A

Industrial Visit Report

On

Karnataka Turned Components Pvt. Ltd .,Bangalore

04-03-2010

A Industrial Visit Report Submitted in partial fulfillment of the requirements.

To

MBA-MKU(Industry Integrated)-IV Sem.

At

Krupanidhi Business School,Bangalore-35

Submitted To:- Submitted By:-

Prof. Bobby Jacob Bhanwar Singh

Reg.No.A8754917
Industry Profile
Industry Profile

Automobiles Components
Indian Automobile Components Industry has been making rapid strides towards
achievement of world-class Quality Systems by imbibing ISO 9000/QS 9000 Quality
Systems. Till now 230 companies in ACMA membership have been certified to ISO
9000 and 87 companies have been certified to QS 9000 and 4 companies awarded to
ISO 14000.

The industry has been exporting more than 10% of its output for the last few years. In
the year 1999-2000, industry has exported US$ million 396 versus US$ million 333 in
year 1998-99. Principal export items include replacement parts, tractor parts,
motorcycle parts, piston rings, gaskets, engine valves, fuel pump nozzles, fuel injection
parts, filter & filter elements, radiators, gears, leaf springs, brake assemblies & bearings,
clutch facings, head lamps, auto bulbs & halogen bulbs, spark plugs and body parts.

India has a good network of manufacturers of Auto components and spares spread all
over the country. These component manufactures also manufacture all kinds of parts for
all Indian vehicles apart from Japanese, German & Continental Vehicles. They have the
capability to design as per client's specification / drawing to provide them quality
service.
International standards are also kept in mind while producing these products. Best
quality materials are used so as to meet the international standards. The list varies from
Alternator Assemblies, Alternator Stators Coils, Alternator Rotors/Coils, Alternator
Rectifiers, Alternator Regulators, Alternator Carbon Brushes, Alternator Vaccum Pump,
Blades, Alternator Plastic Insulators, Starter Assemblies, Starter Armatures, Starter
Components, Electronic Relays, Timer Relays, Signal Flashers, Heater Glow Plugs, Tie
Rod Ends & Ball Joints, Engine Mounting, Suspension Rubber Bushing, Clutch Plate &
Covers Assy, Gaskets, Radiators, Universal Cross Assembly, Couplings, Propeller
Shaft Assy, Fly Wheel Ring Gears, Brake Parts, Nut & Bolts, Jacks, Bearings, Plastic
Gears, Bearing Housings, Wheel Spanners, Filters (Oil, Air, Fuel), Diesel Pump Parts,
Automobile Acessories like Wheel Caps, Car Speakers, Fog Lights, Car Care Products,
CAR AC PARTS, Car AC Condenser, Car Cooling Coil, Car AC Hoses, Car Reciver
Drier, FLCD Kit and Car Batteries.

Some Interesting facts

Indian Auto Industry is the

 Largest Three Wheeler Market in the World

 Second largest Two Wheeler Market in the World
 Fourth largest Passenger Vehicle Market in Asia
 Fourth largest Tractor Market in the World
 Fifth largest Commercial Vehicle Market in the World

The Future Growth Drivers

 Higher GDP Growth

 India's huge geographic spread- Mass Transport System
 Increasing Road Development
 Increasing disposable Income with the service sector
 Cheaper ( declining interest rates) & easier finance Schemes
 Replacement of aging four wheelers
 Graduating from two wheelers to four wheelers
 Increasing dispensable ncome of rural agri sector
 Growing Concept of Second Vehicle in Urban Areas

India is the second Largest Producer of Motorcycles in the world (5.2 Mln) after
China which has a production volume of 12 Mln
Range of Vehicles made in India include

Light Passenger Vehicles including Passenger Cars, MUV's, SUV's, Commercial

Vehicles including Light Commercial Vehicles, Medium and Heavy Commercial Vehicles
and Buses, Tractors including Farm, Earthmoving and Construction Equipments, Two
Wheelers including Motorcycles, Scooters and Mopeds, Three Wheelers including
Passenger Carriers and Goods Carriers.

Turned Components Manufacturing Companies in India :

These following are major turned components manufacturinf companies in India:

 CNC Turned Component,Bangalore

 Pricision Turned Parts

 Brass terminal Bars Hose filting,Jamnagar,Gujrat

 Aggarwal Chempack Enterprises Pvt. Ltd.

 Apollo Engineers,Ludhiana,Punjab

 Ashwani Metals Pvt.Ltd.,Jamnagar,Gujrat

 Creative Manufacturers,Mysore

 D.M. Tools & Components Pvt.Ltd.,Gurgaon,Haryana

 Filtech,Bangalore

 Karnataka Turned Components Pvt.Ltd.,Bangalore

Company Profile
Company Profile:

KARNATAKA TURNED COMPONENTS PVT. LTD.

Company Profile:
Business Type Exporter , Manufacturer , Supplier
Capital in Dollars US $ 120 Million
Export Percentage 25%
Primary Competitive Good Quality, Prompt Delivery and Competitive Price
Advantages
Sales Volume Rs. 24 Crore
No of Staff 200
Year of 1960
Establishment
No of Production 2
Lines
Export Markets USA, UK
Investment on Rs. 8 Crore
Manufacturing
Equipment
OEM Service No
Provided
No of Engineers 50
Monthly Production As Per Customer Requirement
Product Range Automobiles Components, CNC Machined Components,
Components for Automotive Industry, Aerospace Components,
Hydraulic Components, Textile Industry Components, Machine
Tool Components, Pneumatic Components.
The Group - An Overview

With a humble beginning in 1960, D.G.Naidu Group began with a single - minded
determination to explore opportunities in the Precision Components manufacturing
industry. and thus started its pursuit of perfection and its zeal for complete customer
satisfaction.

Adding value to every batch manufactured, by earning and keeping customer trust
and by helping customers earn and keep the trust of their own customers. D.G.Naidu
Group has created a distinct niche for itself in the business.

About Company:

Established in the year 1960, “Karnataka Turned Components Pvt. Ltd.” has
proven to be the most preferred manufacturer, supplier and exporter of Automobiles
Components, CNC Machined Components, Components for Automotive
Industry, Aerospace Components, Hydraulic Components, Textile Industry
Components, Machine Tool Components and Pneumatic Components. Our
products enjoy a unique place in the market, owing to their impeccable quality and
excellent efficiency. Our perfect combination of outstanding quality, customer centric
management, prompt services and cost effectiveness has given us cutting-edge over
our competitors. Today, we have two manufacturing companies which are engaged in
the production of precision engineering components of complex design and close
manufacturing tolerance for the automotive, hydraulic, aerospace, pneumatic,
transmission and machine tool industry. The success that we have achieved is
attributable to the professional expertise and  sheer business acumen of our
personnel.

Product Range of KTCPL:

With the voluminous experience and stringent quality standards, we have developed a
tradition of high-tech engineering, quality manufacturing and very competitive pricings.
We offer an array of products for wide spectrum of industries. Our range of products
include:

 Automobiles Components
 CNC Machined Components
 Components for Automotive Industry
 Aerospace Components
 Hydraulic Components
 Textile Industry Components
 Machine Tool Components
 Pneumatic Components

Quality
Quality, performance and cost effectiveness is the
USP of the company. Our uncompromising
endeavor towards perfection, quality and customer
satisfaction has helped us to achieve the maximum
degree of customer satisfaction and creating a
valuable niche for our products in the international market. We take special care from
the procurement of the raw materials to the final delivery of the finished products. 

The Mission

The continuous development of a company that partners customers in their progress...

delivering products with zero defect... on time.... every time. Targeting always to
surpass their expectations of us.

Infrastructure:
We are backed-up by the state-of-the-art manufacturing unit and latest technology.
We are professionally organized with a team of astute and diligent workers coupled
with hi-tech machineries suitable for carrying out business operations effectively and
efficiently. We undertake strict steps to control any manufacturing defects which may
occur during the production process. Our investment and progress are not only
confined to manufacturing facilities but also equipped with capital measuring
equipments like Co-ordinate Measuring Machine, Roundness Tester, Profile
Projectors, Surface Roughness Testers, Linear Height Gauge and Boroscope. We are
also equipped with the captive power generation so that 24 hours of alternative power
supplies ensure implementation of optimum processes and timely delivery of products.

People Power

Workforce of over 200 dedicated employees form the strong pillars of D.G.Naidu Group.

Qualified engineers manage key positions like planning, production, purchase and
quality assurance activities, within the company. Other technical staff responsible for
day-to-day production has extensive engineering industrial exposure.

The company's people oriented policies are based on a set of well-defined values and
practices. By offering a combination of competitive remuneration recognition and
benefits, careers flourish within the company. Over 80% of its employees have been
with the organization for well over 5 years.

Quality Focus
In D.G.Naidu Group, continuous improvements of processes is not an assignment, but a
way of life. This tradition of quality consciousness is linked directly to the Group's history
of excellence and success.

Quality Management System

Both manufacturing companies of the D.G.Naidu Group, till 2003, were certified as ISO
9002 : 1994 and upgraded to ISO 9001 : 2000 Quality Management System standards.
We are not stopping at this milestone; we strive to achieve higher and more stringent
quality management system recognition.

Customer Ratings

We have been consistently rated over a period of 15 years as an 'A' category supplier
for Quality and Delivery by our reputed customer manufacturing Fuel Injection systems
for Diesel Engines. Over this period, our operating companies have received
Performance Awards and Awards for Excellence.

Further, both operating companies qualify for self-inspection and 'Just In Time' supply of
components for delivery to the Customer assembly lines.

In addition to supplying to a substantial number of domestic customers, our components

and sub-assemblies are exported to the Customers' plants in USA and UK.

Envisioning Tomorrow/Vision

D.G.Naidu Group's vision for the future is seen through the keen eye of the present. We
are well aware that we must lay the foundation today for a future that is promising and
abreast to the volatile changes in technology. With this as a background, the Group
Continually modernizes our facilities by strengthening our infrastructure. It is for this
reason that we have constructed our latest purpose-built factory offering a modern
environment with further opportunity for expansion. We took forward to the future with
hope to explore new horizons.

Precision Auto Turned Parts & Components/Products

Quality Standard:
The quality standard of KTCPL is TS Technical Standard.TS was formulated by three
automobile companies,General Motors,Ford,Cricelor.The quality standard of KTCPL is
TS-16469.

Control System:

The whole processes or operations in KTCPL of manufacturing are based on

CNC(Computer Numeric Control).

Recruitment Process:

All employees in KTCPL are permanent and are recruited by HR Manager .The HR
department of KTCPL is at Kormangla .There are no contract base employees.

Departments:

There are following departments:

1.Production Department

2.Training Department

3.Raw material Storage Department

4.Quality Checking Department

5.Finished Goods Storage Department

6.Manufecturing Department

Major Clients of KTCPL:

The major clients of KTCPL are following:

1.BOSCH

2.MICO

Turn Over in 2009(In Percentage):

The turn over of KTCPL in year 2009 was very low.It was 7%-8%.

Production Process:

There is main operation is Turning Operation.Under turning operation there major

operation is milling operation.Under Milling Operation there are t major 20
operations.For example:

1. Deburring Operation
2. Drilling
3. Cross Holl Drilling
4. Grooving
5. Inscription Rolling
6. Visual Inspection
7. Small Product Checking Process
8. Punching Operation
9. Tapping Operation
 Visit Review

The Industry Visit an Overview:

The Industrial visit was helded on 04-03-2010 to Karnataka Turned Components Pvt
.Ltd., Huskur Road ,Electronic City Post ,Bangalore.

Visit Review:

The company was basically dealing in automobiles components manufacturing .It is 48

years old company. It has TS-16469 Quality Certificate .The name of person from we
met in organization was Mr. Ananth Chief Operation Officer . The name of person who
told us about whole turning and manufacturing operation of organization was Mr.
Ramesh .He is a Production Manager in that company.

During visit we saw that there was total 20 turning operations .The all turning operations
are called milling operations .The operations under milling operation was as follows:

1.Deburring Operation: This operation was related with the deburring and cleaning of
products of KTCPL.
2.Drilling:This operation was related with drilling.In this operation they were drilling hole
in the components /products.There were two type angels hole making process 43
degree and 75 degree.
3.Cross Hole Drilling:This process was related with cross hole doing process in the
products.
4.Grooving:This operation was related with grooving.Grooving means the process of
writing product name,mfg date,product id,etc by using hydraulic roll marker by rolling
machineusing heating and punching process.
5.Inscription Rolling:This process was related with inscription of small product.
6.Visual Inspection:This process was related with the internal checking of manufactured
product by using Techno Scope Machine.The cost of this machine was 12 lakh.
7.Small Product Checking Process:This operation was related with quality checking
of small products.
8.Milling Operation:This operation was related with milling of products.
9.Punching Operation
10.Tapping Operation
11.Quality Checking Process:This operation was related with checking of quality of
finished goods.

Products of KTCPL:

The products of company was as follows:

 Guide Bush
 Spring
 000Nozzle Retaining Nut
 Rod clevis
 383 Gear Segment
 !08 Pump housing
 Guide
 PFS1 Housing
 PF33 Pump Barrel
 319 Cap Nut
 000 Intermediate Fitting
 Aluminium Disc
 Common Rail(It is new product of KTCPL for Nano Car.It is also used in
Bajaj,Mahindra,etc.)

Employees:

There were 200 employees in company and there were three working shifts .Timing of
working shifts was as ,shift 1- 6.15am to 18.15pm shift 2-18.15pm to 6.15am and the
general shift was 8.00am to 20.00pm.

The “ 5S ” Training Before Permanent Employment:

Before going permanent employment ,the employees are provided 5s training. 5s is

“Set of techniques providing a standard approach to housekeeping within Lean
Management”. The 5s are as follows:
“5S”

1. Seiri (Sort)

2. Seiton (Set)

3. Seiso (Shine)

4. Seiketsu (Standardisation)

5. Shitsuke (Sustain)

1. Seiri (Sort): The identification of the best physical organization of the workplace.

2.Seiton (Set):The series of steps by which the optimum organization identified in the
first pillar are put into place.

3.Seiso (Shine): Anglicized as cleanliness.

4.Seiketsu (Standardisation): Standardized Cleanup.

5.Shitsuke (Sustain) :Discipline.

KTCPL An Overview of Picture Gallery and Charts

Turning Pareto Chart Jan-10

Number of Suppliers N.C & 8D/Action Plans-2009

On Job Training-2009-10
Attendance Bonus-2009-10

Picture Gallery Of KTCPL

Personality Development Training In KTCPL,Bangalore