An Organizational Study at Integral Coach Factory

AN ORGANIZATIONAL STUDY AT INTEGRAL COACH FACTORY, PERAMBUR, CHENNAI

SUMMER INTERNSHIP

Submitted in partial fulfillment of the requirement of the award of the degree of “Soft Skill Training” for P.G Courses of University of Madras

By REEMA HEGDE II MBA MA00227

“MASTER OF BUSINESS ADMINISTRATION”

Under the supervision and guidance of Mrs. MARY JASMINE, MBA

(AMIMA)

ASAN MEMORIAL COLLEGE OF ARTS AND SCIENCE

INSTITUTE OF MANAGEMENT

CHENNAI – 600 100

JUNE - 2011

BONAFIDE CERTIFICATE

This is to certify that the Internship Report titled “AN ORGANIZATIONAL STUDY AT INTEGRAL COACH FACTORY PERAMBUR” , is a bonafide record of work carried out by REEMA HEGDE during May 2011 to June 2011 under my guidance in partial fulfillment of the requirements of the ‘Soft Skill Training’ for P.G courses of University of Madras.

MARY JASMINE

INTERNAL GUIDE

DR. R. TAMILARASAN APPALARAJU (DIRECTOR) (DEAN)

Prof. P.

DECLARATION

I, REEMA HEGDE, do hereby declare that this internship report titled “AN ORGANIZATIONAL STUDY AT M/s. INTEGRAL COACH

FACTORY,

MRS.VIJAYALAKSHMI,

CHENNAI” External

guide

under from

the Integral

guidance Coach

of

Factory,

Chennai., submitted in partial fulfillment of the requirement for the award of the degree of Master of Business Administration of University of Madras is a record of an original work done by me during the period of study at Asan Memorial Institute of Management. I also declare that the report has not been submitted for the award of any other degree, diploma, fellowship, or any other similar title of this university or any other university.

PLACE: CHENNAI DATE:

ACKNOWLEDGEMENT

I am greatly indebted to the Director Dr.R.Tamilarasan, Dean Prof. P.Appalaraju

and Prof .P.Appalaraju (Project Guide) of Asan

Memorial Institute of Management (AMIMA) for providing me this opportunity of undergoing and internship training as a part of my curriculum. I convey my sincere thanks to the management of INTEGRAL COACH FACTORY, Chennai who gave me an opportunity to do internship in their organization. My special thanks to Mrs. Vijayalakshmi (Company guide) of Finance Department and other staff members, ICF for their never ending support and assistance to get all necessary information for the successful completion of my internship. I am indebted to my parents and friends for their sustained moral support throughout the period of training.

DATE: B.KAVITHA PLACE:

TABLE OF CONTENTS

CHAPTER

CONTENTS

NO. INTRODUCTION

1.

2.

1.

INTRODUCTION OF INTEGRAL COACH FACTORY

2.

OBJECTIVES OF THE STUDY

3.

SOURCES OF THE STUDY

4.

LIMITATIONS OF THE STUDY

PROFILE OF THE STUDY 1.

INDUSTRY PROFILE

2.

COMPANY PROFILE

1.

VISION

2.

MISSION

3.

QUALITY POLICY

4.

QUALITY OBJECTIVES

5.

QUALITY CERTIFICATIONS

6.

ABOUT THE COMPANY

1.

ORGANIZATIONAL CHART

2.

AUTHORITY & RESPONSIBILITY

PAGE NO.

3.

3.

EMPLOYEE PRACTICES & BENEFITS IN ICF

4.

PRODUCT PROFILE

DEPARTMENTAL PROFILES 1.

HUMAN RESOURCE DEPARTMENT

2.

FINANCE DEPARTMENT

3.

MECHANICAL DEPARTMENT

4.

ELECTRICAL DEPARTMENT

5.

PRODUCTION DEPARTMENT

6.

STORES DEPARTMENT

7.

CIVIL DEPARTMENT

CHAPTER

CONTENTS

NO.

4.

CORPORATE SOCIAL RESPONSIBILITY

5.

SWOT ANALYSIS

6.

COMMUNICATION SYSTEM IN ICF

7.

FINDINGS

PAGE NO.

SUGGESTIONS

8.

CONCLUSION

9.

BIBLIOGRAPHY

10.

CHAPTER 1 INTRODUCTION

INTRODUCTION

An organizational study includes a brief overview of the various departments in an organization. Started in 1952, the Integral Coach Factory (ICF) is a factory for rail coaches located in Perambur.

Integral Coach Factory, Chennai, is a premier Production Unit of Indian Railways manufacturing railway passenger coaches and the first of its kind to be established after the Independence for the manufacture of light weight,

all

steel

and

all

welded

railway

passenger

coaches.

The

organizational study focuses on various departments such as human resource, accounts, mechanical, production, electrical, civil and stores. In addition SWOT analysis, communication system of the organization and the CSR activities has also been included.

OBJECTIVES OF THE STUDY

1.

To understand the functions and performance of the human resource, finance, mechanical, production, electrical, and stores departments.

2.

To gain industrial exposure.

3.

To understand the internal communication and external communication pattern of the firm.

4.

To understand the corporate social responsibilities of the firm.

SOURCES OF THE DATA

PRIMARY

DATA

Primary source of data is obtained by the researcher directly from the respondent which has not been collected previously. Primary data are first hand information collected through various methods such as observation and interacting with various department personnel.

SECONDARY DATA Secondary data is referred to the information already available either published or unpublished sources. Secondary data is collected through books, periodicals, magazines and websites.

LIMITATIONS OF THE STUDY

1.

Reports are prepared only with the availability of facts and figures

2.

Time factor can be considered as a main limitation.

3.

Inadequate data found in the premises.

4.

The study is based on the information available in the records and the information given by the executives.

5.

The reliability of the analysis and conclusion is restricted to the data given in the area.

CHAPTER 2 PROFILE OF THE STUDY

INDUSTRY PROFILE

The Indian railways have always been in the forefront of

development and

utilization

of

appropriate

technologies

for

rail

transport in the country. They have an exclusive research, designs and

standard organization dealing with all aspects of technology relating to rail transport. Immediately after independence the trust was on building indigenous

capabilities

for

meeting

the

requirements of locomotives,

coaches and other rolling stock for meeting the ever-increasing needs of traffic.

The first railway on Indian sub-continent ran over a stretch of 21 miles from

Bombay to Thane. The idea of a railway to connect Bombay with

thane, Kalian and the Thal and Bhore Ghats inclines first occurred to Mr.George Clark, the chief engineer of the Bombay Government, during a visit to Bhandub in 1843.

The formal inauguration ceremony was performed on 16th April 1853, when 14 railway carriages carrying about 400 guests left Bore Bunder. The first passenger train streamed out of Howrah

station designed for Hooghly,

a distance of 24 miles, on 15th August, 1854. An Indian railway was opened as the public traffic, inaugurating the beginning of railway transport on the Eastern side of the sub- continent.

In south the first line was opened on 1st july 1856 by the Madras Railway Company. It ran between Vyasrpady and Wallajah road (Arcot), a distance of 63 miles. In the north a length of 119 miles of line was laid from Allahabad to Kanpur on 3rd March 1859.

These were the small beginning

which in due course developed in to a network of railway lines all over the country. By 1880 the Indian railway system had a route mileage of about 9000 miles. Indian railways, the premier transport organization of the largest rail network in Asia and the world’s second largest under one management.

THE RAILWAY ZONES ARE

1.

South East Central Railway

2.

Central railway

3.

East Central Railway

4.

East Cost Railway

5.

Eastern Railway

6.

North Eastern Railway

7.

North Western Railway

8.

North Eastern Frontier Railway

9.

Northern Railway

10.

South Central Railway

11.

South Western Railway

12.

Southern Railway

13.

Western Central Railway

14.

Western Railway.

PRODUCTION UNITS 1. Chittaranjan Loco Works 2. Diesel- Loco Modernization of workshops 3. Center for railway information system. 4. Container Corporation of Indian Ltd

5. Indian Railway Catering and Tourism Corporation Ltd 6. Indian Railway Finance Corporation IRCON International Ltd 7. Konkani Railway Corporation 8. Mumbai Railway Vikas Corporation 9. RAILTEL Corporation of Indian Ltd 10.Pipavav Corporation.

OTHER ORGANIZATIONAS UNDER INDIAN RAILWAYS

1.

Rail Vikas Nigam Ltd.

2.

Central Organization for railway electrification

3.

Delhi Metro Rail Corporation

4.

Federation of Railway officers Association

5.

Indian Railway Accounts Service Association

6.

Indian Railway Accounting Reforms

7.

Indian Railway Central Organization for Telecom

8.

Indian Railway Stores Services

9.

Indian Railway Welfare Organization

10.

Indian Railways Institute of Electrical Engineering

11.

Indian Railway Institute of Signal Engineering and Telecommunications of Railway Transport.

12.

National Rail Museum

13.

Railway Recruitment Baroda

14.

Railway Staff College, Baroda

15.

Research Design and Standards Organization

16.

Indian Railway Institute of Mechanical and Electrical Engineering

17.

Integral Coach Factory

READJUSTMENT OF ZONES AND IN-HOUSE REFORM

In

Order

to

bring

speedy implementation

of

about

greater

ongoing

efficiency

in

projects , better

Administration , customer

care,

reduction of work load on General Managers etc., Indian Railways have Decided

to create

existing

zones. The

seven new

new

zones by

zones, having

territorial limited

re-adjustment

financial

burden

of on

Railways, will have thin and lean ,efficient and modern administrative set up. Two of the new zones have already started functioning.

NATIONAL RAIL VIKAS YOJANA

With a view to complete stipulated period of

strategically

important projects within a

time , a non- budgetary

initiatives

for

the

development of railways has been launched. Under the scheme all the capacity bottlenecks in the critical sections of the railway network will be

removed at an investment of Rs15000 crores over the next five years. These projects would include:

1.

Strengthening of the golden quadrilateral to run more long- distance mail/ express and freight trains at a higher speed of 100kmph.

2.

Strengthening of rail connectivity to ports and development of multimodal corridors to hinterland.

3.

Construction

of

four mega bridges-two

over River Ganga,

one

on

River Brahmaputra, and one over river kasi. 4.

Accelerated

completion

of

those

projects

nearing completion

and

other important projects.

TIE-UP WITH FOREIGN RAILWAYS

Indian Railways is in constant touch with railways across the world to bring in state-of-art facilities in its system. Towards this, a memorandum of understanding was signed during the English Session of the Indo- Austria joint Economic Commission held in Vienna. This seeks to promote and deepen long-term infrastructure Specific Corporation between Indian and Austrian Railways to their mutual benefit.

COMPANY PROFILE

VISION OF THE COMPANY

1.

To

translate

the

dreams

of

nation

-building

into

reality

with

development of infrastructure with optimal cost. 2.

Manufacture of world-class coaches and be a leader in self- propelled and specialized railway vehicles.

3.

Efficient production to ensure safe and economical transport to all strata of society with ever-advancing technological excellence of Integral Coach Factory.

MISSION OF THE COMPANY

1.

The

mission

area

envelops

several

parameters

like

quality

consciousness and quality improvement in production, ensuring reliability and safety in coach design. 2.

Environmental and ecological preservation, improvisation in design through regular feedback system from passengers and users.

3.

Continuous improvement in the coach aesthetics travel, comfort and safety.

QUALITY POLICY

1.

To

achieve and maintain excellence in quality, reliability and

safety of their products. 2.

To

strive

for

continual

improvement in all

area

to

achieve

leadership in the markets we serve. 3.

To consistently meet or exceed customer expectations.

QUALITY OBJECTIVES

1.

Continual quality improvement of processes, products and services.

2.

Compliance to quality standards.

3.

Technological and human resource up gradation.

QUALITY CERTIFICATIONS QUALITY MANAGEMENT SYSTEM (ISO 9001): 1.

Integral Coach Factory Quality Management system was certified to the new version of the standard, ISO 9001; 2000.

ENVIRONMNTAL MANAGEMENT SYSTEM (ISO 14001): 2.

Integral Coach Factory’s Environmental Management system ISO 14001 was certified in 2001.

QUALITY ASSURANCE 3.

The quality assurance is made by inspection of ICF with inspection cell.

4.

The quality assurance wing is responsible for the quality assurance of shop manufactured items, sub-assemblies and finished cells.

ABOUT THE COMPANY

Integral coach factory is an ISO-9001 company. It has its own design and development wing, the infrastructure and technical known how to manufacture sophisticate modern coaches. ICF all-steel, all –welded, light-weight; ‘integral’ coaches with anti- telescopic and construction. The ICF combines the three major factors of modern passenger transport:Speed, Comfort and Safety.

Initially, ICF was designed to produce only broad gauge shells, which were to furnished by the zonal railways. Later, a separate furnishing division was set up in view of the serve limitation capacity of railway workshops and also to take advantages of mass production techniques presently, coach production is done in shell division and Furnishing division.

ICF manufactures around 125 different types of coaches. They can be broadly classified into Self-propelled COACHES, Trailer coaches, AC coaches, Conventional coaches and Special coaches likes palace on wheels. ICF produced 34,022 coaches as on March 2004. ICF manufactured and supplied 150 containers to Container Corporation India in addition to coaches, production in the last four years. ICF has exported Coaches, Bogies and Spares to 11 countries.

HISTORY OF GROWTH

ICF-India’s premier coach building factory was started in technical collaboration with Swish Car and Elevator Manufacturing Corporation Ltd.., Switzerland . the construction in commenced on March 1952 and the first machine was commissioned by Shri Lal

Bagadur Shastri , Ministry for

Railway, on 2nd october of 1955 a red letter day for ICF when Pandit Jawaharlal Nehru, Prime Minister of India, flagged off the first coach. The furnishing division of ICF was inaugurated on 2nd October of 1962. ICF through the year has been engaged manufacturing many types of coaches year . The maximimum number of types ever produced in a year is 32 different types of coaches in the year 2000 to 2001. Starting with a humble beginning of about 350 coaches per year , ICF has grown to a production capacity of more than 1000 coaches annually. In the year 1998-1999 over 1057 coaches were produced. ICF has exported a total of bogies and 425 coaches to Thailand, Burma, Taiwan, Zambia, Philippines, Tanzania , Uganda, Vietnam, Nigeria, Mozambique and Bangladesh.

1. FACTORY AREA

ICF has a factory area of 189.5 acres. Covered area in shops is 47 acres. Township is spread over 285.5 acres .ICF employs more than 13,000 people. The self – contained town ships consist of 3000 residential quarters with schools, auditorium, stadium, recreation facilities and hospital.

ICF has leveraged its coach building experience of 48 years and 33,000 coaches to stay at the forefront of innovative coach building and retains its leadership position over the years. ICF has successfully incorporated cutting edge technologies into the coach building process.

ICF is committed to improving passenger safety, passenger comfort and maintain ability of the coaches .ICF has a diversified product portfolio into many types of caches, all built to exacting customer requirements.

The main objective of ICF is to manufacture all metal lightweight coaches from ordinary 2nd class to most complicated types of coaches i.e.., AC Expresses, Rajdhani Express etc. ICF has entered into export market also supplying coaches for foreign countries.

ORGANIZATIONAL CHART OF ICF

AUTHORITY AND RESPONSIBILITY

GENERAL MANAGER

1.

Managing and coordinating work of the process managers.

2.

Devising and planning of company policies, and discussing them with the top management for final approval.

3.

Preparing elaborate reports of the functioning and all the company departments, and submit the reports to the top management for practice performance review.

CHIEF ENGINEER 1.

Direct and coordinate the engineer staff in formulating plans, designs and cost estimates of special building projects.

2.

Approving most vendor and contractor agreements associated with the projects or plans. They will be involved in the projects from beginning to end.

3.

Chief engineers will assist with the engineer budget and delegate workloads to their staff.

ASSISTANT ENGINEER

1.

To support senior engineers with design procedures and assessment practices.

2.

Buying new materials, machinery or essential engineering tools and with providing technical on-site support to laborers.

SENIOR SECTION ENGINEER

1.

Supervises professional, technical and support staff on a day-to-day or project

basis,

including

determining

workloads

and

schedules,

developing, implementing and interpreting policies and procedures, evaluating and training staff and making hiring and termination recommendations.

TECHNICIANS

1.

Supervises and participates in constructing research and experimental prototype models from sketches, oral instruction, and blueprints; instructs subordinate technicians and mechanics in proper work methods and techniques.

PRODUCT PROFILE

PRODUCTION WITH INNOVATION ICF has carved a niche in the Indian Railway system by constantly improving the quality of travel through its passenger coach design which has undergone a sea- change from the days of bye-gone era of mere transport of passengers. There has been a steady growth both in the quality and quantity of its production. Over the years ICF has endeavoured to meet passengers expectations through innovations like

1.

Cushioned seats in General Second Class and SLR coaches

2.

Provision of Controlled Discharge Toilet Systems

3.

Anti-injury features in the passenger areas of A/C 2-tier and Sleeper coaches

4.

Enhanced carrying capacity in A/C 2-tier, First A/C and Garib Rath Chair Car

5.

Provision of forced ventilation, PIS/PAS in AC/DC EMUs for WR and CR

6.

UIC vestibules in mainline coaches

7.

Disabled friendly features in SLRD/SRD coaches

8.

Modular toilets in passenger coaches

9.

Stainless steel panelling, handholds in EMUs

10.

Provision of laptop and cell phone charging points in passenger coaches

11.

Use of stainless steel in Pantry Cars including interiors and the equipment.

All this has been made possible through ICF’s commitment to progress and improvement with its dedicated workforce functioning in a contented atmosphere in pleasant surroundings and working conditions. Several welfare schemes like staff quarters, adequate clean water supply, improved medical facilities, online information kiosks, issue of pass centrally, encouragement in sports activities, etc., are provided.

PRODUCTION ICF’s initial plan was to produce 350 Broad Gauge Third Class shells (unfurnished body of the Railway Coaches) only, which were to be furnished by the Zonal Railways workshops. Later, in view of the severe limitation of capacity of the Railway workshops and also to take advantage of mass production, a separate Furnishing Division was added on 2nd October, 1962. The capacity was progressively expanded from the initial 350 shells to 750 fully furnished coaches per annum by 1973-74 with additional inputs. This was enhanced progressively from 850 coaches during 1986-87 to 1000 coaches in 1990-91. The modernization project is under last stage of execution to augment capacity to 1250 coaches and will be over by 2010-11. Capacity is further being enhanced to 1500 coaches per annum through infrastructure additions and modernization of machines.

DESIGN FEATURES The design concept of the coach stipulates that the roof, side wall, end wall and the under frame are joined together by welding, to form a fully integral coach shell. The end-wall construction has been made specially strong to make it anti-telescopic to ensure maximum safety to passengers. Further, crashworthy features are provided with CBC design to minimize impact on passengers during accidents/derailments.

From the basic design handed down by the collaborators, ICF has diversified having established its expertise and skill in this field, to design and manufacture more than 350 different types of coaches for Indian Railways and export market. Every time a new type of coach is launched, emphasis is laid on improving passenger comfort, passenger safety and higher speeds. ICF follows standard inspection procedures to ensure quality from raw material stage to the finished coach.

PRODUCT RANGE ICF has been meeting the needs of the Indian Railways for varied types of coaches, however sophisticated the type may be. Some of the important types are: 1. SELF PROPELLED COACHES 1.

Electric Multiple Units for suburban services in Metropolitan cities;

2.

Diesel Rail Cars;

3.

Metro Coaches for Kolkata Metro Railways;

4.

Diesel Electric Multiple Units & Diesel Hydraulic Multiple Units for nonelectrified routes and Mainline Electric Multiple Units for long distance inter-city commutership.

5.

Accident Relief Trains / Medical Vans

6.

OHE Inspection Cars

2. AIR-CONDITIONED & NON-AIRCONDITIONED PASSENGER COACHES 1.

Air-conditioned Sleeper Coaches of first & second class;

2.

Air-conditioned Chair Cars of first and second class;

3.

Double Decker Coaches with seating capacity for 148 passengers as against the conventional 90 passengers.

3. SPECIAL COACHES 1.

Air-conditioned & Non-air-conditioned Pantry Cars

2.

High Capacity Power Cars for Shatabdi & Rajdhani Express Trains

3.

Air-conditioned Military Ward and Saloon Cars for Indian Army.

4.

Air-conditioned Saloon Cars, Dining Cars, Bar & Restaurant Cars, luxury suites for luxury tourist trains like Palace on Wheels (WR), Deccan Odyssey (CR), The Golden Chariot (SWR), Royal Rajasthan on Wheels (NWR) and Maharajas Express of IRCTC

5.

Lifeline Express for operation of hospital on wheels

6.

Jet Deflector Crane Cars, Inter Communication Coaches for DRDO

EXPORT ICF’s achievement on the export front has been enviable since its inception. Against stiff international competition from more advanced countries like Japan, etc., ICF secured several export orders, most of which are repeat orders. So far, 359 bogies, 11 stainless steel coach shells and 481 coaches including air-conditioned coaches have been exported to 13 Afro-Asian countries. ICF has bagged a number of awards for Export Excellence also.

DESIGN & DEVLOPMENT EFFORTS Complementing

the

existing

design

capacities

and

facilities,

a

fully

computerised Design & Development Cell has been set up with sophisticated state-of-the-art computer designing facilities and testing equipment both for coach components and raw materials. D&D Centre uses 3-D modelling on SolidWorks platform for generating 3-D drawings and IDEAS software for Finite Element Analysis. Strain gauge testing and squeeze test are done on prototypes before commencement of series production.

EMPLOYEES PRACTICES AND BENEFITS IN ICF

There are around 13000 employees in ICF. It is organized into eight functional departments, spanning across two divisions the shell division. The departments are general Administration, Accounts, Electrical, Civil engineering, mechanical, medical, personnel, security and stores.

Working hours: Day 7:00-11:30, 12:30-16:30 Night 17:00-21:00 , 21:45-02:30

Employees Number: A unique six digit number is assigned to every ICF. The employees are requested to quote this number in all their correspondence with the ICF administration.

Previleges Pass entitlements in Indian railways offer free travel and concessions travel facilities to its employees. During the first year of the service an employee is eligible for one set of free pass, which will entitle the holder to travel between two stations on Indian railway, free of cost.

Salary & Allowances: The salary includes the following components 1.

Basic Pay - 50% of the basic pay as dearness pay

2.

House rent allowance @30% of (me) & above subject to certain conditions

3.

Dearness allowance at the rate application from to time of (17% w.e.f 1/1/2005)

Canteen Facilities: There are 4 canteens in ICF one at each division, i.e, shell and furnishing for exclusive use of the staff working inside the factory with extension and one each of the division for the administrative office staff.

ICF Institute: The member of ICF institute can avail the library and other facilities provided in the institute tours, fetes are also conducted yearly for the members. Members have to pay a sum of Rs 5/p.m for employees with the basic pay to

Rs. 5000 and Rs. 7/- for

employees with the basic pay to Rs 5001 and above.

STAFF Benefits Fund The funds provided for scholarship for higher studies of wards of ICF employees purchase of spectacles payment of medical

expenses

for

employees and children.

the

needy,

conducting

of

tour

for

CHAPTER 3 DEPARTMENTAL PROFILES

VARIOUS DEPARTMENTS IN ICF

1.

HUMAN RESOURCE DEPARTMENT

2.

FINANCE DEPARTMENT

3.

MECHANICAL DEPARTMENT

4.

ELECTRICAL DEPARTMENT

5.

PRODUCTION DEPARTMENT

6.

STORES DEPARTMENT

7.

CIVIL DEPARTMENT

1.

HUMAN RESOURCE DEPARTMENT

AUTHORITY FLOW CHART OF HUMAN RESOURCE DEPARTMENT

CHIEF PERSONNEL OFFICER

DEPUTY CHIEF PERSONNEL OFFICER

ASST. PERSONNEL OFFICER

CHIEF SUPER INTENDENT

EMPLOYEES

FUNCTIONS OF HUMAN RESOURCE DEPARTMENT

1.

Recruitment

2.

Selection

3.

Employee training

4.

Performance appraisal

5.

Welfare activities

1.

RECRUITMENT:

TYPES OF RECRUITMENT IN ICF: 1.

THROUGH AGENCY

1.

Railway Recruitment Board

2.

Railway Recruitment Cell

1.

DIRECT RECRUITMENT

1.

Sports quota

2.

Scouts quota

3.

Cultural quota

1.

SPECIAL DRIVE

1.

Ex-serviceman quota

2.

Shortfall in SC/ST/OBC/Minorities

1.

ON COMPASSIONATE GROUNDS

1.

Circumstances in which compassionate appointments may be made.

2.

Person eligible to be appointed on compassionate grounds

3.

Qualifications and conditions to be fulfilled.

1.

SELECTION: Selection is the process of choosing the most suitable persons

out of all the applicants. 1.

Written test

2.

Personal interview

3.

Physical examination

4.

Verification of certificates

5.

Final approval

1.

EMPLOYEE TRAINING: Training is the process of increasing the knowledge and skills for

doing a particular job. Training is a short-term process utilizing a systematic and organized procedure by which non-managerial personnel learn technical knowledge and skills for a definite purpose. Training involves helping an individual learn how to perform his present job satisfactorily. 1.

On the Job training

2.

Vestibule training

3.

Class room training

1. 1.

PERFORMANCE APPRAISAL: Simple checklist method is followed describing the characteristics and performance of employees on the job based on parameters like regularity, respect from subordinates, willingness to help, orderliness in keeping equipment and following instructions properly.

2.

Free form or essay method is also used to rate the efficiency of employees.

1. 1.

MAJOR WELFARE ACTIVITIES IN ICF: Canteens

2.

Tea points

3.

Rest rooms

4.

Stadium

5.

Hospital

6.

Schools

7.

Crèche

8.

Handicraft and tailoring school

9.

Typewriting institute

10.

Ambulance

11.

Staff benefit fund

12.

Quarters

13.

Child care leave, House benefit allowance, Loans

14.

Allowances (TA, Petrol for officers)

15.

Training classes

16.

Water coolers

17.

Marriage hall

18.

Employee holiday camp

Employee Training

For Workers- Apprentice training, Vestibule training, On the Job training. For Staffs-

Indian railway Institute of

civil engineering- Pune,

Indian railway institute of Mechanical, Jamalpur & Electrical Engg, Nasik and Railway Staff college, Vadodara for general , accounts, personnel and stores.

Training Budget Duration of 8 hrs = 1day, Cost of training = Rs.2, 50,000 / Yr Training man days= 2 days / employee / year

PERFORMANCE OF HUMAN RESOURCE DEPARTMENT

1.

FINANCE DEPARTMENT

AUTHORITY FLOW CHART OF FINANCE DEPARTMENT

CHIEF ACCOUNTS OFFICER

DEPUTY CHIEF ACCOUNTS OFFICER

ASST.ACCOUNTS OFFICER

HEAD CLERK

PEON

FUNCTIONS OF ACCOUNTS DEPARTMENT

1.

Maintenance of the accounts of the railway.

2.

Internal check of transactions affecting receipts and expenditure.

3.

Settlement of claims against the railway.

4.

Tendering advice to the administration in issues involving railway finances.

5.

Compilation of accounts.

6.

Compilation of budget and periodical review of expenditure.

7.

Discharging other management accounting functions including reporting of financial data for management, inventory management.

8.

Seeing that there are no financial irregularities in the transactions of the railway

PERFORMANCE OF FINANCE DEPARTMENT FINANCIAL PERFORMANCE (BALANCE SHEET) PARTICULARS

Final

Actuals

Final

Actuals

Final

Actuals

Final

Actuals

Final Grant

Actuals

Grant

2009-

2009-10

10

Grant 200809

200809

Grant 200708

200708

Grant 200607

200607

2005-06 2005-06

OPENING BALANCE

792366 792366 662639 662639 463820 463820 266474 266474 231456 231457

DEBITS 483000 482614 338000 339631 228000 228618 213000 212990 LABOUR MATERIAL & STORES

0

3

0

1

0

6

0

3

200423 2000000

125000 125043 112000 111925 830000 829587 660000 659141 00

15

00

63

0

4

0

7

0 550537

5500000

7

DIRECT PURCHASES

270000 260622 210000 210075 300000 323004 300000 321630 150000 130861

WMS(OH) ADD&REP

240000 240580 210000 223139 120000 122747 87419

95652

80000

80881

140500 131501 104000 103288 MISC.CHARGES

0

1

0

5

900000 909059 700000 742094 660035 618042

192450 191466 160400 160549 119000 119368 981741 988069 GROSS

00

71

00

73

00

70

9

6

833939 8390035

1

DEDUCT FOR ISSUESWITHIN DEMAND

245000 239449 240000 243404 170000 166583 150000 153876 150000 145147 190000 189072 158000 158115 117300 117702 966741 972682

NET DEBITS

819424

00

22

00

69

00

87

9

0

8240035

4

5000

4417

10000

4358

50000

40005

50000

49801

80000

71588

STORES

240000 235032 230000 239046 120000 126578 100000 104075 70000

73559

ROLLING

189000 188896 156700 156818 115600 115714 952310 952947

CREDITS FINISHED PART STORES RETURNED

STOCK PROG.

00

91

00

42

00

68

0

4

815922 8230000

191450 191291 159100 159252 117300 117380 967310 968335 TOTAL

00

40

00

46

00

51

0

0

7 830437

8380000

4

DEDUCT FOR ISSUES

245000 239449 240000 243404 170000 166583 150000 153876 150000 145147

WITHIN DEMAND 189000 188896 156700 156818 115600 115714 952310 952947 TOTAL CREDITS

00

91

00

42

00

68

0

4

815922 8230000

7

CLOSING BALANCE

892366 809897 792639 792366 633820 662639 410793 463820 241491 266474

TURNOVER RATIO

4.72%

1.

4.29%

5.06%

5.05%

5.48%

5.73%

4.31% 4.87%

MECHANICAL DEPARTMENT

AUTHORITY FLOW CHART OF MECHANICAL DEPARTMENT

CHIEF MECHANICAL ENGINEER

DEPUTY CHIEF MECHANICAL ENGINEER

ASST. MECHANICAL ENGINEER

SENIOR SECTION ENGINEERS

TECHNICIANS & HELPERS

2.93%

3.27%

FUNCTIONS OF MECHANICAL DEPARTMENT IN ICF: DESIGN AND DEVELOPMENT OF ICF

1.

The design cell has a Design & Development wing. A CAD Centre is installed which assists in evolution and preparation of new drawings faster.

2.

Design office takes care of the changes in the availability of the new materials, standardization, and obsolescence, feedback reports from the

user

Railways

and

recommendations

by

various

standing

committees and study groups on the Indian Railways.

3.

With the changing requirements of the Railways, the design office is challenged to drastically cut down the design cycle time. The design office can proudly take the credit of development of the following new designs in the past three years.

They are: 1.

Diesel Electric Multiple Units for JAMMU & KASHMIR

2.

Self Propelled Accident Relief Tool Vans (SPART)

3.

ACDC EMU MRVC

4.

Integrated Communication Car (ICC for DRDO)

5.

Jet Deflector Crane Car (JDCC for DRDO)

6.

Saloon Medical Relief Van & Power Car for (MoD)

7.

Indian Railway Catering and Tourism Corporation (IRCTC)

8.

Rajasthan Tourism Development Corporation (RTDC)

9.

LHB - EOG and Hybrid Design.

PERFORMANCE OF MECHANICAL DEPARTMENT Design office has designed more than 400 types of coaches to three different gauges 1676mm, 1067mm and 1000mm. It has produced over 3, 00,000 drawings for coach layout and coach components.

1.

ELECTRICAL DEPARTMENT

AUTHORITY FLOW CHART OF ELECTRICAL DEPARTMENT

CHIEF ELECTRICAL ENGINEER

DEPUTY CHIEF ELECTRICAL ENGINEER

ASSISTANT ELECTRICAL ENGINEER

SENIOR SECTION ENGINEERS

TECHNICIANS & HELPERS

FUNCTIONS OF ELECTRICAL DEPARTMENT:

The Electrical Department at ICF works under the overall control of the Chief Electrical Engineer. The Electrical Design Wing is headed by Chief Design Engineer/Electrical. The Maintenance and Construction Organization is headed by Chief

Electrical

General

Engineer.

Chief

Electrical

Engineer/Quality

Control

and

Commissioning is responsible for Inspection and Quality Assurance of the components and coaches. The functional Wings of Electrical Branch of ICF are as follows:

A. Designs - The Electrical Design Wing is responsible for evolving new designs of coaches, equipments and sub systems, drawings and specifications for components and assemblies. The Design Wing is also responsible for issuing necessary interfaces for electrical equipments for incorporation in the Shell design and inputs required for Production Wing. This wing is also responsible for developing expertise in design of new generation self-propelled coaches, EMUs, DEMUs, Air-conditioned, Non Airconditioned coaches and Luxury Trains for user Railways. B. Production - The Production Wing is responsible for manufacturing of harness, installation of electrical equipments, wiring and complete electrical furnishing of the various types of coaches. The Production wing has developed the expertise in handling of different types of self-propelled coaches including 3 phase AC DC EMUs, EMUs, DEMUs, Ac & non AC coaches including luxury trains for RTDC & IRCTC.

C. Inspection - The Inspection Wing is responsible for Quality assurance of electrical components and systems used for manufacturing of the coaches. This Wing is also responsible for undertaking prototype inspection of newly developed components/equipments. This Wing is also responsible for testing and commissioning of self-propelled coaches and AC coaches to ensure quality and reliability.

1.

Contracts and Development - The Contracts & Development Wing is responsible for liaising with the purchase department for ensuring timely

availability

of

materials

for coach

production,

customer

complaint redressal and discharge of warranty obligations, failure analysis and corrective and preventive actions, development of new Items for coach production and development of additional sources for limited source items.

2.

Maintenance - The Maintenance Wing is responsible for maintenance of Plant & Machinery including numerically controlled & CNC machines, EOT cranes etc. This Wing is also responsible for maintaining power supply for Factories, i.e. Shell & Furnishing, D&D Wing, Hospital, Colony etc. The construction activities associated with new projects, safety works and replacement works of Plant & Machinery are also undertaken by this Wing. This Wing also is undertaking number of green energy projects such as installation of Wind Mill and Solar energy systems.

1.

PRODUCTION DEPARTMENT

FUNCTIONS OF PRODUCTION DEPARTMENT There are two divisions in production department. They are 1.

Shell division

2.

Furnishing division

SHELL DIVISION

The coach manufacturing starts from Shell Division, where the body shell and bogie assemblies are done. The body shell assembly is of all welded integrated design, and it consists of Under frame, Sidewall, Roof and End wall assemblies. A Shell is made of a set of 2 Sidewalls, 2 End walls, 1 Roof and 1 Under frame fitted on two Bogies.

Activities of Shell Division 1.

Sheet metal shop produces all sheet metal items required for the manufacture of Underframe, Sidewall, Endwall and Roof.

2.

Main Assembly shop assembles the Underframe, Sidewall, Endwall and Roof to form a tube like SHELL.

3.

Bogie Frame manufacturing shop manufactures Bogie Frames by Laser Cutting, Press Brakes and Submerged Arc Welding machines. The components are then assembled in jigs and welded to get bogie frames.

4.

Bogie frames, Bolsters, Springs and Wheels are assembled together and Bogies are tested in Bogie Testing machine before they are sent for wheeling.

5.

Final Assembly for fitment of Doors, Partition Frames and Wheeling of Bogies onto the Shells.

FURNISHING DIVISION Aesthetic look, comfort and safety are very much essential for pleasant journey. Furnishing Division takes care of the above by furnishing the interior of the coaches.

Activities of Furnishing Division Furnishing of coaches is done in stages, viz. 1.

Grit Blasting, Painting in Automatic Paint Booths, Drying in Ovens, Lettering.

2.

Flooring, Wiring, Paneling on Side Walls, Window fixing, Partition Panelling, Plumbing, Floor Moulding, Lights & Fans fixing, Seats, Berths and Racks fixing, Air-conditioning where required, Brake fitment and Buffer height adjustment.

The Furnishing Division also does assembly of Self Propelled Coaches where Engine/Electrics for DEMUs and Transformers/Motors for EMUs are fitted, commissioned and tested before despatch.

PERFORMANCE OF PRODUCTION DEPARTMENT 2008- 09 = 1000 Coaches 2009- 10 = 1000 Coaches 2010- 11 = 1250 Coaches Capacity is further being enhanced to 1500 coaches per annum through infrastructure additions and modernization of machines.

1.

STORES DEPARTMENT

AUTHORITY FLOW CHART OF STORES DEPARTMENT CONTROLLER OF STORES

DEPUTY CHIEF MATERIALS MANAGER

ASST. MATERIALS MANAGER

MATERIALS SUPERVISOR

TECHNICIANS & HELPERS

FUNCTIONS OF STORES DEPARTMENT 1.

Receipt on incoming goods

2.

Inspection of all receipts

3.

Storage and preservation

4.

Material handling

5.

Packing

6.

Issue and despatch

7.

Inventory control

PERFORMANCE OF STORES DEPARTMENT Total Value of Procurement by ICF 2008-09 is Rs.1120 Crores 2009-10 is Rs. 1139 Crores

1.

CIVIL DEPARTMENT

AUTHORITY FLOW CHART OF CIVIL DEPARTMENT

CHIEF CIVIL ENGINEER

DEPUTY CHIEF ENGINEER

ASST. CHIEF ENGINEER

SENIOR SECTION ENGINEERS

TECHNICIANS & HELPERS FUNCTIONS 1.

Construction and maintenance of the factory sheds and structures, service and welfare buildings, colonies.

2.

Responsible for providing day-to-day service like water supply, sanitation and sewage disposal, for upkeep of parks, gardens and for all other estate management works. ICF Estate owns an area of 192.254 Hectares (Shell division- 25.89

Hectares; Furnishing division - 50.82 Hectares; Colonies - 15.02 Hectares; Service

and

Welfare

Hectares(approx.).

Buildings

Chief

-

5.45

Hectares;

Engineer-cum-Estate

Afforestation-

Officer

has

40.00

powers

for

acquiring and disposing off lands, controlled by Railway Board. He is also responsible for licensing, leasing, auctioning, and to prevent encroachment, implementing the public premises eviction Act 1971.

CHAPTER 4 CORPORATE SOCIAL RESPONSIBILITY

CORPORATE SOCIAL RESPONSIBILITY

1.

Provision of social welfare services such as drinking water facilities, construction of external sewage, roads, providing health facilities, improving the quality of life through job redesign approach, improving educational facilities.

2.

Extending ambulance and health care facilities existing in the township to the surrounding areas.

3.

Extending educational facilities available in the township to the children of nearby villages, offering scholarship to the needy.

4.

Making the local population aware of the role of ICF and its products and its contribution to the national economy.

5.

Providing support / employment to the disadvantaged or challenged employees. CSR BUDGET - In 2010 out of Rs. 1328 Crores Profit, Rs.5 Crores were spent on CSR activities by the Indian Railways.

CHAPTER 5 SWOT ANALYSIS

SWOT ANALYSIS

STRENGTHS 1.

High purchasing power of customers.

2.

Skilled Employees.

3.

Substantial Market share exists in the passenger segment. So the company can take advantage of the Indian population.

OPPORTUNITIES 1.

Need to increase market share

2.

Could convert existing products in new market.

WEAKNESSES 1.

Trade union pressure

2.

Lack of good organizational climate

3.

Lack of proper training system.

THREATS 1. 2.

Outdated technology. Lack of contractors loyalty.

CHAPTER 6 COMMUNICATION SYSTEM IN THE COMPANY

COMMUNICATION SYSTEM IN INTEGRAL COACH FACTORY

INTERNAL COMMUNICATION a) Upward communication

EXTERNAL COMMUNICATION 1.

Website

ii) Letters, Notices, Calls.

2.

Newspaper

b) Downward communication

3.

Publications

4.

Railway budgets

i) Meetings

i) Employee handbook ii) Newsletters- issued quarterly

COMMUNICATION SYSTEM IN ICF DOWNWARD

COMMUNICATION

1.

ICF communicates vertically downwards, where the line of authority runs distinctly downwards, with each rank clearly below another.

2.

The communication that takes place from manager towards its employees.

3.

Regular meeting to discuss the target and accomplishment

4.

Posters are used to pass in miscellaneous instructions at the work place.

5.

Seminars and discussions are done current status and highlights

6.

Monthly review in concerns and results of each departments.

HORIZONTAL COMMUNICATION Communication is carried out by means of

1.

Periodical meetings

2.

Letters and memos

every

Friday

about

their

3.

Telephonic talk

4.

Face to face discussions

COMMUNICATION FLOW OF INTEGRAL COACH FACTORY

GENERAL MANAGER

CHIEF ENGINEER

ASSISTANT ENGINEER

SENIOR SECTION ENGINEER

TECHNICIANS & HELPERS

CHAPTER 7 FINDINGS

FINDINGS

1.

The organization lacks good employee- employer relationship.

2.

Lack of work related training programs given to the employees.

3.

Outdated technology machinery is being used in the shops.

4.

Negligence of workers in using protective gear at shop floor

5.

Touch screens have been installed at Shell and Furnishing divisions at the locations mentioned below for the benefit of the Suppliers who visit ICF. Suppliers can access the details of their bills by simple touch on the screen

6.

Introduction of timer circuit in the air circulating fans for switching off the fans during non working hours including lunch hours and break hours.

CHAPTER 8 SUGGESTIONS

SUGGESTIONS

1.

The company shall take measures to enable proper negotiations with the unions to maintain good employee-employer relationship

2.

The company shall take steps to ensure that work related training programs are given to each and every employee

3.

The company shall introduce latest technology machinery in the shops

4.

The company shall implement strict rules to ensure wearing protective gear at shop floor and warnings in writing shall be given to employees who do not follow the rules.

5.

The company has maintained good standards of accessing bills for suppliers. The same can be sustained and further improved.

6.

The company has maintained good power saving methods. The same shall be sustained and further improved.

CHAPTER 9 CONCLUSION

CONCLUSION

The summer internship titled “An organizational study at Integral Coach Factory, Chennai” has been of great help to the researcher as an aspirant manager in understanding the functions of various departments in the manufacturing company and to develop academic theoretical knowledge into practical experience. This internship training in ICF gave an idea about their various activities undergone in a heavy industry.

CHAPTER 10 BIBLIOGRAPHY

BIBLIOGRAPHY

BOOKS

1.

L.M. PRASAD, Human Resource Management, Sultan Chand Publications, New Delhi, 2005, Pg 444-455.

2.

P. Saravanavel & S. Sumathi, PRODUCTION AND MATERIALS MANAGEMENT, MARGHAM PUBLICATIONS, CHENNAI, 2011, Pg 31.131.24

3.

V.K. AGARWAL , “ INDIAN RAILWAYS IN FULL SYSTEM”

4.

ICF MANUAL

WEBSITES

1.

http://www.icf.indianrailways.gov.in/

2.

http://en.wikipedia.org/wiki/Rail_transport

3.

www.indianrailways.com

4.

www.scribd.com