Instrumentation is defined as the art and science of measurement and control.Instumentation

can be used to refer to the field in which, instrument technicians and engineers work, or it can

refer to the available methods of measurement and control and the instrument, which facilitate

them.

For core industries like power, oil, gas, petrochemical equipment and chemical etc, there is a

good need for control of instrumentation equipment which will help to function industries

smoothly. A wide range of electronic equipment and instruments needed for control and

measurement of the flow of gas, oil valves, pressure reducing valves, vending valves etc are

used.

In order to have an indigenous source of the supply of control and instrumentation package,

instrumentation limited at Kota, Rajasthan was established in 1964. It produces a wide range of

pneumatic instruments in collaboration with other world renowned companies like Toshiba-

Japan, H & B-Germany, Fuji electric-Japan, ABB-Kyosan, BV-Japan.

The second unit was established exactly a decade later at palakkad dedicated to the

manufacture of control valves, butterfly valves, pressure reducing valves and allied equipments

required for the C & L package being supplied by Instrumentation Limited on a turnkey basis.

The third unit was set up in early 1990’s for the manufacture of UPS for Fuji-Japan and

telephone exchanges of C-DOT at Jaipur.

It is a very competitive industry where new technological developments are common which in

function requires heavy investment in Research and Development facilities. For the companies

engaged in this field face high level of competition. But there is good demand for these

products in the global market in the highly industrialized world.

Company Logo

Instrumentation Limited Palakkad (ILP) is a reputed public sector unit, which was established

in 1964 in Kota in Rajasthan its headquarters. The main advantage of Instrumentation Limited

Palakkad is actual self release in providing the instrumentation schemes to the key sectors of

the company.

The second unit of Instrumentation Limited was set up in Palakkad in 1974 in technical

collaboration with as internationally reputed firm, M/s YAMATAKE-HONEYWELL

COMPANY LIMITED-JAPAN, for the manufacture of industrial process control valves. Later

safety relief valves manufactured in collaboration with M/s ETS, L.BERNARD-FRANCE,

have been adder to the product range. This unit in palakkad concentrates mainly on

pneumatically operated control valves. Preventive control valves were also added in

collaboration with M/s Brown Boberkent-United kingdom and safety relief valves in

collaboration with M/s Neuo-Pignone-Italy

Since the inception Instrumentation Limited Palakkad, has been performing well past

indigenization of productivity resulted is massive savings in foreign exchange for the country.

Instrumentation limited palakkad has stood its ground as the leader in Indian market in control

valve segment in the face of stiff competition from the MNC’s have in joint ventures in India.

All the new products have been developed in house and achievement for indigenization of

nuclear services the low sealed valves.

Instrumentation Limited Palakkad is the first control valve manufacture to have been certified

under ISO-9001. It was December 1994 that the certifying agency IQRS (Indian Register

Quality System) audited ILP and certified quality system practiced on ILP as confirming to the

international standards, ILP started with a turn over of Rs.2 crores in 1976-77 and the unit has

achieved steady growth and in the financial year 2005-06 a turn over of 65 crores.

The company had to face still competition about 9 competitors and the main competitors are

MIL CONTROL ROLL LIMITED, DMV PRIVATE LIMITED COIMBATORE and

MOORCO VALVES- Trichy etc.

Latest Japanese manufacturing technologies have been incorporated and the valves are develop

and produced conforming to international pressure vessel codes, one of the notable features of

the next in the emphasis gives to research and development efforts. The R and D team of the

unit has developed a number of products some of them wins innovation awards. In order to

update technology of development work a Computer aided design (CAD) system has been

established. The development of “Butterfly valves” for steel plants other process plants and

mini hydro power plants are the result of the efforts put in by R and D department.

Instrumentation Limited Palakkad has taken up development and manufacturing critical

components for special projects for the machinery of defence as part of the program of

verification. Currently it is also working on a plan to meet the needs of offshore drilling as well

as task level gauging system.

Instrumentation has reduced various sources to the local industrial community in many ways.

Many of its components are joined from small scale industrial units of neighboring areas.ILP

set up the filter plant for water supply located at kanjikode west. Land and pipeline from near

by malampuzha dam to filter plant was laid of ILP’s cost. ILP has donated land for

construction of pudussery panchayat office.

In short, Instrumentation Limited is a process industrial unit in the occur by and enjoyed a

sequential marked place in manufacture of control valves and master market leadership even

now. It also plays an important role for the development of the industrial belt of kanjikode.

Instrumentation Limited Palakkad has implemented many welfare schemes for local

population. The company allotted land and financial assistance by way of donations for the

setting up of Central school, Kanjikode and also the building of kalyana mandapam in

pudusseri panchayat. Moreover the company has given consideration in promotion of sports

and games. The National Table Tennis tournament and the National Hockey tournament were

conducted in the grounds of instrumentation limited palakkad with the co-operation of all

employees of the company.

Policy:

Instrumentation Limited Palakkad’s policy is to supply quality products as per customer

requirements and hence customer satisfaction through continuous improvement backed by

timely after sales service.

PRODUCT PROFILE

A valve is product rarely noticed by average person, yet it plays an important role in the quality

of life. It is a mechanical device for controlling the flow of air, liquid or gas allowing it to

move in one direction only.

A. CONTROL VALVES

A valve with pneumatic, hydraulic electric or electric powered actuator that automatically fully

or partially opens and closes the valves to a position decided by signals transmitted from

controlling instruments.

TYPES:

Globe (single/Double)

Rotator

Plug

Three ways

PRODUCT DETAILS

CONTROL VALVES

NUCLEAR VALVES

SAFETY RELIEF VALVES

ALLIED PRODUCTS

GLOBE TYPE VALVE

BUTTERFLY VALVES FLOW NOZZLE ORIFIZE PLATE

B. BUTTERFLY VALVES

It is a control valve that utilizes a rottable disc or vane as a valve closure member. It is the most

common type of rotator valve used for control.

TYPES:

Soft sealed valve with no leakage

Metal sealed valve with standard leakage

C. PNEUMATIC ACTUATORS

TYPES:

Spring return diaphragm

Spring return piston

Cylinder type (VA 6,7,8,9)

Double action piston cylinder

D.ELECTRICAL ACTUATORS

TYPES:

Linear and rotator type for ON-OFF and regulating only

D. MANUAL ACTUATORS

TYPES:

Linear and rotator actuators with gearbox and hard wheel

E. FLOW ELEMENTS

TYPES:

Office plate

Flow nozzle

Vertical tubes

F. SAFETY RELIEF VALVES

It is the valve that is designed to protect systems or vessels from excessive pressure.

TYPES:

Full bore

Full lift valve with discharge of co-efficient of -0971.

LATEST UPDATES

High Temperature Service Valves

These valves could handle up to 550oC steam and are designated as HT valves, being available

cage guided and low noise models.

Large size soft seated butterfly valves

Conforming to American Water Works Association Standard, these valves are the best choice

as isolation valves for water and gas applications. Ensuring bubble tight closure, due to soft

seating, these are available in wide range of size from80mm to 2600 mm and materials to suit

any process requirements. These valves can be actuated manually, electrically or pneumatically

with facilities for remote operation. Optionally fitted with automatic trip mechanism, they

function as emergency shut-off valves.

Low noise valve

The low noise cage type control valves are featured with very low operating noise

(aerodynamic noise) when they are used to handle compressive fluids, such as steam, air fuel,

gas, ethylene gas, etc. The cage and valve plug are of multiple hole construction. The

components “restriction", "divergence", "expansion" are laid out in a rational manner to

accomplish low noise pressure reducing action. Valve plug is designed to produce no torque

vibration. Valve plug is held directly inside the cage to resist vibration and wear. The modular

concept in design and construction allows component interchangeability with those of the VDC

cage valves. Thus, valves can be disassembled and reassembled resulting in quick

maintenance, and minimizing down time

Bellows sealed valves

Escape of radioactive or toxic fluids to atmosphere is highly hazardous to the environment.

These valves are specially designed to prevent such escape by provision of bellows seal with

backup gland and leak off connection. To ensure high reliability in any adverse working

conditions these valves undergo very stringent quality checks complete with well documented

reports right from the raw material stage-stretching throughout the various stages of

manufacturing activities till dispatch.

Control valves for high pressure drop service-model VHD

Control valves used in feed water lines for duties, such as boiler start up, feed water pump re-

circulation, water injection for de-super heater, etc. experience large pressure drops. Cavitation

generated during throttling will cause severe problems such as erosion, vibration and noise.

The newly developed model VHD is designed so as to divide a large pressure drop into many

stages by the special construction of the plug and cage, thereby preventing occurrence of

cavitation. The distribution of pressure is made effectively according to the characteristic of the

process and the static pressure in the throttling region is kept above the saturated pressure

VISION

“Manufacture and supply quality products to suppliers”

MISSION

High level customers satisfaction through better quality products and timely delivery.

Excellence with economy.

Production and greater productivity of company growth and national prosperity.

Team work and mutual trust.

Respect and concern for individuals.

PROMOTERS

Instrumentation Limited Palakkad is a public sector undertaking and hence the ownership is

vested in the hands of the Central Government. Governing bodies are Managing Director who

is the Chairman and the Board of Directors. This is a three sector body with one joint secretary

and two deputy managers followed by him.

Organizational Setup

Instrumentation Limited Palakkad is a functional organization. The functional system decides

the whole work to be done and divides it into various functions, which is entrusted to group

functioning managers who are generally specialist in that particular field. The workers receive

instructions from all of them. Instrumentation Limited is a customer oriented firm. The

Commercial department studies the needs of customers. General Manager is the head of the

organization. He is the policy maker and governing body and a group of senior managers aids

him. They help the General Manager in implementation as well as the execution of policy. The

Deputy General Manager also handles some decision making. The engineers are supported by a

group of supervisors. The engineers of each product shop give technical as well as managerial

support to the workers.

:

ORGANISATION CHART

GENERAL MANAGER

AGM(WP)

SENIOR MANAGER(Commerce)

GENERALMANAGER(Panel A)

DEPUTYGENERALMANAGER

(Panel A)

CHIEFMEDICALOFFICER

COMMER-CIAL

MANAGER

DGMENGG.

PRODUC-TION

SENIORMANAGER

PERSONNELADMINIS-TRATION

CIVILWORKS FINANCE DISPENSARY

ENGINE-ERING

PRODUC-TION

PLANNINGCONTROL

DESIGNDEPT.

QUALITYCONTROL

PLANT MAINTENA-

NCE

ANCILL-LARYDEPT.

PURCHASEDEPT.

STOREDEPT.

FOREIGN PURCHASE

DEPT.

CONTROLPLANNING ESTATES

INDUSTRIALRELATION

HRDTRANING

WELFARE

GUESTHOUSE

TRANSPORT

SECURITY

ACCOUNTS

DEPARTMENTS

FINANCE DEPARTMENT

Finance is the most important aspects of the business management. It is the life blood of the

company. The term finance can be defined as the flow of money through organization.

Finance department provides a detailed record of the money coming in and going out out of the

business and prepares accounts as a basis for financial decisions.

DEPARTMENT CHART

Finance department is divided into different sections for efficient working. They are;

1. Sales section

This section maintains the accounts transactions related to sales. Dispatch wing

of the commercial department dispatches the goods manufactured. The payment

transactions are directly related to sales section.

The functions of this department are:

Billing

Maintaining accounts of sundry debtors

Collection follow up

Tax assigned duties

This section goes through the purchase order and checks the conditions given by the

customer about the payment. According to the condition they collect the bill or remained it for

further collection.

2. Purchase section

This section deals with the purchase of the products. As soon as the purchase

orders released and the vouchers & bill is received from the suppliers. The finance

department gets information and the payment will be made within 30 to 40 days from the

receipt of voucher date.

The functions of this department are;

Bill passing

Maintenance of sundry credit account

Dealing with central tax VAT

Payment Procedure

FINANCE (Payment

& Release)

PPC 1 PURCHASE DEPT 2 SUPPLIER 3 RECEIPT 4

PURCHASE DEPT

1-MPR (material purchase requisition) 2-PO (purchase order)

3-Goods 4-RV (receipt voucher)

3. Cash and bank

This section records the cash and bank dealing account i.e. monitor and control the

flow of cash receipts and disbursements to meet the business and other needs of the firm.

Transactions related to cash are recorded in cash book and bank is recorded in bank book.

The payment is made after receiving the item on credit basis. It will make within 30 to 40

days from the voucher date. 100% of payment made through bank against the suppliers

invoice. The department release according to the terms agreed in the orders. Most of the

transactions are made through bank.

The functions of this section are;

Receipt and payment recording

Maintenance of cash book

Maintenance of bank book

Work with bank

Verification of interest

Most of the bank transactions are done through State Bank of Travancore.

3. Pay roll and establishment

When a business established, funds are required for the acquisition of building,

machines, raw materials and so on and for the express of lighting, heating, carriage etc,

incidental to production. The section deals with salaries, wages and other payment to the

staff.

The functions of this section are;

Salaries and wages

Payment for medical facilities

Other payment to staff

Passing of establishment bill

TDS (Tax deducted source)

Accounting of pay roll

Establishment expenses

4. Books and reports

The section direct the preparation of financial reports that summarize and

forecast the organizations financial position such as income statements , balance sheet and

analysis of future earning and expenses.

The functions of this section are;

Complete accounting

General journal

Preparation of P & L a/c and balance sheet

Relation with auditors

Preparation of MIS

HUMAN RESOURCE MANAGEMENT DEPARTMENT

Department Chart

Human resource department has the responsibility of employees welfare, man power

planning, recruitment and selection, manpower training, training and development etc. The

HR department is under the guidance of well qualified general manager with expertise and

experience. There are officers to assist him. The workers have a major role in management

decisions that are made. They are usually encouraged to participate in company’s decision

making process.

HR department consists of six sections, they are;

Recruitment section

Time wage section

Establishment section

Industrial relations section

Welfare section

Training section

FACTORY WORKING HOURS

Shift basis;

SHIFT TIME

First shift 06.20 am to 14.30 pm

Second shift 14.30 pm to 22.40 pm

Third shift 08.15 am to 07.15 pm

OBJECTIVES OF HR DEPARTMENT

To maintain high standards of integrity and behavior by

having professional conduct as the key factor.

To recognize and accept dignity and conduct to human

beings.

To create and develop healthy personnel relationship.

To win the confidence of the working groups.

To be free and frank with the employees.

To have no personal bias and prejudice.

To create utility and loyalty towards the organization.

HR POLICIES

1. Recruitment policy

It includes adversting in newspapers, employment exchanges, educational

institutions and unsolicited apprentices

2. Selection policy

It is mainly based on future manpower requirements. Selection process

involves accepting applications followed by interventions, tests, references and physical

examination.

3. Promotion policy

It is based on the criterion of seniority. A person having 3 years of

experience in the same post and maintains good code of conduct and low absenteeism is

promoted to higher post.

4. Manpower planning policy

The manpower planning policy is a decade old one. Now manpower

policy is not feasible because of the revival time of the company from sickness.

TRANING AND DEVELOPMENT IMPARTED TO EMPLOYEES

Training and development is an important factor of HRM that is adequate emphasis in

the organization. Only 64% of the employees have undergone the training process during the

time of recruitment.

ILP training programs include;

Apprenticeship learning

Job instruction training

Classroom lectures

Conferences/Seminars

Audiovisual/Film shows

Simulation/Computer modeling

Programmed instruction

Retraining

MOTIVATIONAL FACTORS

The major motivational techniques employed in ILP are;

Job security

Personal security

Salary

Benefits

Relationship with colleagues

Relationship with management

Advancement in the job

REWARD FOR THE EMPLOYEES

Medical rewards of employees who did not take medical

reimbursement

Yearly good attendance allowance

Award for acquiring higher qualification

PRODUCTION DEPARTMENT

Production management encompasses a wide array of problems, many of which are unique to

the production area. The size of the undertaking, the company policy specifications, the

number of manufacturing methods, all influences the final decisions. A production manager

must be able to deal with all problems that are relevant to his area.

The production design encompasses;

Product design

Job satisfaction

Equipment selection and replacement

Labour skills and training programmes

Input materials selection including raw materials and sub contracting

Plant selection and layout

Scheduling steps of the plan

Operating and production systems

In ILP 75% of the total production constitute control valve and remaining are flow nozzles,

butterfly valves and safety relief valves. The main work of production department is to

transform drawings, specifications, materials and to do so, the most efficient use of men and

machines are made. The production department is mainly divided into two sections;

Machine shops

Assembly shops

MACHINE SHOPS (FUNCTIONS)

To receive orders from PPC

To study drawing and technology sheet

To get necessary components from raw material stores

To monitor results of inspection

To credit accepted components to component store

To initiate stores about the tools and consumables to

reorder level

The machine shop consists of about 24 lathes, 4 milling machines, 8 drilling machines, 6

grading machines and CNCS. All the CNCS are located in the right end of the machine shop

which forms a separate chain.

ASSEMBLY SHOPS (FUNCTIONS)

To carryout assembly

To plan schedule and monitor the assembly of products

To get the results of various tests done on the final product

To identify finished products in unique manner

The parts are then send in the assembly section where they are assembled, welded, painted, etc.

MAIN SUPPLIERS OF RAW MATERIALS ARE:

A. FOREIGN SUPPLIERS;

YAMATAKE corporations, Japan

ETSL Bernard, France

Tokyo Keisolo Ltd, Japan

STL, Italy

NEKS, Finland

Young Touch, Korea

B. INDIGENOUS SUPPLIERS;

Veege Alloys, Coimbatore

Sangeetha Mial corporations, Mumbai

Bhansi metals, Mumbai

Makund Iran, Mumbai

Alegenda steels, Coimbatore

Rahul metals, Mumbai

Vishnu forge, Coimbatore

MGM Ganesh industries, Mysore

Subhadra alloys, Trichi

PURCHASE DEPARTMENT

Materials are very important factor of production in a manufacturing organization. Materials

amount to nearly 60% of the production and clear from the analysis of financial statements of

various public and private sector organizations. Purchase of raw materials is one of the

important functions of a company, Thus in large concerns it is necessary to have a separate

purchase department and the responsibility for the purchase of all materials required is

entrusted with this department.

The purchasing department must keep itself fully informed about the various sources of supply

of materials, stores and plants etc. Purchase department of ILP purchases raw materials from

domestic market as well as from foreign market.

FUNCTIONS:

Ascertaining requirements

Receiving purchase intends

Exploring the sources of supply and choosing the suppliers

Preparation an execution of purchase orders

Receiving and inspecting materials

SENIORMANAGER

JUNIORENGINEER

ENGINEER (COMMERCIAL)

PROGRESSMAN

OFFICEASSISTANT

Checking and passing the bills for payments

COMMERCIAL DEPARTMENT

Commercial department works with the objective of identifying the customers, the

requirements and to carry out receiving of the contract. This department works as a link

between company and customers. The commercial department carries all marketing activities

of ILP and cares to supply good quality material to the customers.

FUNCTIONS:

Acts as a liaison between company and customer

To select the right product which meets the requirements of customer

To make technical leaflets to the required product

To pass information from customers to the product planning and control department

and quality control department

To monitor the after sales services

To identify customers, their requirements and to carry out contract view

SENIORMANAGER

MARKETINGMANAGER

SHIPPINGMANAGER

SERVICEMANAGER

DEPUTYMANAGER

JUNIORMANAGER

TECHNICALMANAGER

SUPPORTING STAFF

DEPUTYMANAGER

JUNIORMANAGER

SUPPORTINGSTAFF

DEPUTYMANAGER

JUNIORMANAGER

SUPPORTINGSTAFF

MAIN COMPETITORS:

Fisher-USA

KEAT control-UK

Prencs-France

Morocco valve-Trichy

DMV Private Ltd-Coimbatore

TRANSPORTERS OF ILP

Transport corporation of India Limited South eastern railways Associated road carriers An extension network of France Regional officers

EXPORT ACTIVITIES:

Commercial department of ILP looks at export formalities. It is headed by a senior manager and under him a junior engineers who is charged with the day to day activities especially technical matters.

DOCUMENTS USED FOR TRANSACTIONS IN EXPORT ACTIVITIES

Invoice Bill of lading Certification of origin Letter of credit Offer preparation Sales day book Debtors ledger Quality record list

MARKETING DEPARTMENT

The main function of the marketing department is to sell the product. ILP has both domestic markets as well as export market. The major product i.e. produced and marketed in ILP are control valves, butterfly valves, actuators, various accessories, flow elements, safety relief valves, tank level gauges, special valves etc.

ILP conduct various market researches. The present market situation of the company is that it carries 62% of market share through license set up. They segment their market by region base into four i.e. north, south, east and west. ILP has its own products specialist. Their target market is world wide distribution of their product but this is nut yet possible due to assumption that the Indian product is not assuring quality in world market.

Their position strategies are control valves in India. Various methods adopted for sales promotion are seminars which are conducted in metropolitan cities and clients and corporate offices. They conduct customer training process while forecasting the demand of their product they notify that now a days many products is out dated. At the same time they are still improving the existing product manufacture process is still continuing. Prediction is emphatically and still remain as per as valve concerning

MARKETING ACTIVITIES

Carrying procurement activities as per the guidelines of the company Floating enquiries Receiving tenders/quotations Preparation of comparative statements Conducting negotiations Placement of purchase orders Dispatch of material from suppliers works Receipt of material at stores Releasing payments as per purchase orders

MARKETING STRATEGIES

ILP has its own strategies: Identifying the customer needs Developing the valves as per customer requirement Exploring foreign market Maintaining international quality standards Providing after sales services

MAJOR CUSTOMERS OF THE COMPANY

Bharat heavy electrical limited Engineer India limited TATA consulting engineers National Thermal power corporation Steel authority of India limited Cochin refineries Essar Gujarat Larssen and Hobe Reliance industries limited Chemtex engineering TATA honeyurell State Electrical Board of all states Gas authority of India limited

MAJOR EXPORTS

Malta Cyprus Malaysia Doha Zambia Russia

INFORMATION TECHNOLOGY DEPARTMENT

IT department maintains the computer network in ILP. It provides various computer programmes to all departments for their regular work. The information department plays a vital role in the production activity.

There are three networks;

Business application (exclude finance)Finance applicationMain server and other office automation

There are approximately 150 computers and 100 printers. The various e-commerce or e-business practices using mail and e-tenders using these three networks. The instrumentation is the first client of oracle in south India in 1992. In the technological front, the organization is not able to upgrade with the latest technologies.

Systems implemented in Instrumentation Limited Palakkad are;

1. Dispensary accounting and stock management2. Inventory control package

DEPUTYMANAGER

SYSTEMANALYST

HAEDWARETECHNICIANS

PROGRAMMER

ORGANISATIONS CONTRIBUTION TO THE SOCIETY

Instrumentation Limited Palakkad is providing global services.