Automotive Spare Parts and Components
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Transcript of Automotive Spare Parts and Components
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CHAPTER 1
INTRODUCTION
1.1 INDUSTRY PROFILE
Automotive spare parts and components are a lesser known industry yet a big one.
In past few years the industry has grown enormously, even more than the automotive
industry itself not only in the Indian but the global scenario.
The Indian auto component industry is one of India's sunrise industries with
tremendous growth prospects. From a low-key supplier providing components to the
domestic market alone, the industry has emerged as one of the key auto components
centers in Asia and is today seen as a significant player in the global automotive supply
chain. India is now a supplier of a range of high-value and critical automobile components to
global auto makers such as eneral !otors, Toyota, Ford and "olkswagen, amongst others.
As per a report by the Automotive #omponent !anufacturers Association of India
$A#!A%, the turnover of the auto component industry is being estimated at around &( )*.+
billion in +*-). The report states that ) per cent of the auto component industry is
dominated by engine parts, )* per cent by drive transmission and steering parts, and )+ per
cent each by suspension braking parts and body chassis, while e/uipment and electrical
parts capture ) and * per cent, respectively.
The potential compounded annual growth rate $#A0% of the auto component
industry is estimated to be around )*.+ per cent in the period +*-). 12ports from the auto
component industry are estimated to be worth &( .+ billion in +*-), according to the
A#!A report.
1urope accounted for 3.3 per cent of India's auto components e2ports in +*-),
followed by Asia with +.4 per cent and 5orth America with ++.6 per cent. The industry has
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witnessed a shift in the composition of e2ports over the years, with the original e/uipment
manufacturer $71!8TI10 )% segment accounting for 4 per cent of e2ports in +*-).
The share of the aftermarket segment in auto component e2ports stood at + per
cent in the same year. Investments in the auto component industry are estimated at &( 9.3
billion in +*-), according to A#!A.
DESTINATION INDIA
According to the Investment #ommission of India, India is among the mostcompetitive manufacturers of auto components in the world. India is also becoming a global
hub for research and development $0:%.
#ompanies like :aimler #hrysler, ;osch, uors including :elphi,
"isteon, ;osch and !eritor have set up operations in India. Auto manufacturers including
!, Ford, Toyota, etc. as well as auto component manufacturers have set up International
?urchasing 7ffices $I?7s% in India to source their global operations.
Further, increased demand for the passenger vehicles in the country created positive
impact for the auto component manufacturers. The component manufacturers registered @@
per cent growth on a year-on-year basis during the /uarter ending !arch +). The growth
was attributed to the increasing demand of the original spare parts by the customer. 7n an
overall basis, component makers saw rise in revenue in spite of global slowdown in the
auto sector. !a>or players like ;osch, !otherson umi and Amtek Auto reported nearly @
per cent growth in topline, with double-digit surge in profit.
Figure 1.1: Auto component pro!uction p"it
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IN#EST$ENTS
!agneti !arelli, the auto component maker of Fiat group, has forayed into the
country's spare parts aftermarket by entering into a partnership with #arnation Auto, a multi-
brand car servicing facility. The company also plans to increase its revenue from India to
around &( 3+*.66 million by +)@, and e2pects the country to grow faster compared to
other global markets.
yundai Bia, the car component subsidiary of yundai !otor #ompany,
plans to set up an auto component facility at 5ellore, Andhra ?radesh with an
investment of &( +@*.9+ million. The facility is e2pected to be set up in two
phases and would become operational by April +)).
0ane roup, a #hennai based auto component manufacturer, is planning to
invest &( @6.)) million for augmenting capacity for meeting increasing
demand during +)-)).
Ashok !inda roup, an auto component manufacturer plans to raise private
e/uity of around &( +6.4 million for e2panding its business.
erman automotive components company, Ballstabe chneider, has
established its Indian presence by signing a >oint venture $="% agreement with
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Thane-based !ecnam ?roducts and !umbai-based :eshmukh 0ubber
Borks ?vt Ctd.
The world's largest automotive component manufacturer, ;osch, plans to
invest &( 3.@ million in India over the ne2t three years. DIndia will be an
important market for the company in the immediate future,D said ;ernd ;ohr,
#hairman of the tuttgart-based ;osch Automative roup.
Tyre manufacturer, Apollo Tyres Ctd, is set to make #hennai its
manufacturing and research and development $0:% hub and is establishing
a &( 3.6 million manufacturing facility, which is likely to see an additional
investment of &( ).* million.
The Tamil 5adu government has cleared the proposal of tyre manufacturer,
=E Tyre Industries Ctd, for setting up a new production facility in the state,
which would attract around &( 36 million in investment.
POLICY INITIATI#ES
The government has taken many initiatives to promote foreign direct investment
$F:I% in the industry.
Automatic approval for foreign e/uity investment up to ) per cent of
manufacture of automobiles and components is permitted
The automobile industry is delicensed
Import of components is freely allowed
The !inistry of eavy Industries and ?ublic 1nterprises has envisaged the
Automotive !ission ?lan +6-+)6 to promote growth in the sector. It targets to
Increase turnover to &( )++ billion G &( )@* billion by +)6 from &( 3
billion in +6
Increase e2port revenue to &( @ billion by +)6
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?rovide employment to additional +@ million people by +)6
The automotive sector is e2pected to contribute ) per cent of the country's
:? by +)6
The auto component industry welcomed the government's announcement of e2cise
duty rollback being limited to + per cent during the &nion ;udget +). The government also
announced the increase of the deduction limit for 0esearch and :evelopment $0:% in the
sector from )@ per cent to + per cent.
LOO%IN& AHEAD
According to A#!A,
7verseas auto-component manufacturers, especially small and medium
enterprises $!1s% should invest more in capacity enhancements andreenfield manufacturing in India to meet growing domestic demand for
auto-components
Investments in Auto-IT sector is a high potential area
To encourage new wave of partnerships at the Tier +8 level covering the
entire automotive supply chain to address not only product technology, but
also D?rocess TechnologyD
12change rate used ) &: H 36.3 I50 $as on =une +)%
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AC$A
The Automotive #omponent !anufacturers Association of In!i' $A#!A% is
the nodal agency for theIn!i'n Auto#omponent Industry.
Its active involvement in trade promotion, technology up-gradation, /uality
enhancement and collection and dissemination of information has made it a
vital catalyst for this industry's development. It's other activities include
participation in international trade fairs, sending trade delegations overseas
and bringing out publications on various sub>ects related to the automotive
industry.
A#!A is represented on a number of panels, committees and councils of the
overnment of In!i' through which it helps in the formulation of policies
pertaining to the In!i'n 'utomoti(e in!utr).
For e2change of information and especially for co-operation in trade matters,
A#!A has signed !emoranda of &nderstanding with its counterparts in &A,
#anada, &E, France, Italy, pain, =apan, outh Eorea, !alaysia, &ority of
the total 'utocomponent output in the organi
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1.* CO$PANY PROFILE
ROOTS INDUSTRIES INDIA LTD +RIL,is a leading manufacturer of horns in India
and the ))th largest horn manufacturing company in the world, ead /uartered in
#oimbatore, India.
077T have been a dominant player in the manufacture of orns, #asting products,
Industrial cleaning machines, ?recision products and other products like 1lectronic orns,
;rake hoes, ;rake ?ads, alogen Camps, 0elays, !elody !akers, 0oots ?arking uide
ystem, ?iston 0ings, Flashes, etc.,
ince its establishment in )*9, 077T had a vision and commitment to produce
and deliver /uality products adhering to International standards. Bith a strong innovative
base and commitment to /uality 077T has occupied a key position in both International
and domestic market as suppliers to leading 71! and aftermarket.
0IC is the first Indian and first manufacturing company in the world to get I7 8 T
)6*3* #ertification based on effective implementation of J * #ertification and ":A 6.)
#ertification. 7ther certifications like 1 G #ertification from 1urope, I7 )3) #ertification,
and J) #ertification add crowns to it.
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Their competitors includes ;osch, Cucas-T", !inda Industries, arley #o,
"ibrant Auto components, 5ational 1lectric company, etc.,
Its customers include the massive automobile giants like !ercedes, Ford, !itsubishi,
!ahindra !ahindra, Toyota, Fiat, Tata !otors, ;a>a> Tempo Ctd, Einetic onda, T",Ceyland, etc., 0egardless of the vehicle you drive - from a Tata !otors truck to a !ercedes
car - chances are that you will be using a made-in-#oimbatore horn.
0oots Industries India Cimited, one of the eight companies under the 0oots group,
has been making electric horns since it started operations in )*9 as American Auto
ervice. ;esides a variety of horns, the 0oots group now manufactures various auto
accessories, including halogen headlamps and fog lamps and parking and reversing
sensors. Its clients include such big names as :aimler#hrysler, !itsubishi, !ahindra and
!ahindra, Toyota, Tata !otors, T" !otor #ompany and ?iaggio. 0oots products find their
way to the &nited tates, 1urope, Best Asia and Africa.
Thriving on high-end research and diversification, the 0oots group also manufactures
a range of non-automotive products, including cleaning e/uipment, castings and precision
tools. The group is constantly innovating and developing original technology.
The technical collaboration with ;osch A for auto products in )**@ set the group on
the path of sustained technical growth. It also has collaboration agreements with other
erman companies for non-auto products - with ako for multicleaners and Kinser for te2tile
machinery. The 0oots group's obsession with technology is evident from the range of the
state-of-the-art tools it uses for 0: - solid modeling, hard prototyping, drafting and
graphics. Its metrology laboratory is a comprehensive calibration-cum-consultancy centre
that offers electrical, mechanical, pressure and vacuum calibration. It also offers speciali
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1.- THE FOUNDER:
An obsessive hobby went into the making of this self-made industrialist. ;orn in an
agricultural family, young 0amasamy had a great interest in repairing automobiles. This led
to his getting the master's degree in Automobile 1ngineering from Cincoln Technical
Institute, &A in )*6* and developing a uni/ue 0adiator #oolant 0ecovery ystem, which is
today standard e/uipment in almost all vehicles manufactured by the advanced countries.
In )*9, !r. 0amasamy promoted !8s. American Auto ervice, which was taken
over in )**+ by 0oots Industries ?rivate Cimited, a company promoted by !r. 0amasamy.
This company entered into technical collaboration with 0obert ;osch, the world
leaders in auto electrical to manufacture all the range of ;osch orns.
!r. 0amasamy had a very in/uisitive and innovative temperament. This led to his
having many firsts in his distinguished career. ervo brakes were designed for the first time
in India by !r. 0amasamy. e designed the first high fre/uency Bind Tone type horn which
was smaller and lighter than conventional horns. ;esides all the other firsts, !r. 0amasamy
introduced electronically controlled !usical Air orns for the first time in the Borld. The thirst
for innovation and drive to move forward, led to the establishment of a die casting unit to
meet the captive re/uirement of 077T.
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In )*49, !r. 0amasamy set up a full-fledged modern tool room e/uipped with the
latest machines for the manufacture of precision tools and dies. e promoted 0oots
!ulticlean Ctd., a >oint venture in Techno-financial collaboration with !8s. ako Berke
mb, ermany to manufacture world class Industrial Floor #are and Floor #leaning1/uipments.
0!#C is successfully spreading the concept of !echani
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1. ROOTS &ROUP OF CO$PANIES:
The companies are vi
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0oots Industries places a premium on original technology and innovation.
0oots' indigenous talent has kicked off a spree of growth unmatched in the history of
automobile 71 manufacturers.
ROOTS AUTO PRODUCTS LI$ITED
0oots Auto ?roducts ?rivate Cimited $0A??C%, the largest supplier of Air
orns in India caters to the needs of several 71!s Ashok Ceyland, #aterpillar India
and =#; 1scorts. 0oots Air orns also find a place of pride in ?assenger vehicles,
Trucks, 1arth !oving e/uipment, !aterial andling e/uipment, etc. 0oots Air orns
are e2ported to countries in 5orth America, 1urope, !iddle 1ast, Africa and AA0#
region.
ROOTS $ULTICLEAN LI$ITED
The genesis of 0oots !ulticlean Ctd., $0!#C% is due to the vision of the
promoter of 0oots group of company about the re/uirement of sophisticated cleaning
e/uipment in the country following globali
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The superior /uality products and the added advantage of good after sales
service has established the company as the country's largest manufacturer of floor
cleaning e/uipment.
0!#C started the manufacture of mechani
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ROOTS CAST PRI#ATE LI$ITED
0oots #ast ?vt. Ctd., $0#?C% $formerly known as Aruna Auto #astings ?rivate
Cimited% was established in )*43 to meet the captive re/uirements of the 0oots
group.
Bith its ever probing eye on the needs of the market, the company in the late
4s e2panded its operations to manufacture igh ?ressure :ie #ast Aluminum and
Kinc components to the e2acting needs of various customers in Automobile and
Te2tile Industries with a high degree of Juality and ?erfection.
0#?C now has established itself as a ma>or player in the die cast component
manufacturing thanks to the e2pertise built in the core activities like tool design, tool
making and pressure die cast component manufacturing.
0#?C supplies machined castings and sub-assemblies as per customer
re/uisitions.
ROOTS PRECISION PRODUCTS PRI#ATE LI$ITED
0oots ?recision ?roducts was established in )*49 to address the in-house
tooling needs of the diverse industries in 0oots group. 7wing to continuous
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improvement and investment into better resources, the company has become self-
sufficient.
It is catering to the needs of various industries. 0?? acts as a one-stop
solution for tooling and precision machining.
ROOTS $ETEOROLO&Y LA/ORATORY
0oots' state-of-the-art !etrology Caboratory is a comprehensive calibration
centre in outh India that offers mechanical, electrical, tor/ue, pressure and vacuum
calibration instruments - all under one roof.
The laboratory is e/uipped with advanced facilities traceable to national 8
international standards. 0!TC is accredited by 5ational accreditation ;oard for
Testing and #alibration laboratory as per I78I1# )9+@ +@ standards in the field
of !echanical G :imensions, ?ressure8"acuum, Force.
The laboratory offers on-site calibration facility and serves the industry to
#alibrate surface table
#oordinate measuring machine
?rofile pro>ector
Toolmakers !icroscope
?ressure switches
?ressure gauges
Temperature indicators
Temperature sensors8scanners
1lectronic transmitters
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?ressure reducing valves
7vens, etc.
The e2pertise of the laboratory has attracted many renowned ?ublic and
?rivate ector undertakings.
ROOTS POLYCRAFT LI$ITED
0oots ?olycraft $?#% was established in )*44 to manufacture precision plastic
components. It is e/uipped with latest microprocessor in>ection molding machines to
maintain consistent process parameters.
7ver the years, ?olycraft has gained skills and uni/ue techni/ues tomanufacture small and medium si
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R % N'ture Cure Home is the brainchild of :r.Erishnaswamy ounder.
The ome was inaugurated and blessed by is oliness, ri wami atchidananda
!ahara>, Logaville, "irginia, &A. For the past + years, 0E 5ature #ure ome has
treated thousands of people including eminent personalities from &A, France, Italy,ingapore, The ulf #ountries, ermany and &E.
0 E 5ature #ure ome was established way back in )*94 by :r. 0.
Erishnaswamy ounder - a strong believer of 5aturopathy - with a high goal of
promoting health in each and every individual through 5aturopathy and Loga.
tarted with a capacity of >ust + beds, 0 E 5ature #ure ome has grown
into a full-fledged centre with 6 beds, capable of meeting the ever-increasing health
needs of the people. This new building was inaugurated by . . ri. wami
atchidananda>i !ahara>, &..A., on 3th !arch )*43. This home is built in an ideal
location, has ade/uate and well furnished accommodations like eneral Bard,
pecial Bard, 0egular and :elu2 #ottages A8c. for inpatient treatment.
This 0E 5ature ome, a leading 5ature #ure #entre in Tamil 5adu, has a
history of over +3 years of treating suffering humanity, scientifically based on
5aturopathic principles and educating them in managing day to day health problems.
SACHIDANANDA 0OTHI NI%ETHAN
The school, S'tci!'n'n!' 0oti Ni2et'n, is a !atriculation, 1nglish
medium, co-educational, residential public school, secular in nature, which lays
emphasis on our great Indian culture, high moral values and universal brotherhood.
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It provides, in addition to high /uality education, e2cellent facilities for various
#o-#urricular Activities, #omputer 1ducation, Art, Loga, wimming, Earate, !usic,
:ance, am 0adio and various other club activities.
1.5 $ILESTONES
1345?romotes American Auto ervice for manufacture of 1lectric
orns.
134* First to manufacture ervo ;rakes for Cight !otor "ehicles.
1360oots Auto ?roducts ?rivate Cimited was established to manufacture Air orns.:ie #asting &nit commences commercial operations.
1366?olycraft, a unit for ?lastic In>ection !oulding wasestablished.
13350oots Industries ?rivate Cimited takes over 1lectric ornbusiness.
133*
0!#C enters into Techno-Financial collaboration with !8s. ako
Berke mb, ermany.
133*0oots Industries ?rivate Cimited obtains the 5ational#ertification - II mark of /uality.
133?roduction of floor cleaning e/uipment commences. 0oots Industries ?rivate Cimited wins American International Juality Award.
1333;ecomes the first horn manufacturer in Asia to obtain J*
*555;ecomes the first horn manufacturer in Asia to obtain ":A 6.)and the first in the world to win I7 8 T )6*3*
*555 The first to introduce digitally controlled air horns and lowfre/uency, low decibel irritation free =umbo Air orns.
*55-0oots Industries Ctd., orn :ivision is accredited with I7)3) )**6
*55-0oots Industries Ctd., upgraded its I7 8 T )6*3* from )***version to ++ version
*550oots Industries Cimited $0IC% opens its ) e2clusive 12port 7riented &nitat their orn :ivision,Thoppampatti, #oimbatore to cater the needs of Ford 5orth America.
*55 0IC's 17& commences its supplies to Ford, 5orth America
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*55
0oots !ulticlean Cimited $0!#C% inaugurates its ) 17& ?lant at Eovilpalayam,#oimbatore
*55 0IC successfully launches its !alaysian ?lant
*55The group company American Auto ervice is accredited withI7 *) +
*557 0oots Industries Ctd., is certified with ! *, a pre-
re/uisite for J) award for Ford Automotive 7perationsuppliers. Focus on ystems and ?rocesses
*5570oots !etrology Testing Caboratory has been accreditedby 5ational Accreditation ;oard fortesting calibration in the field of !echanical G Cinear
Angular
*5570oots Industries Ctd., is awarded J) by Ford !otor#ompany
*557 0oots Industries Ctd., orn :ivision upgraded its I7 )3)from )**6 version to +3 version
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1.8 9UALITY POLICY PROCESSES
They are committed to provide world-class products and services with due
concern for the environment and safety of the society.
Root In!utrie In!i' Limite! ; 9u'"it) Po"ic)
This will be achieved through total employee involvement, technology up
gradation, cost reduction and continual improvement in
Juality of the products and services
Juality !anagement system
#ompliance to J! re/uirements Juality will reflect in everything
they do and think
Juality in behaviour
Juality in governance
Juality in human relation J&ACITL - A5 ACC ?10"AI"1 15TITL
0oots is committed to manufacture customer-centric and technology-driven
products on par with international /uality standards. For e2ample, the horns
manufactured undergo a rigorous life-cycle test and are sub>ected to an endurance
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1.4 OR&ANI
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EXE TECH- EXECUTIE TECHNICAL ASSISTANT
SO- SECURITY OFFICER
FO- FRONT OFFICE
CHAPTER *
THE DEPART$ENTS
*.1 PRODUCTION DEPART$ENT
Figure *.1: Org'ni='tion'" c'rt o> te Pro!uction Dep'rtment
ASSEM!LY DESIGN
PRESS SHOP PROCESS ENGINEERING
PLANT MANAGEMENT
PM 1 PM 2
SECRETARY
MKT ALE PM3 PM4
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P"C PURCHASE
PPC SU!-CONTRACT
PRODUCTION DEPART$ENT OF HORN DI#ISION OF ROOTS INDUSTRIES
INDIA P#T LTDcomprises of the following sections vi
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!ounting bracket
Turning crews
asket
THE PRINCIPLE:
The A# supply to the terminal base lead to the flow of current through the coil
via the contact points between the point plate and point plate holders which in turn
induces an electro motive force inside the coil.
The magnetic field thus created pulls in the armature rod connected to the
diaphragm until it breaks the contacts of the point plate and the point plate holder that
breaks the flow of current thereby demagnetior categories,
Air horns
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1lectric horns $!anufactured in 077T%
crew type
#rimp type
0ivet type
7n the basis of the tone type it may be.,
igh tone
harp, focused and covers a long distance
Cow tone
Bide, blunt, less focused and covers a shorter
distance
THOSE $ANUFACTURED /Y ROOTS:
Bindtone
"ibrosonic
#leartone
;osch 0ange
0oots *
!egasonic
martone
pider
FA+
0 9
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THE PRESS SHOP:
The child parts for a typical type horn are manufactured inside the press
shop. The parts include.,
;lank
ousing with #0
:iaphragm
Tone disc
Eeeper rings rills
!ounting brackets
?oint holder point plates
Figure *.*: Org'ni='tion'" tructure o> Pre op
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OR&ANI
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pring teel
!ounting ;rackets, ?oint ?late, ?oint older
$ACHINES:
Automatic ?ress
&sed for ousing alone
!echanical feeder ?ress
&sed for ?oint plate, ?oint holder, ;lank, !ounting
;rackets
?ower ?ress
&sed for ousing, Tone disc, crews
ydraulic ?ress
&sed for :iaphragm
?neumatic ?ress
&sed for Tone disc, ?iercing 7peration
PROCESSES:
HOUSIN&
Raw Material H$%& G'()) C%**+, O%*.%* H$%)+,
R-)*&+0
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P+&+,
L**&+,
T&++,
HOUSIN& @ SCR ASSE$/LY
Raw material Output (housing+SCR)
(Housing)
P$& $(*+,
TONE DISC
Raw Material Output
(Tone disc)
THE COIL ?INDIN& SECTION:
The processes include.,
SCR RIETING
PLANISHING
LANCING
TAPPING 5SU! CONTRACTORS6
!LANKING
LETTERING
FORMING
PIERCING
POWDER COATING
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?oint plate and point holder riveting
#oil winding onto the spool
0ooting and #utting
#leaning
THE ASSE$/LIN& SECTION:
PROCESSES:
). #7IC CAT#I5
+. #7IC C7I5 N ?7I5T ?CAT1 N 1AT #7:I5 N
T10!AC ;A1 A1!;CL
. ?7I5T 7C:10 A1!;CL T10!AC ;A1 0I"1TI5N
BA10
3. :IA?0A! A1!;CL A5: TIT15I5
@. ?01 #0I!?I5 FI5AC #0I!?I5
6. AI0 A? !1A&0I5 A:=&TI5
9. T10!I5AC #7551#T70 ;15:I5 !7&5TI5
;0A#E1T A1!;CL
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4. ?7B10 &??CL, 705 T&5I5 T1TI5
*. T&5I5 0A51 !1A&0I5 1ACA5T :I?15I5
). J&ACITL A&0A5#1 BIT ) I5?1#TI75
)). TI#E10I5 A5: :1?AT#
*.* $AR%ETIN& DEPART$ENT
$'r2eting is essentially about marshalling the resources of an organi
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MR!"T
REPLACEMENT ORIGINAL EQUIPMENT EXPORT MARKET
REPLACE$ENT $AR%ET
It is a econdary market that supplies accessories, spare parts, second-hand
e/uipment, and other goods and services used in repair and maintenance. ome
aftermarkets, such as those for automobile add-ons, parts, tires, wheels, are very large. The
aftermarket or replacement market encompasses parts for replacement, collision,
appearance and performance, including electric propulsion. The aftermarket provides a wide
variety of parts of varying /ualities and prices for nearly all vehicle makes and models on the
road.
#onsumers have the option of repairing their vehicles themselves $known as the do-
it-yourself segment% or can take the vehicle to a professional repair facility $known as the do-
it-for me segment%.
ORI&INAL E9UIP$ENT $ANUFACTURER $AR%ET
An origin'" euipment m'nu>'cturer, or OE$, manufactures products or
components that are purchased by a company and retailed under the purchasing company's
brand name. 71! refers to the company that originally manufactured the product.
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Bhen referring to automotive parts, 71! designates a replacement part made by the
manufacturer of the original part.
71! may also refer to a company that purchase, for use in its own products, a
component made by a second company.
EBPORT $AR%ET
12port marketing is a process of finding buyers8importers and approaches them with
the e2pectation of e2port orders with a well-planned strategic marketing process followed
and performed well to get success in International !arket.
ANNUAL PRO0ECTION PLAN:
It is a plan for production, staffing, inventory, etc. It is usually linked to manufacturing
where the plan indicates when and how much of each product will be demanded. This plan
/uantifies significant processes, parts, and other resources in order to optimi
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Tie overall business planning and forecasting to detail operation.
1nable marketing to make legitimate delivery commitments to
warehouses and customers
Increase the efficiency and accuracy of a company's manufacturing
5ormally, ?revious off TakeN :emand forecastH A55&AC ?CA5 to monthly to
weekly and day plan will be made and as per production takes place
DESPATCH DOCU$ENTATION
1. ?ackaging list cum delivery #helan
P'c2ing "it- The e2porter or his8her agent---the customs
broker or the freight forwarder---reserves the shipping space
based on the gross weight or the measurement shown in the
packing list. #ustoms uses the packing list as a check-list to
verify the outgoing cargo $in e2porting% and the incoming cargo
$in importing%. The importer uses the packing list to inventory
the incoming consignment.
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De"i(er) Ce"'nis a proforma invoice that accompanies at the
time of delivery which contains the !aterials and /uantity of
goods dispatched.
*. Transport invoice, 0oad permit, central 12cise gate pass
-. #ommercial invoice
A commerci'" in(oice is a form identifying the seller and
buyer of goods or services, identifying numbers Oinvoice
numberP date, shipping date, mode of transport, port of entry,
delivery and payment terms, and a complete listing and
description of the goods or services sold including, /uantities,
prices, discounts.
The commercial invoice form is considered the most important
document in international trade, because merchandise is not
allowed to clear customs at the destination without one.
That is even true if the goods are samples and have no
commercial value.
This document is usually the one that all the service providers
first look to for information about your shipment. It is important
to prepare the commercial invoice as clearly and accurately as
possible to avoid problems with your shipment.
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The #ommercial Invoice is a #ustoms re/uirement, not a
transportation re/uirement. Bhen someone is engaged in
international trade, #ustoms re/uires a #ommercial Invoice
form.
*.- PURCHASE DEPART$ENT
7n receipt of the plan made in by the production department the purchase
department would ac/uire the necessary raw materials to the production process. It
comprises of the following steps.
Figure *.: F"o o> procee in te Purc'e Dep'rtment
;ICC 7F !AT10IAC
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PROCEDURE USED:
A/C An'")i
o A- items are normally less in /uantity but of high value
o ;- items somewhere between A and #
o #- items are of less value but of more /uantity
"15:70
1"AC&ATI75
T1A! 7F 15I5110
0I1 15J&I0L
1"AC&ATI75
?&0#A1 70:10
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Supp"ier
o +@ vendors totally supplying about 3 components in @ product
range.
R'ting te upp"ier
o Juality inspector checks the materials and confirms its compliance to
the re/uired standards
o #odes are given to products that are accepted or re>ected
o 0ating is done every month and supplier will be retained or changed
as per the rated results
*. STORES DEPART$ENT
IDENTIFICATION
o Tags are provided to the products in the department to both the raw
materials and the finished goods. It includes.,
;C&1 TA- waiting for inspection
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0115 TA- accepted
L1CC7B TA- conditionally accepted
01: TA- re>ected
HANDLIN& $ATERIALS AND E9UIP$ENTS
T07CC1L
?CATI# :0&!
?CATI# T0AL
!AT10 #A0T75 ;7Q
"10TI#AC TL?1 #A0T75 ;7Q
*.7 INFOR$ATION TECHNOLO&Y
Figure *.7: Org'ni='tion'" c'rt o> In>orm'tion Tecno"og)
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De(e"opment er(er;Bhere the consultants do all customi
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!aterial master ;7! changes - characteristics, !0?
controller, prices, cost, components, storage location,
etc.
!aterial movement inventory tracking
oods receipts and material document postings
PP ; Pro!uction P"'nning
The ?roduction ?lanning module of A? takes care of !aster
data needed like ;ill 7f !aterials, 0outings and Bork #enters
and stores it in one separate component.
"arious stages of the planning system can be planned by
using components like
ales and 7peration ?lanning
Cong Term ?lanning
:emand !anagement
!aterials 0e/uirement ?lanning
SD; S'"e Ditriution
The A? ales :istribution $:% module is one of the most
important A? modules and is the key module in the 7rder-to-
#ash business process.In particular, many A? customers find
that automating data loading in the following processes leads
to large efficiencies
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5ew customer master creation
#ustomer master changes G credit terms,
block8unblock status, address, sales hierarchy, partner
functions
?ricing conditions creation and changes including
customer-specific pricing
ales orders and credit memos creation, including
those received directly from customers, distributors,
resellers, or sales orders collected in other systems
#hanges in sales orders8/uotes G changes in pricing,delivery dates, /uantities, items, location
#ontracts and rebate agreement creations
9$; 9u'"it) $'n'gement
The A? J! module supports tasks associated with /uality
planning, /uality inspection and /uality control throughout an
enterprise. It sets the specifications for /uality and standard
testing procedures, controls the creation of /uality certificates
and manages notifications related to /uality. It also stores the
/uality data for raw materials, goods-in-process and finished
goods.
The companies can use the #omplaint !anagement for
achieving their /uality goals. This process provides the
notification and analysis of non-conformities, defects, and
failures that are related to products, processes, or services.
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0econciliation and entry of ?-card statements
Incoming payments other bank information
#ustomer invoices
Fi2ed assets creation and maintenance
Ad-hoc reporting of A8? or A80 line item data.
;udgeting and other planning transactions
RI$S:
An in-house developed 10?.
Front 1nd G A? $ Active erver ?ages%
;ack 1nd G JC erver.
*.8 FINANCE DEPART$ENT
The finance department is the department or committee which manages the money used in
an organi
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!onitoring service providers
Technical assistance to service providers
#ontract administration
;illing
?roperty inventory
eneral accounting records
Fi2ed assets records
#ustody of funds
:istribution of pass-through funds
#ash flow
Investments
:ebt administration
0isk management
Internal financial reports
12ternal financial reports
tatutory reports
Ta2 reports
THE /UD&ET
It is duty of finance department of company to make the budget before actual
providing money to any department. It will be helpful to fulfill each department with
minimum cost. Finance department can take the past records from respective
department. It will be useful for making better budget. Annual business plan $A;?% is
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$ANA&E$ENT OF FINANCIAL RIS%S
Finance department takes many measures for managing the financial risks of
company. For reducing loss of fund due to happening li/uidity, solvency or financial
disaster, finance department makes a good plan and also takes the help of debt
collectors, insurance companies and other rating agencies for reducing financial risk
STATUTORY PAY$ENTS
ales ta2, 12cise duty, T:., are calculated and paid in time.
/OARD OF DIRECTORS:
!r. E.0amasamy
!r. 5.omathinayagam
!r. Eavidasan
!r. #.".0.?anikar
!r. ;.?.0angasamy
!r. 0."arun Earthikeyan
!rs.0.Lokanayaki
!r.E.aravanasundaram
EBECUTI#E CHAIR$AN $D:
!r.E.0amasamy
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#ICE PRESIDENT;FINANCE CO$PANY SECRETARY:
!r.E.0avi
AUDITORS:
!8s. ubramanian "asudev #o
#hartered Accountants, alem.
/AN%ERS:
;I
#iti ;ank
?un>ab 5ational ;ank
RE&ISTERED OFFICE:
0.E. Industrial 1stste
anapathy, #oimbatore-63)6
FACTORIES:
igh ?recision 1ngineering :ivision
anapathy, #oimbatore G 63)6
orn :ivision
Thoppampatti, #oimbatore-63))9
RECORDS $AINTAINED
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#A ;77E
?1TTL #A;77E
;ICC 01#1I"A;C1 ;77E
?&0#A1 ;77E
?&0#A1 01T&05 ;77E
AC1 ;77E
AC1 01T&05 ;77E
;ICC ?ALA;C1 ;77E
?A ;77E
PERFOR$ANCE OF THE CO$PANY
Turnover $+4-*% 0s. *6*.)4 Cakhs
*.4 EN&INEERIN& RESEARCH CENTRE
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The 1ngineering 0esearch #entre $10#% is involved in the continuous
improvement and enhancement of design to increase performance and reliability.
The 10# functioning under three distinct heads cater to the needs of 0oots
Industries, 0oots !ulticlean and 0oots Auto ?roducts.
Though there is a three-pronged operational ethos, the 10# is integrated and
meshed seamlessly with one single ob>ective that of design research and
performance monitoring. Through e2tensive product engineering, the 10# cell of
077T achieves the following
:esigning and developing new products with customer focus.
#onducting re/uired tests to ensure product reliability.
Initiating necessary corrective and preventive action for ensuring
peak performance
Fine-tuning products with available components to satisfy
customer re/uirements.
The 10# consists of the best talent that includes engineering graduates, ITI
brains and design engineers. The team works with top-notch tools like
?roe+i+ - for solid modeling
Auto#A: + - for :rafting
#orel:raw " 4. - for raphical Applications
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THE APPLICATION EN&INEERIN&
o This department plays a ma>or role in the development of new designs of
products to the desire of the 7riginal 1/uipment !anufacturers
o These people initially en/uire the needs of the 71! and develop a prototype with
the process engineering and product engineering of the 10#.
o Then the developed product is initiated for approval from 71!. 7nce cleared,
pilot batch production takes place, with the successful implementation of the pilot
batchR the production team goes for the mass production.
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*.6 HU$AN RESOURCE DEPART$ENT
PERSONAL CULTURE
The management has been encouraging and promoting a very informal culture,
D?ersonal touchD, sense of belonging, enabling employees to become involved and
contribute to the success of the company. The top management also conscientiously
inculcates values in the people.
?OR% EN#IRON$ENT
pecial and conscious efforts are directed towards housekeeping of the highestorder. 0enovation and moderni
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TOTAL 9UALITY $ANA&E$ENT
#ustomer Focus is not merely a bu
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Through interaction with workmen in these sessions, a process of + way
communications has been initiated and valuable feedback has been received on worker
feelings, perception, problems and attitudes. imultaneously management has
communicated the problems faced by them and the plans to overcome these problems.
0oots have a strong people-oriented work culture that can be seen and felt across all
its member concerns. Bhether they work in group or in isolation, their effort is well
appreciated and achievements well rewarded.
They have a sense of belonging and they revel in an environment of openness and
trust. #ross-functional teams function as one seamless whole and foster the true spirit of
teamwork.
0oots as a learning organi
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The main ob>ective of the organi