INTRODUCTION TO COMPANY
Established in 1992 by a visionary Shri Meghjibhai Patel, the company, K Patel
Metal Industries Pvt. Ltd. has grown today as a pioneer in manufacturing super
enameled and bare copper wires and strips. Copper wires and strips are general
purpose industrial raw materials with wide applications in manufacture of
transformers, motors, alternators, relays, switches, domestic appliances, lighting
fixtures and a host of other electrical and electronic products. The manufacturing
facility in Mumbai is equipped with latest machinery and equipment and the head
office is located at Borivali, Mumbai from where all marketing operations are
conducted whereas their sales office is located is Nasik. The company has a notable
national presence and has carved out a niche in International market. Their customers
include major electrical equipment manufacturers in India and abroad, and they
export products in Gulf countries and Africa. They have a highly qualified and
professional team supported by reputed technologists and disciplined work force. As
experienced insulated copper winding wires / strips producer, the group acquired
skills in product development, understanding international customer needs and quality
assurance practices. In the company's quest to meet the most discerning needs and
requirements of their valued customers, no compromise is made on quality. It has
customers across world who have accepted brand and quality.
To sustain its image as a quality conscious organisation, the group has commissioned
a quality assurance facility equipped with latest equipments. The group is awarded
ISO 9001:2000 certification and the products are also certified by UL & RDSO. The
company does not follow the Economic Order of Quality.
The company maintains stock records for finished products, for major store items,
raw consumption record, finished production record; finished goods dispensed record,
sales return register, purchase register, sales register, purchase return register and cash
Q.1 Briefly describe the product
Q.2 How is the product manufactured?
Q.3 From where do you get the raw materials?
Q.4 Is E.O.Q. followed by your company?
Q.5 Is labour paid by piece or by time?
Q.6 What are the various incentives given to the labourers?
Q.7 How much is the sales of the company approximately?
Q.8 Where is the factory located? Any other branches, if any?
Q.9 How many offices do you have?
Q.10 What are the various stock records maintained by the company?
Q.11 Could you provide us the tentative cost sheet of the product?
Q.12 To which company do you supply your products?
INTRODUCTION TO PRODUCT
The company manufactures many wires namely Enamelled Rectangular
Copper wire strips, Enameled round copper wire, Glass fiber covered copper wires
and strip, Paper covered copper wires and strips, Bare copper wire &strips.
However the main product it manufactures is Enamelled Rectangular Copper Wire
Strips. These strips are of many varieties including Polyester Enamelled Rectangular
Copper Wire Class, Polyesterimide Enamelled Rectangular Copper Wire Class,
Polyesterimide over coated with polyamide-imide enamelled Rectangular Copper
Wire Class, Polyvinyl acetal enamelled Rectangular Copper Wire Class.
After receipt of raw material CC Rod a sample having length of 500 mm is being sent
to Quality Control Laboratory for inspection. After receipt of Inspection report the
Copper rod is taken for start up of production as per the production plan.
Firstly the Copper Rod is taken in Bull Block/RBD to reduce the dimension of raw
material Copper for required dimensions. After drawing sizes from Bull Block/RBD
the material is sent for Wire Flattening Mill/Annealing/Enameling according to
production plan. In the Wire Flattening Mill the process will go on up to required
size and then the same is taken for Annealing followed by Enameling.
After Annealing process samples are sent to the Lab for testing. After Quality
confirmation the material is send for further process like Enamel Coating, Glass Fibre
Covering & Paper Covering.
After all the processes there is a process inspection as per quality plan, samples are
sent to Laboratory for final testing.
After final testing the material is being shifted to weighment and then transferred to
Bonded Storage Room (BSR) for despatches. Each and every consignment is
accompanied by a Test Report from Q.C Laboratory.
INTERRELATIONSHIP OF PROCESSES
Receipt of order,
specifications, inspn. plans &
Receipt and logging Review of enquiry, offer approved samples, resolving
Marketing of enquiry making discrepancies review &
Review of order, stocks
Indent on vendor , Supply
Planning & Purchasing review and pending
prodn. planning monitoring
Vendor evaluation / Revaluation of
Stores Receipt of supply from
vendor & customer / receipt
of finished product Customer
QA plans &
Inspection/ Calibration Customer complaint
Quality Assurance Customer
raw material, Production & Final
Production production. process inspection inspection
Maintenance Preventive &
PAYMENT TO WORKERS
The workers are paid generally on an hourly basis. This is because their working
hours keep on fluctuating depending upon the orders received by the company. Since
they work on a temporary basis the easiest way to pay them remuneration is by the
The company provides them with other benefits to boot their morale. Some of these
include housing facilities, production incentives, and medical allowances. The
company takes great care of the employees and ensures physical security as the
production processes are hazardous to the safety of the employees.
SUPPLIERS AND CUSTOMERS
The raw materials required for manufacturing the product are obtained from various
companies which are Hindico Industries Ltd – unit Birla copper, Sterlite Industries
Ltd; Polycab wires Pvt Ltd; Dr. Beck Ltd(India) – insulating material.
The product is supplied to L &T, Bharat Bijli Limited, Crompton Greaves, Bharat
Heavy Electrical, Indian Railway, Defence(army and navy), ABB Ltd, Encore
switches gear and cable Ind Ltd, Kerala electrical and allied Eng. Co. Ltd, the Hukeri
Taluka Co-op rural electrical Ltd(Karnataka), Emerson network power(India) Pvt.
COST SHEET OF ENAMELED COPPER STRIP
PARTICULARS Rs. NO. OF KG. COST PER
Copper rod 35,00,000 10,000 350.00
Varnish 1,20,000 10,000 12.00
Transport Inwards 25,000 10,000 2.50
PRIME COST 36,45,000 10,000 364.50
Power and Fuel 75,000 10,000 7.50
Labour Charges 60,000 10,000 6.00
Stores and Consumable 5,000 10,000 0.50
Repairs to Plant and Machinery 10,000 10,000 1.00
Factory Cleaning 2,500 10,000 0.25
Factory Lighting 20,000 10,000 2.00
WORKS COST 38,17,500 10,000 381.75
Directors Remuneration 20,000 10,000 2.00
Telephone and Mobile Expenses 4,000 10,000 0.40
Commission 15,000 10,000 1.50
Rent, Rates and Taxes 2,000 10,000 0.20
Printing and stationery 2,000 10,000 0.20
Security Charges 3,000 10,000 0.30
Legal expenses 2,000 10,000 0.20
General Expenses 6,000 10,000 0.60
COST OF PRODUCTION 38,71,500 10,000 387.15
SELLING AND DISTRIBUTION OVERHEAD
Packing Material 32,500 10,000 3.25
Sales and Promotion 6,000 10,000 0.60
Rent of Warehouse 30,000 10,000 3.00
Commission on sales 60,000 10,000 6.00
COST OF SALES 40,00,000 10,000 400.00
Add: PROFIT 8,00,000 10,000 80.00
SALES 48,00,000 10,000 480.00