     b) Machine safety guards
     c) No trash/chips/coolant around machine
     d) Grinders: opening between tool rest and wheel less than 1/8”


  4. Electrical
     a) No extension cords
     b) Electrical cords – Not on pedestrian traffic areas
     c) Easy access to electrical panels
     d) Machinery / Equipment properly grounded
     e) Electric substations closed and locked with warning signs


  5. Environmental
     a) Coolant waste tank – utilization
     b) Machine chip storage areas – organized and chips contained
     c) No unmarked bottles /cans/ tubes
     d) No unused bottles / cans / tubes
     e) No chemical spills on floors
     f) Proper ventilation around painting areas

BABASAB PATIL                                                          45
          FLOWSERVE MICROFINISH VALVES PVT LTD


  6.   Housekeeping
       a) No broken /damaged /floors
       b) No wet areas including toilets
       c) No trash on the plant floor
       d) No trash around the JV property
       e) Location of trash cans inside the JV property
       f) Aisles clearly marked – repaint if needed
       g) Everything should have a home


  6. General
       a) Fire extinguishers every 15 meter or 50
       b) Fire extinguishers – periodically inspected and documented
       c) Easy access to the ‘Fire Extinguisher’
       d) Nothing stationery in aisles
       e) No storage in the marked aisles areas
       f) No storage the painted yellow/red areas
       g) No splinters / sharp corners on any device/object/part
       h) Everything properly organized/secured




BABASAB PATIL                                                          46
           FLOWSERVE MICROFINISH VALVES PVT LTD

                                         DATA ANALYSIS




                 work experience in flowserve microfinish valves pvt,ltd

                    more then 10 years


                                                          les s then 5 years




                    5-10 years




 Analysis: From the above graph we understood that 30% of the employee’s are working
 from less then 5 years, 50% of them are working from 5-10 years, and 20% of them are
 working from more then 10 years.

Interpretation: From the survey it is revealed that majority of the employees (50%) are
working from 5 to 10 years.




 BABASAB PATIL                                                                      47
          FLOWSERVE MICROFINISH VALVES PVT LTD




Analysis: From the above graph it is observed that out of the total, 20% employees are
aware about 40-60% of the company safety measures. And 40 % employees are aware
60-80%. About the company safety measures.



Interpretation: As per the survey we come to know that 60-80% numbers of employees
are aware of company’s safety measures.




BABASAB PATIL                                                                        48
            FLOWSERVE MICROFINISH VALVES PVT LTD




                           safety measure company has provides

                                                                      shoes

                                                                hand gl oves
                                                         safety(eye)gl asses




                   all the above




Analysis:


From the above graph shows that the company has provided all required safety facilities.
Shoes, Hand gloves, Safety (eye) glasses, Face shield etc. 94% workers are having all
these facilities and remaining 2% workers are having shoes and hand gloves.


Interpretation:
As per the survey we come to know that 94% of the employees are having all the
facilities of safety measures of the company.




BABASAB PATIL                                                                        49
            FLOWSERVE MICROFINISH VALVES PVT LTD




                  emergency safety tools available in company premises


                                                          emergency signals(li




                     all the above




Analysis:
From the above and graph shows that all required emergency safety tools are available at
company premises. Emergency warning bell, Emergency exit doors, emergency phone,
and emergency signals (light) etc. 96% of the workers are knows about all these and only
4%
Interpretation:
As per the survey it is interpreted that 96% of the employees are knows about all
emergency safety tools available in company premises.




BABASAB PATIL                                                                         50
            FLOWSERVE MICROFINISH VALVES PVT LTD




                  company has trained how to use of fire extinuishers




                                                                   yes




Analysis:
From the above table and graph shows that the training of fire extinguisher, company has
given training to the all workers about how to use the fire extinguishers in case of fire
accidents. 100% workers are trained.



Interpretation:
As per the survey all the employees are trained how to use fire extinguisher.




BABASAB PATIL                                                                         51
            FLOWSERVE MICROFINISH VALVES PVT LTD




                      ventilation and lighting facility in working area



                   average


                                                                very good




                   good




Analysis:
From the above table and graph shows that the company has well ventilation and lighting
facility at working area. The 40% workers are told very good and 28% workers are told
good and 32% workers told that average about the ventilation and lighting facility.


Interpretation:
As per the survey 40% of the employees are satisfied with the company lighting in
working area.




BABASAB PATIL                                                                       52
            FLOWSERVE MICROFINISH VALVES PVT LTD




                   are you satisfied with company's safety norms


                  highly sati sfied




                                                            moderate




                  satisfied




Analysis:
From the above table and graph shows that the workers are satisfied with company’s
safety safety norms.22% employees are moderate and 15% are satisfied and 13%
employees are highly satisfied with company norms.


Interpretation:
As per the survey 44% of the employees are moderate about company’s safety norms




BABASAB PATIL                                                                      53
            FLOWSERVE MICROFINISH VALVES PVT LTD




                  does company takes sugggestions or opinions from you




                                                                  yes




Analysis:
From the above table and graph shows that, the company takes suggestions about the
safety from workers.100% are told yes’. Company has takes suggestions.


Interpretation:
As per the survey all the employees are told company takes suggestion or opinions about
safety measures.




BABASAB PATIL                                                                        54
            FLOWSERVE MICROFINISH VALVES PVT LTD




              in case of accidents how does the company compensates


                   any others (spec ify)



                                                              ins urance




                   compensation




Analysis:
 From the above table and graph shows about the insurance and compensation facility of
the company. 32% employees are told insurance and 60% employees are told
compensation and 8% are told others.


Interpretation:
As per the survey 60% of the employees are told compensation is provided in case of
accidents.




BABASAB PATIL                                                                         55
            FLOWSERVE MICROFINISH VALVES PVT LTD




                       is company provides you any type of loans


                   other




                                                        children education l




Analysis:
 From the above table and graph shows about the loans, the company provides loans to
the workers. 98% workers are told company provides children education loans to workers
and 2% other loans.


Interpretation:
As per the survey 98% of the employees are said that company provides children
education loan.




BABASAB PATIL                                                                      56
            FLOWSERVE MICROFINISH VALVES PVT LTD




                  are you satisfied with overall management safety polies


                     neither satis fied,no


                                                            highly sati sfied




                     satisfied




Analysis:
 From the above table and graph shows that the company workers are satisfied with over
all management policies. 40% are highly satisfied and 30% are satisfied and 30% are
nither satisfied nor dissatisfied.


Interpretation:
As per the survey 40% of the employees are highly satisfied with over all management
safety policies.




BABASAB PATIL                                                                          57
         FLOWSERVE MICROFINISH VALVES PVT LTD



                                        Findings

     50% of the employees in Flowserve Micro finish Valves are working from past 5-10
      years and 5% are working from last 5yrs that is they have good experience.


     It is being observed that 80% of employees are aware of 60-80% of safety measures
      policies remaining 20% employees are aware of40-60% safety measure policies


     The company almost provides all safety measures as it is opinion of 94% of employees.
      Remaining 6% employees are dissatisfied.


     The company almost provides all safety tools as it is opinion of 96% of employees. Rest
      4% employees are only knows about emergency signals (light).


     100% employees have agreed that they are trained in using fire extinguishers.


     40% employees find that ventilation and lighting facility is very good. Remaining 28%
      workers are told good.


     Only 26% employees are highly satisfied and rest of 74% employees are moderate about
      safety norms.


     The company provides only the 60% compensation and 40% insurance to the employees.


     The company provides 98% children education loan which is not enough for the
      employees existence.2% others.




BABASAB PATIL                                                                              58
        FLOWSERVE MICROFINISH VALVES PVT LTD

                                SUGGESTIONS


       The company may conduct seminars on the safety policies so as to make all
        the employees be aware of it.

       As the accidents that occur during the welding, cutting, drilling and polishing
        the company may provide the insurance facilities to employees in case of any
        bad events (accidents) are takes place (occurs) especially the employees who
        work under risky job.




BABASAB PATIL                                                                       59
          FLOWSERVE MICROFINISH VALVES PVT LTD

                                   CONCLUSION


       During the study we come to know that all workers of FSMFV Pvt Ltd are
satisfied regarding company’s all safety measure facilities. The company has takes care of
employees. Company has provides all basic required safety facilities to employees.

         At Flow Serve Micro Finish Valves pvt Ltd the study of Safety Measures
reveals that the more caution take for safety and personnel protective equipment. The
zextent of occurrence of accidents are uncared conduct by the work, which results hit, fall
or slip etc .Flow Serve Micro Finish Pvt Ltd has safety committee of members, which
comprises each person from administration department to the worker. Flow Serve Micro
Finish Valves Pvt Ltd company conduct safety walk or round once in fifteen days along
with the worker and safety members once in two months safety training for Flow Serve
Micro Finish Valves Pvt Ltd conduct safety meeting once in quarter safety audit is done
once in a year from Flow Serve USA. Flow Serve Micro Finish Valves Pvt Ltd has first
aid facility, kept suggestion box, safety slogans are written on the walls. Flow Serve
Micro Finish Valves Pvt Ltd sents safety reports to Flow Serve USA corporation once in
every month. The company has got safety facility award from Flow Serve USA
corporation.




BABASAB PATIL                                                                           60
         FLOWSERVE MICROFINISH VALVES PVT LTD




                             BIBLIOGRAPHY


1. Company Manuals:

 a) Work instruction

 b) Procedure

2.Company Safety Measures Checklist and through observation

3.HRM By P.Subbarao

Websites:

  a) www.microfinishvalves.com

  b) www.microfinishgroup.com




BABASAB PATIL                                                 61
          FLOWSERVE MICROFINISH VALVES PVT LTD


                                  QUESTIONNAIRE


Dear Sir/Madam,
Your Valuable opinion by filling of the questionnaire given below.


    1) Personal profile


       Name          :                                        phone no:


       Age           :                                        Email ID:


       Occupation:


Please read each statement given below carefully and put a tick in the column which bet
reflects your personal opinion.


   2) How long you have been working here?


     a) Less than 5 years [ ]     b) 5years – 10 years [ ] c) More than 10 years [ ]



   3) To what extent are you aware about the company’s safety measure policies?
      a) 10 – 20%         [ ]                b) 20 – 40%     [ ]


      c) 40- 60%          [ ]               d) More          [ ]



   4) What type of safety Measures Company has provides you?


     a) Shoes            [ ]      b) Hand gloves      [ ]    c) Safety (eye) glasses   [ ]


    d) Face shield       [ ]      e) all the above     [ ]



BABASAB PATIL                                                                           62
           FLOWSERVE MICROFINISH VALVES PVT LTD


    5) What are the emergency safety tools available in your company premises?


     a) Emergency warning bell         [ ]          b) Emergency exit doors     [ ]


     c) Emergency signals (light)      [ ]            d) All the above          [ ]



    6) Whether company has trained how to use of fire extinguishers in case of fire?


     a) Yes      [ ]           b) No         [ ]


If No, the reasons are:

            Lack of interest in yourself                                     [ ]

            Lack of Training                                                 [ ]

            Any others (specify)………………………………………..


    7) How is ventilation and lighting facility in working area?


     a) Very good [ ]      b) good [ ] c) average [ ] d) poor [ ] e) very poor [ ]


    8) Are you satisfied with company’s safety norms?


.


Highly dissatisfied       Dissatisfied             Moderate       Satisfied           highly
satisfied


   9)     Does your company takes suggestions or opinions from you?(about safety
measures)


     a) Yes      [ ]          b) No          [ ]



BABASAB PATIL                                                                              63
         FLOWSERVE MICROFINISH VALVES PVT LTD

  If No, the reasons are:

   Lack of time                              [ ]

   Lack of interest in the Management        [ ]

   Any others (specify)…………………………………………………



     10) What are the options given by the company in case of accidents?


   a) Insurance       [ ]          b) Compensation             [ ]


   Any others (specify)…………………………………………………



  11) Is your company provides you any type of loans? (like)


   a) Housing loan     [ ] b) children education loan [ ] c) other [ ]



  12) Are you satisfied with overall management safety policies?


  1) Highly satisfied                                [    ]
  2) Satisfied                                       [    ]
  3) Neither satisfied, nor dissatisfied             [    ]
  4) Highly dissatisfied                              [    ]
  5) Dissatisfied                                              [ ]




BABASAB PATIL                                                              64
      FLOWSERVE MICROFINISH VALVES PVT LTD



  13) Any suggestions regarding safety measures……………………………………
  ……………………………………………………………………………………..
  ……………………………………………………………………………………..




     THANK YOU FOR SPENDING YOUR PRICIOUS TIME WITH ME




BABASAB PATIL                                                   65
      FLOWSERVE MICROFINISH VALVES PVT LTD




BABASAB PATIL                                66

								
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