Organisation Study Nirapara Complte Report

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ORGANIZATIONAL STUDY

AT

NIRAPARA ROLLER FLOUR MILLS PRIVATE LIMITED

Changanasery

REPORT

submitted to Mahatma Gandhi University in partial fulfillment of the requirements for the award of the degree of

MASTER OF BUSINESS ADMINISTRATION

Submitted By

PRANAV SASI

Reg. No. 61509

Under the guidance of

Mr. .SREEJU P.S

Prof. AJAI KRISHNAN

G

Company Guide

Faculty Guide

DEPARTMENT OF MANAGEMENT STUDIES

MAR ATHANASIOS COLLEGE FOR ADVANCED STUDIES

TIRUVALLA

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CERTIFICATE

This is to certify that this report, based on the organization study conducted

by PRANAV SASI, second semester MBA student of our college for 30 days

starting from 20

th

March to 20

th

April 2015 at NIRAPARA

ROLLER

FLOUR MILLS PRIVATE Ltd COMPANY Changanassery , is a

bonafide record submitted in partial fulfillment of the requirements for the

degree of Master of Business Administration of Mahatma Gandhi

University, Kottayam.

Prof. AJAI KRISHNAN G Prof. LIGO KOSHY Faculty Guide Head of Dept. of Management Studies

Rev. Fr. Pradeep Vazhatharamalayil Signature of the External Examiner Principal

MAR ATHANASIOS COLLEGE

FOR ADVANCED STUDIES

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CERTIFICATE

FROM

THE

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DECLARATION

I hereby declare that this report titled “Organizational Study at “NIRAPARA

ROLLER FLOUR MILLS PRIVATE Ltd COMPANY” has been

prepared by me during the academic year 2015 - 2016, under the guidance of

Prof. AJAI KRISHANAN G , Department of Management Studies,

MACFAST, Thiruvalla.

I also hereby declare that this project report has not been submitted to any

other University or institute for the award of any degree or diploma.

PRANAV SASI

30/4/2015

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ACKNOWLEDGEMENT

The study will not be completed without acknowledging my sincere gratitude to all persons who have helped me in the preparation of this dissertation.

I would like to thank the management and staff of different departments of “NIRAPARA FLOOR MILLS PVT LTD” for their valuable help in completing this organizational study.

It is my great pleasure to convey my deep and sincere thanks to Mr. Sreeju P.S (HRD) for his guidance and support.

I owe a deep gratitude to our respected principal Rev Fr Pradeep Vazhatharamalayil and our HOD Ligo Koshy for permitting me to take up this study.

My respected guide Prof Ajaikrishnan G has shown a keen interest in my study ,and offered valuable suggestion and I am indebted to him.

My family and friends helped me and I would like to record my special thanks to them, I also take this opportunity to thank the almighty god who enabled me to successfully complete this study.

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LIST OF FIGURES

Fig. No

Title

Page No.

1 Organizational Structure

29

2 Structure of production Department

37

3 Production Process Flow Chart

40

4 Structure of Human Resource

Department

42

5 Structure of Sales & Marketing

Department

47

6 Structure of Purchase Department

49

7 Structure of Administration

Department

51

8 Structure of Finance Department

53

9 Pictorial Rep of Swot Analysis

60

10 Pictorial Representation Of

Porter’s Five Force Analysis

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ABBREVIATIONS

ISO : International Organization for Standardization

SWOT: Strength Weakness Opportunities Threats

PF : Provident Fund

ESI: Employee State Insurance HRD: Human Resource Development

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CHAPTER – 1

INTRODUCTION

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INTRODUCTION

I underwent an organizational study at NIRAPARA ROLLER FLOUR MILLS PRIVATE LIMITED COMPANY to acquaint myself with the business environment for a period of 30 days from March 20th , 2015 to April 20th as a part of the MBA curriculum at the school of management studies of M.G UNIVERSITY.

The study was conducted to understand the structure, function and processes of various departments and their interdependence. During the course of study I was able to successfully interact with the employees of the organization. They were happy to give me all possible information. They also took me to the worksite where I got the first hand information about the manufacturing process and its functions.

The Methodology consists of data collection through observation,

interview and literature review. The data collected from different sources are classified, analyzed and interpreted. based on which an organization structure, its functions and various departments are identified. The various departmental functions are clearly identified and their process and activities carried out are recorded. An in-depth analysis is made us to understand the departmental process based on which a process chart is prepared. The analysis further formed the basis for identifying the departmental interdependence. The study further revealed some of the challenges faced by the department. The study helped me to obtain an exact picture of fact based on which, a swot analysis is done. Finally, with the help of latest statistics available from the organization. The present trend and current scenario of fact is clearly revealed.

1.1 SCOPE OF THE STUDY

Work force constitutes a major factor in the proper functioning of an organization. It is the proper satisfaction of the employees that facilities the fulfilling of company’s objectives. Any attempt to increase the productivity, efficiency of labor can

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bear fruit only if the workers are given the right type of work environment and are

provided with these amenities of life which have direct bearing on his physical efficiency.

In a broad sense the scope of this study is an attempt to know about the organization as a whole and also about the functions and practices of the organization and duties and responsibilities of different staffs. The study helps to understand the nature, the working conditions, work environment and the issues that the company is facing

1.2 SIGNIFICANCE OF THE STUDY

The study aims at understanding the application of management theories and organizational culture in a live organization scenario. The major objective of the Organization Study is to have a better understanding of the area-wise subjects taught in the Business Management Programme. Such a study can also be beneficial to the company for various decision making purposes.

The importance of my Organization Study is:

 This study was helpful to provide knowledge about modern organisations and its function

 It helps to know about various machines used in the factory and office and its functions

 It helps the students to develop skill required for preparing, maintaining and handling of office record and its functions

 The study will provide an overall idea about the working conditions and employees level of satisfaction regarding various factors like salary, benefit, welfare and working environment

 It provides an idea about the financial position of the company and its future position.

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1.3 OBJECTIVES OF THE STUDY

The main objectives of the ORGANISATIONAL STUDY at “NIRAPARA ROLLER FLOUR MILLS PRIVATE LIMITED

 To study about the overall structure and administrative set up of the company.  To study about the structure of various departments in the organization.  To have an idea about products of the company and production process.

 To understand and study about the overall objectives, policies, and practices of the organization.

 To study the overall performance of the company.

 To understand the practical applications of the theory in an organizational setting.  To identify the major strengths weakness opportunity and treats faced by NIRAPARA

ROLLER FLOUR MILLS PVT LTD

1.4 METHODOLOGY

In short Research Methodology deals with the objective of research study, the

method of defining the research problem, the type of hypothesis formulated, the type of data collected, methods used for collecting and analyzing the data etc

Methods of Data Collection

The study is a descriptive type undertaken by visiting the firm. The information and the data required for the study is carried out through two types of data. They are

primary data and secondary data.

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It is collected from individuals including employees & managers of different sections of the organization. The personal medium used by the research in this project is face to face interview with the respondent and observation method.

METHODS FOR COLLECTING PRIMARY DATA

OBSERVATION METHOD

It may be defined as a systematic viewing of a specific phenomenon in the proper setting for the specific purpose of gathering data for a particular study

a)

INTERVIEW METHOD

It is the direct method of collecting data. It is a verbal method of securing data. For the purpose of this study direct interview of employees and workers are done.

I interacted with the employees and understood the work and responsibility carried by each of them. This helped me to understand various department and their functions clearly. Further discussion with them revealed some key functions and process carried by each department and the departmental interdependence.

Secondary data

It is collected from various records like the annual report, company brochure, Quality Management System and other manuals maintained by the company. Secondary data are those which have been collected by some other person for his purpose and published. So researcher is said to use that type of data for this study. Following are some of secondary source of data. This method is also known as indirect method. Company’s internal records, publication, Annual report, Journal, Statutory report, Website.

The data collected company’s departmental manual added key information to this report add help me to understand the process carried by each

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department in detail. Annual reports are used as statistics to reveal the present scenario of the organization.

a) NEWS PAPERS & MAGAZINES

Audited reports, articles published in news paper and magazines related to Nirapara roller mills helps researcher for his study.

b) WEBSITES

Websites of Nirapara, websites of some market survey companies or share broking firms sites and official sites of government helps more to conduct this study.

DATA AUTHENTICATION

The process chart prepared for each department was given to respective

department heads for correction. The rough report prepared was also given to the organizational guide for correction.

1.5 REFERENCE PERIOD

The present study was conducted for a period of one month commenced on 20

th

March 2015.

1.6 LIMITATIONS OF THE STUDY

The following are the limitations of the study:  Time was a major limiting factor.

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 Lack of co-operation from certain departments due to their work load.

 Reactants on the part of mangers in disclosing confidential was also a limitation of study.  Lack of cooperation from departments was of time taking

1.7 PRESENTATION OF THE REPORT

The report has been below contain following chapters: Chapter 1 : Introduction

Chapter 2 : A Short Profile On Food Industry In India

Chapter 3: Nirapara Roller Flour Mills Pvt Ltd An Over View

Chapter 4: Product Profile Of Nirapara Roller Flour Mills Pvt Limited

Chapter 5: Functional Departments Of Nirapara Roller Flour Mills Pvt Limited

Chapter 6: Performance Analysis Of Nirapara Roller Flour Mills Pvt Limited

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CHAPTER – 2

A SHORT PROFILE ON FOOD INDUSTRY

IN INDIA

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The food industry is the complex, global collective of diverse businesses that together supply much of the food energy consumed by the world population. Only subsistence farmers, those who survive on what they grow, can be considered outside of the scope of the modern industry. Food marketing brings together the producer and the consumer It is the chain of activities that brings food from “farm gate to plate.”The marketing of even a single food product can be a complicated process involving many producers and companies. For example, fifty-six companies are involved in making one can of chicken noodle soup. These businesses include not only chicken and vegetable processors but also the companies that transport the ingredients and those who print labels and manufacture cans. The food marketing system is the largest direct and indirect nongovernment employer in the United States.

In deciding what type of new food products a consumer would most prefer, a manufacturer can either try to develop a new food product or try to modify or extend an existing food. For example, a sweet, flavored yogurt drink would be a new product, but milk in a new flavor (such as chocolate strawberry) would be an extension of an existing product. There are three steps to both developing and extending: generate ideas, screen ideas for feasibility, and test ideas for appeal. Only after these steps will a food product make it to national market. Of one hundred new food product ideas that are considered, only six make it to a supermarket shelf.

The food industry faces numerous marketing decisions. Money can be invested in brand building (through advertising and other forms of promotion) to increase either quantity demanded or the price consumers are willing to pay for a product. Coca Cola, for example, spends a great deal of money both on perfecting its formula and on promoting the brand. This allows Coke to charge more for its product than can makers of regional and smaller brands. Manufacturers may be able to leverage their existing brand names by developing new product lines. For example, Heinz started out as a brand for pickles but branched out into ketchup. Some brand extensions may involve a risk of

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damage to the original brand if the quality is not good enough. Coca Cola, +for example, refused to apply the Coke name to a diet drink back when artificial sweeteners had a

significantly less attractive taste. Coke created Tab Cola, but only when aspartame (NutraSweet) was approved for use in soft drinks did Coca Cola come out with a Diet Coke. Manufacturers that have invested a great deal of money in brands may have developed a certain level of consumer brand loyalty—that is, a tendency for consumers to continue to buy a preferred brand even when an attractive offer is made by competitors. For loyalty to be present, it is not enough to merely observe that the consumer buys the same brand consistently. The consumer, to be brand loyal, must be able to actively resist promotional efforts by competitors. A brand loyal consumer will continue to buy the preferred brand even if a competing product is improved, offers a price promotion or premium, or receives preferred display space. Some consumers have multi-brand loyalty. Here, a consumer switches between a few preferred brands. The money that manufacturers invest in developing, pricing, promotion, and placing their products helps differentiate a food product on the basis of both quality and brand-name recognition.

The food industry is very competitive and is constantly changing to react to consumer demands and technological developments. As the world population increases, we are challenged with new ways to produce and package foods. As a result there is a great demand for young people to work in food businesses. Day by day, wide varieties of new food products have been increasing in the food industry. So food industry has been growing with new food products in the variant fields of the food industry such as in the fast food, sea food, hotel foods. Thereby people get easily attracted towards this type of food product and their demand of food products is constantly changing as

well. But, even if the food industry is very competitive and is constantly changing to consumer demands, one particular type of food products is standing out of these constant changing demand, i.e. Agro-food products. Agro food products retain their demand among the people throughout the years. This is only because of awareness of benefits of agro food

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products by the people. It has got lots of benefits. By Consuming, it will not cause any harmful effects to the people.

The most important and useful one in the agro food products is Wheat products. It is believed that wheat developed from a type of wild grass native to the arid lands of Asia Minor. Cultivation of wheat is thought to have originated in the Euphrates Valley as early as 10,000 B.C., making it one of the world's oldest cereal crops. In the Mediterranean region, centuries before recorded history, wheat was an important food. Wheat played such a dominant role in the Roman Empire that at the time it often was referred to as a "Wheat Empire."

Wheat, which can be produced in a wide range of climates and soil conditions, grows in areas as far north as the Arctic Circle and as far south as the equator. The production of wheat is so widespread that it is being harvested somewhere in the world in any given month. But wheat grows best in regions having temperate climates with rainfall between 12 and 36 inches per year. The United States ranks fourth in world wheat production, following: 1) China; 2) the Commonwealth of Independent States; and 3) the European Community (whose major producers are France, the United Kingdom and Germany).

One of the easiest dietary changes to make, and one that carries a real health punch, is replacing refined grains with more healthful whole wheat. This one change in diet can have a significant impact on health, from helping to maintain a healthy weight to helping to avoid certain kinds of cancer. Recent studies, including one at the University of Iowa, have suggested that higher levels of whole grain, including whole wheat, in the diet were associated with a lower risk of both breast cancer and heart disease.

Other studies have associated the consumption of whole wheat and other whole grains with a reduced risk of diabetes, obesity and cardiovascular disease. The USDA is now recommending that every adult consume three servings of whole wheat and other whole

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grains every day, but most people fall short of this important mark, averaging only one serving per day.

Whole wheat and cancer prevention

There is now considerable evidence that a diet rich in whole wheat and other whole grains plays an important role in lowering a person’s risk of cancer. The major cancer fighting ingredient of whole wheat is thought to be dietary fiber. Dietary fiber is believed to play an important role in the prevention of cancer, and whole wheat breads and other products are rich sources of this dietary fiber.

In addition, whole wheat and other whole grains are thought to reduce levels of serum insulin. High levels of serum insulin have been associated with higher risk of cancers of the breast and colon, so lowering these levels may have an effect in the prevention of cancer.

Whole wheat and selenium

Whole wheat and other whole grains can also be rich sources of the mineral known as selenium, although the actual selenium content of the grain will vary according to the selenium content of the soil. Vitamin E, however, seems to be present in high amounts in just about all whole wheat and whole grain products. Vitamin E is thought to be a strong cancer fighter which has the power to prevent cancer-causing chemicals from doing harm. In addition, whole grain products like whole wheat bread and crackers also contain many important micronutrients.

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Whole wheat products and other whole grains have been shown to have a significant impact on overall health, and a diet rich in whole wheat and other whole grains has been associated with an overall increase in health and an overall decrease in obesity. That may be because whole wheat is a high energy, nutrient rich and relatively low calorie food. The rich nature of many whole wheat products seems to promote a feeling of fullness and reduce the risk of overeating.

Rice was the only food for the South Indians during the past. But after the Second World War there was scarcity for rice and they were compelled to take wheat as an alternative food. The high protein content and resultant nutritional value and absence of the negative factors of rice and also the economy promoted them to substitute rice by wheat to the extent of 30-35% so that there is almost an equal demand for rice and wheat and their products.

In the past, rice and wheat flours required for domestic use were made at home by women, using conventional equipments like stone grinders. Later with the invention of electricity the conventional grinders have given way to mixes and wet grinders. But it is time consuming and not at all economical. In the present day scenario, where women are also employed or engaged otherwise to assist in making a living for their family, powdered rice and wheat –ready for use, have gained very much importance. Thus “NIRAPARA ROLLER FLOUR MILLS PVT LTD” engaged in the manufacture of these flours in roller flour mills have come into being.

The unit have a capacity to produce 40.000 kg’s. of Wheat flour per day of a single shift operation. There is a good scope for the unit. The major products manufactured by this company are MAIDA, ATTA, and SOOJI.

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CHAPTER: 3

NIRAPARA ROLLER FLOUR MILLS PVT LTD:

AN OVER VIEW

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3.1 INTRODUCTION

Rice was the only food for the South Indians during the past. But after the Second World War there was scarcity for rice and they were compelled to take wheat as an alternative food. The high protein content and resultant nutritional value and absence of the negative factors of rice and also the economy promoted them to substitute rice by wheat to the extent of 30-35% so that there is almost an equal demand for rice and wheat and their products.

In the past, rice and wheat flours required for domestic use were made at home by women, using conventional equipments like stone grinders. Later with the invention of electricity the conventional grinders have given way to mixes and wet grinders. But it is time consuming and not at all economical. In the present day scenario, where women are also employed or engaged otherwise to assist in making a living for their family, powdered rice and wheat –ready for use, have gained very much importance. Thus units engaged in the manufacture of these flours in roller flour mills have come into being.

The proposed unit will have a capacity to produce 20,000 kgs of Wheat flour per day of a single shift operation. There is a good scope for the proposed unit. The goodwill of the promoters as the manufacturers of quality wheat products “NIRAPARA” will definitely be an added advantage to the unit.

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SCOPE

There are a number of small and medium scale units engaged in the manufacture of these products in the state. However, the productions of these units are not sufficient and the rest is met by the units of Tamilnadu. Also there is an ever increasing demand for the products with more and more families abandoning the conventional methods and switching over to packed powdered products. The goodwill of the group will be an added advantage. Thus, the proposed unit will have immense scope and potential.

MAJOR PRODUCTS

The major products produced by Nirapara Roller Flour Mills are MAIDA,ATTA AND SOOJI .One of the prominent features of this products is its quality. They produce pure and quality products and thereby they meet the customer satisfaction. Another important feature is its price. They value the products, which is very much affordable to common man.

Even if the products have its own wide varieties of features, The Company mainly concentrates only towards the quality of the product. Its only because of, they give importance to customer satisfaction rather than profit maximization.

LOCATION AND INFRASTRUCTURE

The company is located at Industrial Nagar in Changanacherry.

RAW MATERIALS AND ITS AVAILABILITY

The promoters already have arrangements for procurement of wheat for the existing units.

POWER

The unit requires 400KVA electric power which is available from the nearby power line.

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MANUFACTURING PROCESS

The manufacturing process has mainly two divisions-cleaning and milling. The wheat received is removed of foreign particles like stones and other impurities, dust by De-stoner, sieves and washing machines. It is then conditioned and powdered in Roller Mills. Then it is packed in 90 kg gunny bags and polythene bags of 50 kg, 25kg, 10kg and 1kg.The manufacturing activity is carried out in 100% hygiene

conditions.

CAPACITY PRODUCTION

As mentioned earlier, the unit will have a capacity to produce 20,000kgs of wheat per day in a single shift. The unit will be working double shift and at a 60% capacity during the first year, 70% during the second year,80% during the third year and 90% from the fourth year onwards.

MARKETING AND SELLING ARRANGEMENT

The market for the product is all over Kerala. The company will sell the

products directly through wholesalers, retailers of general items and margin free shops.

3.2 STRATEGIC INTENT

VISION

“To enhance customer satisfaction and achieve exponential growth to leadership through world class products and services”.

MISSION

Zero breakdowns Zero maintenance Zero wastage

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QUALITY GOAL

To be the leader in quality and value of production and services.

QUALITY MANAGEMENT PROCESS

 Focus on customers.  Establish vision, mission

 Understand, standardize, stabilize, and maintenance process  Plan, do, check, act for continual improvement and innovation.

OPERATIONAL POLICY

 Achieve process stability and reliability.  Control every process to decide target.  Improve process capability.

PRINCIPLES

 Customer satisfaction- anticipates, understand and excel at meeting customers’ needs.

 Continue; improve a current level of performance of process, products and services.



Process emphasis- focus on process as the means to improve results

.

MANAGEMENT LEADERSHIP

Creative and maintain a shared vision, consistency of purpose and supportive environment that includes appropriate recognition and reinforcement.

EMPOWERMENT

Creative a culture where people have the knowledge, skills authority for events of

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STASTICAL METHODS

Understand the concept of variation. Apply appropriate statistical methods for continual improvement and innovation.

EMPLOYEES DEVELOPMENT

Knowledge and support lifelong learning and personal growth.

PARTNERSHIP

Build long- term relationship with customers and suppliers.

ASSESSMENT

Assess performance and benchmark against world’s best.

QUALITY IMPROVEMENT METHODOLOGY

 Problem description  Containment action  Define root cause  Verification of cause

 Permanent Corrective Action  Implementation

 Effectiveness

3.3 Organization chart

It is the type of record which shows the formal relationship among different positions in the organizational structure which is intended to be achieved by executive. They are the sources of information to outsiders who are interested in getting information about the organizational structure. The organizational chart follows by NIRAPARA is a traditional chart that shows the position of each level with the flow of authority downward and flow of responsibility upward.

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ORGANISATION STRUCTURE OF NIRAPARA ROLLER FLOUR MILLS

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CHAPTER – 4

PRODUCT PROFILE OF NIRAPARA

ROLLER FLOUR MILLS

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The Major Products produced by Nirapara Roller Flour Mills are MAIDA, ATTA and SOOJI, WHEAT BRAN. The basic raw material needed is only WHEAT. It is believed that wheat developed from a type of wild grass native to the arid lands of Asia Minor. Cultivation of wheat is thought to have originated in the Euphrates Valley as early as 10,000 B.C., making it one of the world's oldest cereal crops. In the Mediterranean region, centuries before recorded history, wheat was an important food. Wheat played such a dominant role in the Roman Empire that at the time it often was referred to as a "Wheat Empire."

Wheat, which can be produced in a wide range of climates and soil conditions, grows in areas as far north as the Arctic Circle and as far south as the equator. The production of wheat is so widespread that it is being harvested somewhere in the world in any given month. But wheat grows best in regions having temperate climates with rainfall between 12 and 36 inches per year. The United States ranks fourth in world wheat production, following: 1) China; 2) the Commonwealth of Independent States; and 3) the European Community (whose major producers are France, the United Kingdom and Germany).

One of the easiest dietary changes to make, and one that carries a real health punch, is replacing refined grains with more healthful whole wheat. This one change in diet can have a significant impact on health, from helping to maintain a healthy weight to helping to avoid certain kinds of cancer. Recent studies, including one at the University of Iowa, have suggested that higher levels of whole grain, including whole wheat, in the diet were associated with a lower risk of both breast cancer and heart disease.

Other studies have associated the consumption of whole wheat and other whole grains with a reduced risk of diabetes, obesity and cardiovascular disease. The USDA is now recommending that every adult consume three servings of whole wheat and other whole grains every day, but most people fall short of this important mark, averaging only one serving per day.

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Whole wheat and cancer prevention

There is now considerable evidence that a diet rich in whole wheat and other whole grains plays an important role in lowering a person’s risk of cancer. The major cancer fighting ingredient of whole wheat is thought to be dietary fiber. Dietary fiber is believed to play an important role in the prevention of cancer, and whole wheat breads and other products are rich sources of this dietary fiber.

In addition, whole wheat and other whole grains are thought to reduce levels of serum insulin. High levels of serum insulin have been associated with higher risk of cancers of the breast and colon, so lowering these levels may have an effect in the prevention of cancer.

Whole wheat and selenium

Whole wheat and other whole grains can also be rich sources of the mineral known as selenium, although the actual selenium content of the grain will vary according to the selenium content of the soil. Vitamin E, however, seems to be present in high amounts in just about all whole wheat and whole grain products. Vitamin E is thought to be a strong cancer fighter which has the power to prevent cancer-causing chemicals from doing harm. In addition, whole grain products like whole wheat bread and crackers also contain many important micronutrients.

Whole wheat products and other whole grains have been shown to have a significant impact on overall health, and a diet rich in whole wheat and other whole grains has been associated with an overall increase in health and an overall decrease in obesity. That may be because whole wheat is a high energy, nutrient rich and relatively low calorie food. The rich nature of many whole wheat products seems to promote a feeling of fullness and reduce the risk of overeating.

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MAJOR PRODUCTS

4.1 MAIDA

Maida flour is refined and finely milled wheat flour. It is also known as Maida flour or general purpose flour. In the mills Maida flour is obtained by grinding it on the rollers and by filtering it through a fine mesh. In South India it is made from tapioca. It bears a resemblance to cake flour or pure starch and is prepared from endosperm. In India it is used to make a variety of food items like puri, chappati, paratha, etc. as well as for making pastries, cakes and many different types of bakery items like bread, toast, biscuits, etc.

Maida takes longer time to digest so it is commonly believed that food items prepared from maida flour are not very healthy. However during festive season, maida flour is used as a basic ingredient in preparing various dishes. The food items prepared out of maida flour gives a good taste. Maida is considered to be free from synthetic fiber so it is very nutritious. Many industries manufacture it hygienically without even touching it with the hands. They carry out milling and filtering process in such a manner that it aids to preserve the protein content of maida flour in large amount.

4.2 ATTA

Atta is obtained from grinding complete wheat grains. It is creamy brown in color

and quite coarse compared to other types of flour. Since nothing is removed from true whole meal Atta, all the constituents of the wheat grain are preserved. Atta available in market varies in its fiber content from very low to whole of natural fiber in wheat, around 12%.

Traditionally, Atta is made by stone grinding, a process that imparts a characteristic aroma and taste to the bread. High bran content of true whole meal atta makes it a fiber-rich food.

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This may help to regulate blood sugar as well have other health benefits. The temperatures attained in a chakki (mill or grinder, traditionally from stone), produced by friction, are of the order of 110-125 deg C. At such high temperatures, the carotenes present in the bran tend to exude the characteristic toasty smell, and contribute to the sweetness of the Atta.

MANUFACTURING PROCESS

The raw materials for production i.e. Wheat is brought from FCI and also from states like Punjab & Haryana and is stored in go down. Flour milling process is simple and continuous. There are mainly two stages namely Cleaning and Milling. From the milling section the products go to the packing section.

Cleaning: The wheat received in gunny bags from lorries is cleaned by Reel

machine, Separator, Aspirator and Magnetic Separator to remove impurities like husk, sand, silicate, dust and iron particles. Then the wheat is stored in wheat bins.

From these bins the wheat goes to De stoner, where all the stones will be

removed by means of specific gravity and from there the wheat passes through disc separator where all the impurities like broken wheat, cockle seeds and other foreign matter are removed. Further, wheat is treated in Scourer machine for the removal of fine dust from the crease of the wheat. The dust is exhausted by powerful aspiration and polished grains are passed through intensive damper, where, with the control of wheat flow and float meter, water is added to the grain. Now the wheat is kept in concrete bins for 18-36 hrs for conditioning. After conditioning wheat is once again passed through separator and aspirator for secondary cleaning and then to the second scourer to polish the grain and to remove any adhering dust to grain before it goes to the milling section.

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Milling: In the milling section, the grain is gradually ground by Roller Mils

equipped with centrifugal cast chilled iron rolls with specified grooves. The stocks are ground by each roller mill and are of different particle sizes, which is achieved by passing the grain stock through plan sifter, equipped with series of wooden sieves of wire or nylon clothing, by different aperture to sieve the ground stock and separate them in different particle sizes. The stock of same size are brought for common treatment to different roller mills, thereby making a continuous process. During the process, coarse endosperms are separated and treated in purifier, which runs on a negative air pressure with centric action having different nylon clothing frames. The stock is stratified, thereby the light branny particles are removed from the stock and pure endosperms are separated from different frames. This keeps the quality of the product absolutely free from fiber. At the tail end of the process, brain finishers are employed to remove the stock adhering to the bran thereby enabling maximum flour extraction from the wheat. The air which is used for the transport of materials along with fine dust particles are treated in Filter dust collector where the pure air is exhausted, claiming all the fine particles back in to the system. All the machines are connected to different destinations by steel pipes and fittings to handle the stocks in most hygienic manner.

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CHAPTER -5

FUNCTIONAL DEPARTMENTS OF NIRAPARA

ROLLER

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Departmentation is the process of grouping activities into units for the purpose of

administration. In other words, it denotes grouping of related jobs and activities without violating the principle of homogeneity over which an executives has authority to exercise and assert.

Every organization needs a well established administrative set up for efficient functioning. Nirapara has established finance, production, human resource development, sales & marketing, purchases, quality departments under the supervision of experienced and competent officers. All the departments are under the control of department heads that are controlled by Managing Director.

5.1 PRODUCTION DEPARTMENT

STRUCTURE OF PRODUCTION DEPARTMENT

Fig: 2 Production Department Miller Floor Manager Roll Men Quality Tester Production manager

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Technology

The most advanced Swiss technologies are used.

Raw material

The basic raw material used for production is wheat. Wheat is a grass, originally from the Fertile Crescent region of the Near East, but now cultivated worldwide. In 2007 world production of wheat was 607 million tons, making it the third most-produced cereal after maize(784 million tons) and rice.

Production process

The raw material for production i.e. Wheat is brought from FCI and also from states like Punjab & Haryana and is stored in go down. Flour milling process is simple and continuous. There are mainly two stages namely Cleaning and Milling. From the milling section the products go to the packing section.

Cleaning: The wheat received in gunny bags from lorries is cleaned by Reel machine, Separator, Aspirator and Magnetic Separator to remove impurities like husk, sand, silicate, dust and iron particles. Then the wheat is stored in wheat bins.

From these bins the wheat goes to De stoner, where all the stones will be

removed by means of specific gravity and from there the wheat passes through disc separator where all the impurities like broken wheat, cockle seeds and other foreign matter are removed. Further, wheat is treated in Scourer machine for the removal of fine dust from the crease of the wheat. The dust is exhausted by powerful aspiration and polished grains are passed through intensive damper, where, with the control of wheat flow and float meter, water is added to the grain. Now the wheat is kept in concrete bins for 18-36 hrs for conditioning. After conditioning wheat is once again passed through separator and

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aspirator for secondary cleaning and then to the second scourer to polish the grain and to remove any adhering dust to grain before it goes to the milling section.

Milling: In the milling section, the grain is gradually ground by Roller Mils equipped

with centrifugal cast chilled iron rolls with specified grooves. The stocks are ground by each roller mill and are of different particle sizes, which are achieved by passing the grain stock through plan sifter, equipped with series of wooden sieves of wire or nylon clothing, by different aperture to sieve the ground stock and separate them in different particle sizes. The stock of same size is brought for common treatment to different roller mills, thereby making a continuous process. During the process, coarse endosperms are separated and treated in purifier, which runs on a negative air pressure with centric action having different nylon clothing frames. The stock is stratified, thereby the light branny particles are removed from the stock and pure endosperms are separated from different frames. This keeps the quality of the product absolutely free from fiber. At the tail end of the process, brain finishers are employed to remove the stock adhering to the bran thereby enabling maximum flour extraction from the wheat. The air which is used for the transport of materials along with fine dust particles are treated in Filter dust collector where the pure air is exhausted, claiming all the fine particles back in to the system. All the machines are connected to different destinations by steel pipes and fittings to handle the stocks in most hygienic manner.

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PRODUCTION PROCESS FLOW CHART

Raw Fig: 3

Role of:

Production manager

Raw Wheat MMMMMM Wheat

Separator Aspirator Disc Separator Scourer Washer

Purifier Plan sifter Ist Break Grinding

bins Extoleter Temperin g bins Purifier Reducing rolls Plan sifter Product Bran Shertz Reducing rolls

Plan sifter A series of purifiers, reducing rolls and shifters repeat this process

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 He is in charge of production, maintenance and responsible for handling any problem with respect to production.

 Responsible for maintaining ISI formality such as (a) Testing and maintaining 4 registers.

 The quality of flour produced everyday is to be get tested at factory lab.

 He is to check the punctuality of workers and ensured that no one comes late for work; no one leaves the company premises. Before cease work without the proper permission and to be replaced HRD without delay.

 He is responsible for taking for initiative action for purchase of spare parts and to consult with the management.

 He checks the quality of flour produced and also the production charts (SPC) at least 4 times a day and to give necessary instructions as and when required.

Operator

 He is in charge ‘daily check life’.  He should check the following factors:

Supervisor

 He ensures that employees under them are not undertaking any work or business other than that of the company.

 He is the custodian of first aid box. And sickness of any worker, the supervisor should render all to get medical treatment and other aids.

 All type of leave for workmen should be recommended by the production manager and approved by the company manager.

 Shift supervisor will be responsible for all workers at the factory and mere attention should be given to punctuality, general behavior.

 Workers under him wear proper uniform. Any complaints/ knowledge of any fraud, theft or any misconduct by any workman must inform to HRD.

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 Tea breaks and lunch breaks are to be regulated strictly.

 No worker should be permitted to leave the working place before completion of his work.

 Ensure each worker clean his working area before he leaves, tool board and tools are to be cleaned.

In Nirapara Roller Mills, the production department have two managers i.e., company manger and production manager. Both the mangers are controlled by the General Manager of the company.

5.2 HUMAN RESOURCE DEPARTMENT

STRUCTURE OF HUMAN RESOURCE DEPARTMENT

Fig : 4

Personnel management is that part of management function which is primarily concerned with the human problems in industries. In order to solve these problems personnel management is assigned a very important role to play labor, being an important

Human Resource Department

HR Manager

Operation Manager

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factor of production needs motivation and power guidance from the side of management to get the desired result.

DUTIES, RESPONSIBILITIES AND INSTRUCTIONS

1. To find suitable solution for all confusion. 2. In charge of continuous improvement

a. Organizational change, Organizational development, Action plans. 3. Acquisition of human resource

a. Determination of the kind or quality of personal, Job analysis, Job description, Job specification, Man power planning, Recruitment, Selection and Induction. 4. Post appraisal interview.

5. Evaluation of performance appraisal system. 6. Potential appraisal and promotion.

7. Training and development

 Preparation of assessment report of employees.  Impact training as per schedule.

 Handling the disciplinary cases.  Welfare of employees.

 Implementation of various improvement activities in the interest of the company.

 To maintain discipline amongst the employees.

 Publications of notice in advance with respect to holidays, working hours, dress etc.

 Counseling or screening of employees, if require.

 Generally cleaningness of workplace and company surroundings.  Preparation of accident report as when required.

Employee welfare

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(a )Economical status

Company providing the facility of PF, ESI etc for their employees.

(b) Health and Safety

First aid: first aided facility is provided in the factory for all employees.

Drinking water: Effective arrangement of drinking water at suitable points conveniently suited for all workers.

Latrines and Urinal: Company provides latrine and urinal facilities.

(c)Canteen

By nutrient, hygienic foods are provided to the total employees. Functioning time: 24 hrs (each shift)

Operation : token system

(d)Accommodation

Free accommodation is provided in the company for all employees.

Functions of HR manager

 Noted the leave of employees

 To check the feedback of the decision taken by the production manager and company manager.

 To check the manpower is allocated and watching the feedback.  To verify these complaints and take initiative action.

 Should watch the activities and give necessary instructions.

STANDING ORDERS OF NIRAPARA ROLLER MILLS

In Nirapara Roller Mills workmen shall be classified as permanent, probationers, temporary, casual and apprentice. Immediately on recruitment, the name of the workmen and the grade or category to which he belongs shall be entered in the muster roll. Every workman appointed in the factory shall be on probation for a period of one year. Every workman shall on being admitted to the service, sign the ‘form’ with the regular to

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conditions of services signifying his consent to comply with the standing orders for the company. The periods and hours of work for all classes of workman shall be posted upon a notice board at the time keeper’s office or factory building.

Attendance

The workman shall be at work in the factory at the time fixed and notified. However, a workman in a relay shift shall normally not leave his post until he is relived by his successor or otherwise instructed by Head of section or any other superior officer empowered to instruct. All workman unless specifically exempted shall enter and leave the factory through the time office gate or main gate. Any workman who is more than half hour late shall be liable to be treated as absent for half a day. All workmen are liable to be searched while entering or leaving the factory premises, or at any time while in the factory, by the person authorized by the management on this behalf. All workmen will be entitled to national and festivals holidays as per the Kerala Industrial Establishment Act. However, the management reserves the right to detail any workmen to work on a holiday subject to the provision of the Act.

Promotion

No workman shall be entitled to be promoted as of right. All promotions shall be on the basis of merit and suitability in the discretion of the management. No strike of any kind shall be staged by the workman without giving the company 14 days notice. There of within one month of the proposed strike, and without reasonable cause.

A workman found guilty of misconduct shall be imposed any one or more of the following punishments, warning, censure, and suspension for a specified period. Demotion to a lower post, imposition of fine, reduction in pay, discharge from service, dismissal from service.

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Secrecy

All process, plans, photographs, designs or drawing pertaining to the company whether of repaired by the workman or otherwise are secret documents which no persons shall publish or causes to be publish. No workman shall disclose any secret or secret information regarding the company’s activities to any person except when it is necessary to do so during the performance of his duties.

Fines

Fines may be imposed on workman in accordance with the payment of Wages Act on workman covered by the said Act. However, the Management may in its discretion impose fines on workman not covered under the said Act or the same principles, as in the Act.

Certificate of Termination

Every permanent workman shall be entitled to a service certificate at one time of his dismissal discharge or retirement from service.

Resignation

A workman accept one who is under obligation to serve the company for a minimum period of service, who wishes to resign and leave the company’s services must give the company the same notice as the company is required to give him under the clause Number 24 (9).A workman who has contracted with the company to serve for a minimum period of service shall not be allowed to resign before the expiry of the said minimum period of service.

Factory Operator

He is in charge of identification of defects or failures

The Human Resource department is the strongest department of Nirapara Roller

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It has a well established industrial relation and this department gives more importance to the welfare and the safety of the employees. Also the time management of Nirapara is very good. All these section are under the direct control of HR manager.

5.3 SALES & MARKETING DEPARTMENT

STRUCTURE OF SALES AND MARKETING DEPARTMENT

Fig :5

MARKETING

 To identify opportunities, preparation of marketing strategies and plans for guiding products and programs towards building up the opportunities and also monitor whether the sales people are implementing this program.

 Responsible for

1) To relay on market research. 2) To identify understand segment. 3) To spend time in plan.

Sales Department

Sales Manager

Sales Assistant

Executives Tele Marketing

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4) To think long term and short term strategies. 5) Aim to produce profits and gain market share.

6) Pre occupied with the planning the right products and marketing strategies to meet the customer long seen needs.

7) To recommend solution for improving sales, understand the problem, monitoring competitors activities and to determine customer satisfaction. 8) To use the telemarketing executives and sales coordinators for getting orders

and inform the bill amount for the purpose of cash discount. 9) Responsible for dispatching the lorry with the full load.

10) To allocate marketing effort in relation to long seen profit potential of the targeted segment to develop winning offers for each marketing segments. 11) To decide the root, dispatches and the compliance.

12) In charge of sales and collection and no credit.

13) Advertisement, promotional materials, exhibitions etc.

SALES

To right orders after margin.

 Separate orders for all units.

 Set up and click the sequence of order for dispatch in root wise.  Address and phone number clearly in the order slip.

 Cash discount rate % should mention before it sent for nakkel print

Sales section

 To draw the root of dispatch ascertains the local capacity for each lorry loaded (10 tones as per load). In the case of the load for dispatch is not full the sales manager phone and obtain maximum load capacity. The dispatch is planned such a manner maximum load capacity is attained for each lorry.

 The dispatch slip is handed over to the Floor Manager.

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5.4 PURCHASE DEPARTMENT

STRUCTURE OF PURCHASE DEPARTMENT

Fig : 6

The purchase department plays a very important role in this organisation because purchasing has its effect on every vital factor concerning the manufacture, quality, cost, efficiency and prompt delivery of goods to customers. Its function is to procure materials, supplies, services, machines and tools at the most favourable terms consistent with maintaining the desired standard of quality. Purchasing is the most important function of materials management as the moment an order is placed for the purchase of materials, a substantial part of the company's finance is committed which affects cash flow position of the company. Thus, if the size of a business concern permits, there should be a separate purchasing department and the responsibility for purchasing all types of materials should be entrusted to this department. The head of this department is usually known as the Purchase manager or the supply manager or the chief buyer.

It is one of the most important departments which deal with purchase of raw material. This department is headed by Purchase Manager. His duty is to order the tones of wheat required by the company. Then he has to make ensure that the raw material sent by the suppliers is of required quantity and moreover it is his responsibility to check whether the

Purchase Department

Purchase Manager

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raw material is of standard quality. If the raw material is not of the standard quality the raw material will be rejected and will send back to the suppliers. If they are of good quality it will be used in the production department.

Documentation

The purchasing department has a lot of documentation to maintain and file as a part of its job requirements. Those documents include paperwork from other departments asking for material or products needed to operate. Most purchasing departments utilize what is called a purchase order when ordering products and services. This order is used by the accounting department so the company that supplied the material can get paid.

Monitoring

Most companies require the purchasing department to maintain a monitoring procedure for the inventory or stock that needs to be on hand. Each department, especially in the

manufacturing industry, uses a lot of material in the production process. A minimum supply is needed for the production process to continue while new materials are ordered. Monitoring inventory and stock will save a company a lot of money in the long run.

OBJECTIVES

 To make continuous availability of materials so that there may be uninterrupted flow of materials for production.

 To make purchase competitively and wisely at the most economical prices.

 To make purchase in reasonable quantities to keep investment in materials at minimum.

 To purchase proper quality of materials to have minimum possible wastage of materials and loss in production.

 To develop good supplier relationship which will ensure the best terms of supply of materials.

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 To develop alternate sources of supply so that materials may be purchased from those alternate sources if a particular supplier fails to supply the materials.

 To adopt the most advantageous method of purchase to ensure smooth delivery of materials from suppliers and to avoid the risks of any disputes or financial loss.

 To serve as an information centre on the materials knowledge relating to prices, sources of supply, specifications, mode of delivery etc.

5.5 ADMINISTRATION DEPARTMENT

STRUCTURE OF ADMINISTRATION DEPARTMENT

Fig:7

Administration

An organization unit that performs management activities benefitting the

entire organization includes top management personnel and organization. This department is headed by Administrative manager. He is otherwise called Office Manager.

DUTIES OF ADMINISTRATIVE MANAGER

An administrative manager oversees the administrative operations of a

business or organization. An administrative manager may supervise administrative Administrative Department

Administrative Manager

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personnel within an office, such as receptionists, filing clerks, secretaries, or executive assistants. He or she may also be the sole person that provides administrative support to a particular division, department, or business or organization as a whole.

In addition to performing general administrative tasks such as filing, data entry, correspondence, scheduling appointments and meetings, and fielding queries, an administrative manager is typically responsible for implementing and managing a business or organization’s administrative systems. This type of management may include such responsibilities as procuring and managing the budget for office supplies, implementing the business or organization’s filing and documentation retrieval systems, overseeing the operation of office equipment such as photocopiers, printers, and fax machines, and managing the calendar and schedule of one or more executives.

Because administration is integral to the operation of all businesses and organizations, an administrative manager position can be found in virtually any industry. Although experience within a similar industry is generally preferred by businesses or organizations seeking administrative managers, the utmost importance is typically placed on previous experience in administration. For example, if two individuals apply for an administrative manager position with a paper supply company, preference will typically be given to the candidate with a solid track record of administrative experience, versus the candidate with a background in the paper supply industry who may have fewer administrative skills. As a business or organization grows, so too does its need for administrative support and management. Whereas the title of “secretary” was once used as an umbrella term to describe most administrative positions, growing businesses and organizations today often require a series of administrative personnel to accommodate the responsibilities integral to office administration. Regardless of whether an administrative manager supervises other personnel within an office, he or she may still be considered the first point-of-contact for general office queries within a business or organization. If an administrative manager is employed in an office that does not have a human resources department, he or she may also be responsible for new employee orientation, including the management of contracts,

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payroll documents, and briefing new employees on the operations of the business or organization.

In short, Administrative Manager focus into the following areas:  Ensuring punctuality and discipline amongst the office staff.

 To look after all matters of the company related with the government departments.  To deal with all correspondence and settlement of company with all government

departments. Preparation of all relevant return and notification as per schedule.

 To make visit to all government departments as and when detailed by the management and to render feedback on various visits or settlements.

 To give timely advise and guidelines to other staff regarding departmental settlement of the company.

In Nirapara Roller Flour Mills, the main responsibility of the administrative

manager is to ensure punctual and discipline among the office staff. It is the duty of the

administrative manager to give timely advice and guidelines to the staff regarding departmental settlement of the company.

5.6 ACCOUNTING & FINANCE DEPARTMENT

STRUCTURE OF FINANCE DEPARTMENT

Fig: 8

Finance Department Chief Accountant Executive Accountants

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It is one of the most important departments which maintain the accounts of the company.

Accounts/ finance department

 Calculation of monthly salary of office staff. Until otherwise notified all employees shall be paid on last working day of month.

 Calculation of wages of factory employees. The wages slip and computer print of wages must be collected back from the concerned supervisors with workers individual signature.

 Submission of cheques received from parties to bank.  Accounting of dishonored cheques.

 Preparation of slips for all bank transactions.  Preparation of bank reconciliation.

 Trial balance tally is to be ascertained and when call for.

 Inform the management all due payment in advance and ensure payment of creditors on due date as per the instruction before issuance of cheques of any nature, the accounted should ensure that the efficient fund balance is available. No cheques is to be issued without having sufficient fund.

 Finalization of accounts

o Miscellaneous accounts are to be adjusted. o Nullification of all balances

 Submission of returns- ensure that monthly, quarterly, half yearly and annual returns are submit on due date.

 Besides duties he/ she is to assist administration in correspondence and other works related to sales tax, service tax, P.F, E.S.I, IT, labor welfare fund and industries departments in consultation and approval of manager administration.