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Automation
Automation Is the use of control system and information technologies to
reduce the need for human work in the production of goods and services. In the
scope of industrialization, automation is a step beyond mechanization. It is used to
reduce human interferences.
Disadvantages of Automation
Huge capital to be invested
Increase in unemployment rate due to machines replacing human.
Technical Limitations
Security threats
High costs of maintenance.
Industrial Automation
Industrial Automation is a discipline that includes knowledge and expertise
from various branches of engineering including electrical, electronics, chemical,
mechanical, communications and more recently computer and software
engineering. Automation & Control by its very nature demands a cross fertilization
of these faculties.
Industrial Automation Engineers have always drawn new technologies and
implemented original or enhanced versions to meet their requirements. As the
range of technology diversifies the demand on the innovative ability of these
Engineers has increased.
Industrial automation engineers carry a lot of responsibility in their
profession. No other domain demands so much quality from so many perspectives
of the function, yet with significant restrictions on the budget. The project
managers of industrial automation projects have significant resource constraint,
considering the ever changing demands of its management, trying to adopt the
rapid acceleration of the technological changes and simultaneously trying to
maintain the reliability and unbreakable security of the plant and its instruments.
Global Industrial Automation
The global industrial automation services market is predicted to grow at a
CAGR of around 11% during the forecast period from 2015-2019. The need for
automation in manufacturing plants to boost productivity, especially in the oil and
gas, power, chemical and petrochemical, and automotive industries is driving the
high growth of the market.
High labour costs in countries like China are also driving the growth of the
industrial automation services market. During 2012, China accounted for nearly
16% of the global manufacturing output. Due to the increase in labour costs,
China’s market share decreased in the following years. To mitigate the high labour
costs and improve productivity, automation companies in the region are adopting to
cloud-enabled automation.
The project engineering and installation segment accounts for the largest
share of the market followed by the maintenance and support segment. The
consulting services segment is predicted to emerge as the fastest growing segment
by the end of 2019 in the industrial automation market. The increase in regulatory
issues and laws across industries such as food and beverages, pharmaceuticals,
chemicals, and petrochemicals have surged the demand for industrial automation
consulting services.
The DCS segment accounted for nearly 45% of the market share during 2014.
The high demand for power is the primary driver for the growth of this segment.
The increase in food safety regulations across the pharmaceutical and oil and gas
industries have also pushed the demand for services associated with DCS,
especially in the APAC region.
SCADA is the second largest segment of the market, and they help monitor and
control industrial processes and infrastructure in manufacturing plants. Power, oil,
and gas industries are the largest end-users of SCADA-based automation solutions.
EMEA led the global industrial automation services market during 2014 and is
expected to do so till the end of 2019 but with a decrease in its market share. The
Americas will also witness a decline in market shares during the forecast period
due to the shift of automation services to the APAC region.
APAC would see the fastest growth during the forecast period with countries
like Japan, South Korea, India, and China being the major revenue contributors in
the region.
Automation in India
India, due to the large size of its domestic market, has been very attractive
for international companies for long. It was only due to political and economic
barriers the automation solutions took time to reach the Indian shores. The other
big challenge in India was opposition from the workers. Automation has always
had the negative image of being a job killer. During the late 1980s, when the
process of automation began taking foothold, with willing political support and
able technical advice, there was tremendous apprehension and protest. Popularly
known as `computerization', it was apprehended by many trade unions in India that
such computerization (automation) would make the labor redundant and hence
would lead to joblessness. However, with the force of liberalization gradually
setting in during the early 1990s leading to increased pace of economic growth, the
availability of jobs and increase in wages wiped out the earlier apprehension.
Automation had its economic relevance. In an earlier protected domestic market
environment, most companies had adequate demand for their products and hence
had little incentive to modernize their activities. However, in an open economic
environment, with competition coming in from the rest of the world, it was
necessary for these businesses to focus on quality and reliability in production and
emphasize on customer needs. Automation proved to be a solution for quality and
reliability in production, leaving space for the business organizations to focus more
on market and customer needs. The automation industry that started as a small
business, providing automation solutions to some manufacturing and service units,
has grown many fold during the last two decades. The growth is so phenomenal
that the industry is now worth billions of dollars in India.
Business Trend
As stated earlier, the Indian automation growth story has been very
inspiring. The sales growth of the Indian automation sector was an average annual
growth rate of 29.6% during the period from 2000 to 2008. The industry's sales,
which was at $494M during 2000, reached $3714M by 2008. The growth rate was
around 16% annually. As industrial growth was slow in this period, so also was the
growth in automation. The four years starting from 2004 was a golden period
for most developing and developed economies. The growth rate during this period
in the automation sector was an eye-popping 44.5%. The rate of industrial
production went up to 11.5% in 2006-07 and the manufacturing sector contributed
91% to this. As automation supports other industrial sectors, the rate of growth of
the automation industry paralleled that of industrial growth during this period.
Growth Forecast
For a period of eight years, the industry defied all ups and downs in the
economy to keep up a steady growth. This shows that the industry will be able to
continue to grow strongly and reach$19017M by the end of financial year 2014.The
forecast assumes that most of the factors contributing to the industry's growth will
remain unchanged during the coming five years. The global industrial automation
market is forecast to reach more than $200 billion by 2015. Moving forward, three
key factors are expected to transform the face of industrial automation: energy
efficiency, advanced technology and emerging economies. The global industrial
automation market is forecast to reach more than $200 billion by 2015. Moving
forward, three key factors are expected to transform the face of industrial
automation: energy efficiency, advanced technology and emerging economies.
Emerging Economies The BRIC nations – Brazil, Russia, India and China –
along with other emerging economies worldwide are forecast to sustain high
growth in industrial automation markets. The strongest growth is expected in
emerging markets in the Middle East, Southeast Asia and Eastern Europe.
However, in more developed regions like North America and Western
Europe, opportunities exist in the modernization of old infrastructure. In
addition, flexible manufacturing will likely aid regional customization by
aligning the product portfolio to suit market demands.
PEST Analysis
Political
Companies in this industry have to deal with many political systems in
different countries as the global interest in automation. Some countries have a good
environment for business growth and survival but others present difficult
conditions. Government intervention in the United States is minimal while in other
countries, such as China, government control over business is high. As of
SKYTECH they may face threat from the tie with GE and Danfoss as they face the
economies of various countries.
Economic
The automation industry is affected by fluctuations in interest rates, exchange
rates, and money value. Factors such as deflation and inflation as well as
government spending in different countries often influence business productivity
and profitability.
Social-Cultural
Norms, culture, religion, and social customs often determine how a business
should conduct itself in a particular country or environment. The culture in a
particular country determines the working hours, employment policies, procedures
for appointing managers, and the type of goods to be produced. With GE being a
multinational company, it has to adapt to different cultural challenges so has to
SKYTECH as per the requirement with that od GE’s.
Technological
The rate of technological advancement varies with each country. The countries
with the highest rate of technology advancement are the Unites States and Japan,
both of which General Electric has a presence. Globally, technology is advancing at
a very high rate. Hence SKYTECH has an advantage with regards to the
technological aspect.
Porters Five Forces Model
Products
Skytech Infinite innovative industrial automation solutions use best-of-
breed vendors and technologies to drive energy savings throughout your
organization. We can help you adopt emerging and established solutions to
continuously optimize across your operations. From Drives and controllers to
industrial PCs and software solutions, Skytech infinite helps you increase
productivity and efficiency, reduce energy consumption and better manage
resources.
Services
Turnkey Automation Projects
Motor Control Center Panels
Industrial Automation Training
PLC Control Panels
Software Development
AMC & Support Services
Instrumentation
Solutions- Process
Design and deploy a number of automation systems for different processes.
Few of them are Lime Calcination Plant, Boiler Plant, Turbine Unit automation,
Cement plant automation, Ash handling Plant.
Solutions-Vacuum
The Vacuum Process sector constitutes a larger segment of customer base.
Developed and deployed a number of automation control systems for various
Vacuum processes including Furnace, Sterilizers and Coating Units.
Established in 1997
In 2001 turned No. 1 Solution Provider of GE India and is still maintaining.
Expanded Execution team in 2003
Established shop floor in 2006
Distinctive departments were established in 2008
Regional office was established in Chennai in 2010
In 2013 SKYTECH became the authorized channel partner for Danfoss
Industries
Regional office at Hyderabad was established at 2014
Principles
Premier solution provider for GE
Authorized channel partner for Danfoss
Product Review
VersaMax DP, Data Panel, Quick Panel, Quick Panel Control, Simplicity
Station
VersaMax Nano, VersaMax Micro, VersaMax PLC, Series 90-30, Series 90-
70, PAC Systems RX3i, PAC System RX7i
Versa Point, VersaMax I/O, Field Control, Genius I/O, VersaMax IP
Variable Frequency Drives (VFD)
A variable frequency drive is a type of motor controller that drives an
electric motor by varying the frequency and voltage supplied to the electric motor.
VFDs’ are also called as variable speed drive, adjustable speed drive, adjustable
frequency drive.
VFDs are used in applications ranging from small appliances to the largest of
mine mill drives and compressors. However, around 25% of the world's electrical
energy is consumed by electric motors in industrial applications, which are
especially conducive for energy savings using VFDs in centrifugal load service and
VFDs' global market penetration for all applications is still relatively small. That
lack of penetration highlights significant energy efficiency improvement
opportunities for retrofitted and new VFD installations.
Over the last four decades, power electronics technology has reduced VFD cost
and size and has improved performance through advances in semiconductor
switching, simulation and control techniques, and control hardware and software.
Program Logic Control (PLC)
A programmable logic controller or programmable controller is a
digital computer used for automation of industrial electromechanical processes,
such as control of machinery on factory assembly lines, amusement rides, light
fixtures. PLCs are designed for multiple arrangements of digital and analog inputs
and outputs, extended temperature ranges, immunity to electronic noises and
resistance to vibration and impact. Programs to control machine operation are
typically stored in battery-backed-up or non-volatile memory.
Various PLSs’
Durus Controller
VersaMax Micro and Nano
Series 90-30
Series 90-70
VersaMax I/O and Control
Verticals Served
Power
Water
Infrastructure
Oil and gas
Metal
Chemicals
Food and beverages
Textiles
General Electric
GE is an American multinational conglomerate corporation incorporated
in New York, and headquartered in Fairfield, Connecticut. As of 2015, the
company operates through the following segments: Appliances, Power and Water,
Oil and Gas, Energy Management, Aviation, Healthcare, Transportation and
Capital which cater to the needs of Home Appliances, Financial services, Medical
device, Life Sciences, Pharmaceutical, Automotive, Software Development and
Engineering industries.
History of GE is a significant part of the history of the Unites States.
GE has evolved from Thomas Edison’s home laboratory into one of the largest
companies of the world, following the evolution of electrical technology from the
simplest early applications into high – tech wizardry of the early 21st century .GE
ranked 5th in the Fortune 500 in 2003 and operates in more than 100 countries
worldwide and generates approximately 45%of its revenues outside Unites States.
Mission:
GE does not have an exact mission statement but operates following the four
main values being Imagine, solve, build and lead.
Vision: “We bring good things to life”
The Danfoss Group is a global producer of products and services used
in areas such as cooling food, air conditioning, heating buildings, controlling
electric motors, Compressors, Drives and powering mobile machinery. The
company is also active in the field of solar and wind power as well as district
heating and cooling infrastructure that targets entire cities and urban communities.
Danfoss employs approximately 24,000 people worldwide with its headquarters in
Nordberg, Denmark.
Danfoss was founded in 1933 by Mads Clausen, and is today almost entirely
owned by The Bitten and Mads Clausen Foundation. In 2002 Danfoss joined the
United Nations Global Compact, consisting of nine principles with social and
environmental responsibility.
Danfoss has an annual sales turnover of 34 billion DKK (2012), and has sales
companies in 47 countries and 56 factories in 18 countries around the world.
Products
Refrigeration, air conditioning
The control of electric motors
The heating of buildings
Solutions for renewable energy such as solar, power and heat pumps.
SWOT Analysis:
Strengths
Weaknesses
Opportunity
Technological disaster
Exposure to global economy
Mature market
Slowdown in industrial production
Unpredictable development changes
Chapter 3
Organizational Structure
Organizational Structure:
Organizational structure is a system used to define a hierarchy within an
organization. It identifies each job, its function and where it reports to within the
organization. This structure is developed to establish how an organization operates
and assists an organization in obtaining its goals to allow for future growth. The
structure is illustrated using an organizational chart. For most companies, the
design process leads to a more effective organization design, significantly
improved results and employees who are empowered and committed to the
business. The hallmark of the design process is a comprehensive and holistic
approach to organizational improvement that touches all aspects of organizational
life, so we can achieve:
Managing
Director
Vice
President
Production
Executioning &
commissioning
Chapter 4
Marketing:
Functions:
Generate order acceptance, once order has been received from the customer
Analyze the cost for the order received
Fix the budget for the project or the order received
Planning for further business development
Communicate with the managers of other branches with regards to business
expansion (domestic and global)
Keep a tab on the growth of the company
Decide on new customers to target
Vision
Growth of 40% for the next financial year, with a current growth of 20 –
25% the current financial year (2014 – 2015).
One of the method of the vision being attained is by trying for a tie up with Pepsi
Co.
Finance:
Functions:
Allocation of funds
Financial planning
Monitoring the debtors and creditors.
Enhancement of business projects.
Budgeting and Tax Planning
Up gradation of day to day transactions.
Day to day reconciliation of transactions.
Evaluations of financial performance.
Accounting and auditing.
Term deposits at the time of non-requirements of funds.
Projects:
Production
This team is responsible for the programing of the panels as per the customer
requirement
The engineers test the panel after the programming is done for any fault in
the product to be delivered
Once the product is checked it is delivered to the customer, double packed
The commissioning team checks for the commissions to be paid for the
delivery of the product
Also responsible for the after sales services.
Supply Chain:
Purchase
PURPOSE:
To establish a documented procedure to define the purchasing activity.
SCOPE:
It covers the processes such as selection and evaluation of vendors and
purchasing of goods/materials.
RESPONSIBILITY:
Purchase I/c is responsible for the effective implementation of this procedure in
coordination with D&D I/c, Accounts I/c and VP.
ABBREVIATIONS:
MEASURE OF PERFORMANCE:
Respecti Target
Measure of Unit ve Level
Sl. No Method Frequency
Performance s Departm /Permitt
ent ed Level
Vendor
1. Vendor quality and Once in 6 Purchase
% 90%
Performance delivery months I/c
rating
VENDOR RATING
VR is done for measuring the performance of the vendors on two bases they are
based on delivery and quality.
DELIVERY RATING (Max 40%)
Quality rating (QR) = Quantity accepted + (0.7 x Quantity accepted under deviation)
Total quantity Supplied
Stores:
Weekly inventory report to be prepared and also get accounted without delay
Weekly project material status required
DC required for all incoming/outgoing materials
Incoming materials should be checked with respect to the PO, immediate
action should be taken if any issues found with the materials
Weekly meeting conducted for both production and stores
Human Resource
Applications
The HRM shall apply to and govern to all employees in the services of
SKYTECH except to the extent otherwise expressly excluded
The HRM shall not apply unless otherwise specified to persons who are:
1) Appointed after superannuation
2) Appointed on contract basis
3) Appointed on casual bases
4) Appointed on temporary basis
5) Engaged as a trainee
The VP has the authority to amend the HR policies.
Scales of pay
The management reserves the right to fix and release the pay scale and
allowances for the different grades of employees from time to time.
The HRD in consultation with the management will decide on the pay scales
to be allowed.
Increment Policy
Increment accrues from the day following that on which it is earned, it shall
be sanctioned annually.
It will be based on performance of employee.
When the employee is in probation period, it is not mandatory to provide
increment for that employee.
Increment shall be paid to the employee in probation period when his
performance is excellent.
No employee appointed in temporary, contract, re-employment and daily
wages are eligible for annual increment.
Recruitment
They hire the most talented and deserving candidates as per company
policies providing equal opportunity without any discrimination.
They follow equal employment policy not only during recruitment/hiring but
also while giving promotions, training, transfer, retention and determining
layoffs.
Recruitment process
The HRD will receive all the employment requisitions from the department
heads and will analyze the requisitions. The HRD will also analyze whether the
vacancy needs to be filled from within SKYTECH INFINITY or from outside.
Classification of Employment
Permanent
Probation
Contract
Temporary
Casual
Trainee
Work Environment
The SKYTECH INFINITE stands for quality, equal opportunities and high
standards of education. It aims as developing right attitude and help
personalities become adoptable
Workplace Culture
Respect for all employees
Equality at work
Integrity in all the policies and practices
Opportunities to grow and develop careers
Recognition for talent
Open Door Policy to encourage the employees to speak their minds to the top
management.
Attendance
Attendance register is maintained by the company at different facilities of the
company and those who are late will be liable for debit of one-day casual leave for
late attendance for every three times in a month.
Payment of Salaries
Shall be paid on or before 5th day of the succeeding month through their bank
accounts.
Performance Appraisal
Objective:
To help employees perform to their optimum level
To help employees develop as an individual as well as in their career
To help in the administration of promotions, increments and other rewards
To ensure that the potential and skill of employees are utilized to the
maximum for the betterment of the company.
A) System:
Appraisal period for all the employees shall be from January 1st to
December 31st.
B) Occasions:
When a temporary/ probationary employee is to be confirmed
Once in 12 months (regular performance appraisal)
When specially called for by Competent Authority (Special Appraisal).
Leaves
Granted to employees with a good intention of providing rest, recuperation of
health and for fulfilling social obligations.
Types of Leaves:
Casual Leave
Sick Leave
Earned Leave
Maternity Leave
Loss of Pay.
Style:
The leadership style is democratic in nature wherein the top management
shows a belief in equal rights in the working atmosphere. The top management
delegate planning, decision making, organization’s overall operating approach, also
the way in which the employees present themselves to outside world, suppliers and
clients and other responsibility to followers. The decision making is participative in
nature where all the middle level and lower level management is allowed to suggest
the idea in the decision making process. The style followed is MBO.
The employees work on a team basis. They are co-operative in nature, the
team functions within the organization.
Staff
The organization has effective staff of participative in nature with positive
attitude towards organizational goal and also performing efficiently with effective
results in achieving organizational goal. The promoters have the unique quality in
them of choosing the right person for the right job at the right time.
Conduct Rules
Every employee of the company shall be governed by the code of conduct and
every employee is liable for the disciplinary action for any of the mentioned rules
are breached.
Every employee, at all times take all possible steps to ensure and protect the
interest of the company
Every employee shall maintain good conduct, pay attention to all persons
during transactions and negotiations. All employees shall carry out lawful
and responsible to the decisions of the superiors
Every employee shall take all possible steps to ensure integrity and devotion
to duty of all persons for the time being under this control and authority
Chapter 5
Findings, Suggestions and Conclusions
Findings:
The net sales of the company from the last five years is increasingly steadily
The company has good track record of performance from the last decade
The company has maintained good relationship with customers
They provide excellent working environment to its workflow
There are mainly six departments - Marketing, Finance, Projects and Supply
Chain departments which take care of the operations within the organization
The company maintains a system of direct marketing and there are no
distributors for supplying finished products to the customers
The company has 100% utilization of the capacity in order to achieve high
turnovers and maintain a good profit margin
The company is also trying hard to expand business when it comes to acquiring
new customers
The company has received a various award over the years a few of them
being:
The company has to plan the production, formatting and operation layouts
various places within the factory so that raw materials flow in the right
directions with less wastage of time and materials and lesser piling up of work
in progress
The company should maintain all the production records in the factory, the
time lost in production, causes for delay, changes in capacity, absenteeism,
underestimation of machines, tools, materials and manpower, errors in
processing and inspection and receipts of schedules so that the problems
affecting production and automation can be analyzed and necessary actions
can be taken to minimize them.
Once the job is in the area where the operation is to be performed, the company
has to be determine when and whom the job is to be performed and should
also determine the sequence in which the waiting orders are processed. This
should be put up in the work place and thus will help in the timely
implementation of production orders.
A schedule on the general priorities of the job and the date by which the job
should leave the area within the constraints setup by the schedule has to be
maintained in the work place in order to ensure that there are no delays in
delivering the orders placed by the customers
The production department has to maintain a production order note stating the
start and finish times for the production of each order, thereby determining the
time restricted for the production of every order
Conclusions
From the overall study of the organization, it is quite clear that Skytech Infinite
Pvt Ltd. has extended its own wings in the Automation industry successfully
which is evident from its National presence (the tie up with GE and Danfoss)
and the various awards it has received for its excellence.
It has well advanced and skilled manpower for manufacturing its various
panels with good standards.
All the management team members are well qualified and experienced persons
to carryout business operations in a most profitable manner and generating
new opportunities for the expansion and the development of the business to
the global level.
As per my study there is a very good co-operation among the employees and
the company is financially sound which ensures its continual and assured
growth in the future.