BIOGREEN ENERGY SYSTEM Pvt.Ltd.

Manu Singh Baghel – 25

Operation Management Assignment

About the Firm –

Company Owner – Mr. Vijay Kumar Dumbali

Business Type – Exporter / Importer / Service Provider / Manufacturer / Whole Seller / Distributor / Supplier / Trading Company

Established in 2003.

Area of Expertise / Functionality – Generators , Control Panel , Turbines, Commissioning,

Value Engineering.

Head Office – Aishwarya, Bhusari Colony, Opposite Sringeri Mutt, Kothrud, Pune - 411023, Maharashtra 

Assembly Centre – Honga Industrial Area, Belgaum , Karnataka

Turn over last year – Rs. 16,38,000,00 on March 2012.

Various Functional Block –

Sales / Marketing – 04 employees

Sales Engineering – 03 employees

Project Technology (Design, Research & Development) – 05 employees

Purchase / Procurement – 02 employees

Assembly / Production – 07 employees

Quality Control (Expert + Project Tech. Ass. / Sales Engg. Ass.) – 03 employees

Export / Dispatch – 02 employees

Commissioning – 07 employees

Strategy and Tactical Management – 03 employees

Post Dispatch Services – same as Commissioning ~ 02 employees

Finance / Accounts – 02 employees Human Resource – 02 employeesMechanical Deptt. – 2 engineers + 3

techniciansElectrical Deptt. – 2 engineer + 2

techniciansProject Innovation – 03 employees (all

engineers – electrical, mechanical, service)Sales & Application Engineering – 04

employeesPurchase, Supply – chain & warehousing/

Storekeeping – 07 employees

They distribute their goods to many cities like – Nasik, Malegaon, Mumbai, Pune

urban and sub – urban like pimpri – chinchwad, Ahmadnagar

West Bengal (HUL), Karnataka, Rajasthan (Hindustan Zinc) Assemble at from Belgaum,

Karnataka as well as Pune plant.

Turbine parts are being imported/procured from

Skinner Power System (Pennsylvania, USA)

Triveni Garebox, Karnataka.

Tharmocompressor are procured from Mazada, Gujrat.

Components and assembling process (operation) – It is casing with rotor mounted at the

top containing a bearing assembly part rotating the shaft.

Following is a bearing consolidating the overall weight of the rotor.

It is turbine casing both upper and lower encapsulates the main turbine structure.

Side view of rotor and its blade - Rotor shaft is assembles to the upper case of the turbine.

It is trip valve, which get tripped in case of turbine generating abnormal speed or parameters.

This component is the governor valve disc. In case of trip valve getting tripped this valve gets stick with steam inlet pipe and stop the further steam flow.

Steps in turbine assembling – Putting/placing turbine and gearbox on skid. Placing of lubricant oil cooler at the support. Placing gear pump, level gauge, 3 way valve and filters

on the support mounted on the skid. Placing pressure and temperature gauge at place. Main oil pump to bearing of turbine and gearbox has

been established. Ermotto coupling joints pipe to pipe without threading.

With its help Lubricant oil coming out of the turbine is piped to

recycling and cooling purpose mingled with lubricant oil cooler.

Piping and instrumentation take place as per the lubricant piping diagram.

Hydraulic testing after whole assembling process. Painting and packaging.

Steps in supply chain – Enquiry for the turbine as per the requirements of customer Parameters mentioned such as temperature, pressure and

process pressure for the plant (normally less than the actual pressure generated) are desired specifications.

After this calculation takes place for the power generation as per the specifications thermodynamically.

HMBD (heat mass balance diagram) issued to the customer for feasibility checking purpose.

If client agrees and feels satisfied with the model, then technical and commercial quotes are sent to customer, where negotiation takes place.

Purchase order is generated from client side, 20% of the capital cost is being paid by the client.

Customer drawings are made available within 1 month and 20% money is again being paid by the same party.

Detailed engineering takes place based on which turbine and its components are procured as it is a time consuming process.

Skid drawing and prototype is developed. After getting the ordered material assembling

and manufacturing of other parts and components start taking place.

After assembling customer can witness a quality assurance test at the factory.

After getting ready rest 60% of the amount is being paid and turbine is dispatched.

Commissioning engineer set the synchronizing, aligning and skidding operations at the site and mount on the foundation.

A commissioning certificate is being led from the client side.

Service is provided on the site over the 1 year warranty period.

IT – Enabled SCM –

Electronic data interchange – EDI Internet/extranet Electronic commerce Enterprise resource planning – ERP E- procurement Supplier relationship management – SRM Advanced planning and scheduling – APS E-logistics

Leading to following results – Reduced latency and reaction time Decreased contingency and obsolete

inventory Lower operating costs Fewer or no shortages Improved overall performances Enhanced customer responsiveness More predictable forecasting Enhanced speed to market Sharing of best practises Collaborative R&D Profit sharing

Interview Pattern –

We have manage Semi structured Interview to ensure Flexibility and Relaxed context.

One – to – One Verbal Interview. Informal Interview.

Questionnaire Pattern –

Some Questions were differed according to the designation of the interviewee. (e.g. More stress on Motivational and satisfaction factors for some employees)

To include at least 2 questions per segment i.e. – Operations and workings Motivational Elements Job Satisfaction Working Environment and culture Job Profile Satisfaction (3-4 questions) Problems / Conflicts Resolution Coordination Element.

Four Employees we interviewed -

Mr. Swapnil Kumbhar Senior Executive Engineer (32 Years)

Mr. Vilas Chinke Executive Engineer (31 Years)

Mr. Abhay Singh Parihar Application Engineer (27 Years)

Miss Vaishali Dhangar Technology Engineer (23 Years)

Two Customers / clients for the organization –

Satyam Petrochemical (Mr. Rajendra Kute) located at Uraj (Pune - Kolhapur Highway)

Mr. Dasgupta (Hindustan Uniliver Limited)

Functional Blocks with the arising problems –

1. Sometimes Unable to match with the commitments.

2. Dysfunctioning of control panels and other tools operating and maintenance issue.

3. Inefficiency in execution by customers error in execution of diagrams, prototype, designs.

4. Too much dependency upon IBR (Indian Boiler Rule) by NEMA (National Electrical Manufacturer Association)-23 & Inter changeability Rule Standardization.

5. Lack of coordination between employees having various streams of engineering and academic backgrounds Dispute / Conflicts.

6. Miscommunication between client and dispatching / exporting department cargo movement / date of delivery.

7. Errors in technical / required specification deviation in delivery from requirements.

8. Working hour pressure (load of work) 8+2 hours with negligible motivating factors.

9. Slow rate of enhancement in job profile employee unsatisfaction

10. Low market demand Low Salary increment.

Problems Continued ...