INDUSTRY INTERNSHIP BATCH: 2013-2017
INTERSHIP REPORT BATCH: 2013-2017 GIFTS AND UTILITY PRODUCTS
NAME OF THE INDUSTRY : HITAISHI KK MANUFACTURING COMPANY NAME OF INTERNEE : JOYDEEP PARAMANIK
DEPARTMENT OF FASHION AND LIFESTYLE ACCESSORY NATIONAL INSTITUE OF FASHION TECHNOLOGY, KOLKATA
CERTIFICATE
PREFACE Summer internship project is a part of NIFT curriculum; the students of sixth semester (Fashion and Lifestyle Department) are supposed to do for a period of 8 weeks in a manufacturing house of interior products and hand crafted accessories. The product range may include home accessories, kitchen, bar, bathroom accessories, corporate items, packaging solutions, handicrafts using metal, glass, ceramic, wood, leather, acrylic, natural fibres and mixed media for both export and domestic market. This exposure to the professional field was to enable us to grasp practical knowledge about the functioning of the industry, its manufacturing processes and marketing as well. The 8 week work in the industry affected my entire design process and gave it a different angle in which I gave serious concern to the liability and sensitivity of the material, its availability, design acceptance among the customers, marketing and most importantly it’s costing. The document proceeds with the introduction to the company history, profile, its various units and spread of work. The main focus of the document is the work flow and various steps involved in the manufacturing of the products, simultaneously describing the concerned departments and their roles. Each and every details starting from getting orders, indenting - material, hardware and labour, pre-production process, manufacturing steps, post production process, are covered in sequence.
ACKNOWLEGEMENT The project would not have been possible without some people who played an important role during my internship project throughout. During the project I was supported and encouraged by many of my well-wishers and therefore I would like to convey my sincere thanks to them. My sincere thanks to Mr. C. Mandal course coordinator, F and LA Department, NIFT Kolkata. I would also like to convey my gratitude to my faculty guide Ms Jayati Mukherjee.I use this opportunity to thank Mr. OP Prahaladka (CEO of Hitaishi KK), Mr. D P Surekha ( MD of Hitaishi KK), Mr. Bibhor Sethi(commercial manager), Mr Suvra Gayan my industry mentor, Mr S S Pal ( R n D deaprtment), Mr. Amitava Roy ( Merchandsing and Logistics manager- Unit- 3), for giving me the opÂŹportunity to work in their organanization and for their constant support and guidance. My sincere thanks to all the staff members, merchants and emÂŹployees of Hitaishi KK, for their humble corporation during my internship. Lastly my hearty gratitude to my parents who encouraged me throughout to learn something. And last but not the least I thank my friends, for they have been standing upright to support me at every step till date. Thanking you Joydeep Paramanik
CONTENT COMPANY HISTORY COMPANY PROFILE OVERVIEW FACTORY INSTALLATIONS ABOUT UNIT III FLOW OF WORK FACTORY LAYOUT ABOUT WOOD LINKS IN INDIAN MARKET INTERNATIONAL FAIRS SAMPLING DEPARTMENT PRODUCTION FLOW SAWING DEPARTMENT SEASONING DEPARTMENT MANUFACTURING PROCESSES JOINTS DIFFERENT WOOD JOINTS FINISHING PROCESS FINISHING DEPARTMENT LACQUER FINISH ASSEMBLY PACKAGING SHIPMENT PURCHASE DEPARTMENT STORE MANAGEMENT MAINTAINANCE LABOUR MANAGEMENT QUALITY CONTROL COST AND ACCOUNTING THE MARKETING DEPARTMENT ACCOUNTS DEAPRTMNET CLIENTELE INTERNSHIP PROJECTS SWOT ANALYSIS REALIZATION FEED BACK CONCLUSION BIBLIOGRAPHY
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1 COMPANY HISTORY Wooden products have always seen a potential demand worldwide. Various qualities of wood and finish is of utmost interest though taste differs country wise. Hitaishi –KK manufacturing company caters to the world premier handicrafts market. With 40 years of experience in the fine wood working it is an esteemed organization maintains an efficient quality assurance system, hence regarded as India’s premier craft group. With an ancestral business in timber trade; Hitaishi KK was established in 1975 as a manufacturing unit of wooden packaging boxes for machinery parts by Mr. O.P.Prahaladka; an engineer by profession. A decade later the product line diversified. After exploring international markets; visiting clients and gathering information through world trade. Mr Prahaladka founded considerable demand for violin parts in ebony and introduced the same as the first product line of finished goods. Thus in 1990, the gift items and corporate products were introduced. In 1992 Hitaishi first participated in the Birmingham Fair. Although the first two attempts failed to get the desired response, Hitaishi was able to make a few fancy deals and this initiated growth of the company . In the late 90’s horns, jute, MOP, musical instruments items were introduced. Hitaishi focused on the quality of the products to make them easy penetrators in the international market. In competition with the Italian competitors ,they won the Export Excellence Award every year and is India’s first ISO 9002 certified craft company by EXIM Bank.
2 COMPANY PROFILE HITAISHI-KK (Formerly Hitachi –kk) India’s premier craft group, is one of the most successful SME producer of Fine quality,products in wood, cattle horn and bone, sea shell, metal and in their various materials combinations. Our entire production output is exported to Germany, USA, UK, Japan, France, Italy, Saudi Arabia , Switzerland, Korea and other parts of the world. Since 1974 the main manufacturing units of the company are located in and around Kolkata where more than 1200 craft families are supported. Hitaishi-KK has worldwide recognition for its innovation in home utility and home décor products, in musical products industry and wall décor, in games and in exclusive gifts products categories. COMPANY NAME- Hitaishi KK manufacturing company YEAR OF ESTABLISHMENT- 1975 LOCATION- corporate H O 1, B.K. Paul Avenue Kolkata 700 005, India CONTACT DETAILS-Tel : +91 33 2271 6301 – 04 Fax : +91 33 2218 0586 MAIL ID AND WEBSITE-E-mail : ho@hitaishi.com www.hitaishi.com OWNER- Mr. O P Prahaladka MANAGING DIRECTOR- Mr. D P Surekha BUSINESS TYPE- manufacturer, supplier,exporter and trader.
Hitaishi Group
String Instruments Parts & Acceries
Gift & Home Decor Fashion Jewellery
Jute, Cotton & Canvas Bags
Horn Accessories & Furniure Art & Picture Framing
Percussion & Musical Toys Customized Machinery
3 OVERVIEW Hitaishi is a technology driven company with advance and latest manufacturing and tooling facilities, and hasconstantly upgraded in order to maximize its strength.They have in house wood drying chambers ,modern machines for wood working. They regularly train and re-train young people who share their vision and strive for perfection. The management is young and professional at all levels and has good team spirit, team work and team performance. They have an extensive collection of high end home Décor products, Furniture accessories, Drums & Kids percussions, Walking sticks, utility boxes, Gift boxes for chocolate ,sweets ,tea and dates , Small gifts as well as promotional items. The company exhibits its products in major international trade fairs in Frankfurt, Hong Kong and in India every year. They have an in-house design and product development team which constantly innovates products for every upcoming exhibition. They work with some of the finest companies in the world and a number of international design groups also work in close co-operation as they offer complete design protection and exclusive designs to their customers. Since 1987, Hitaishi-KK has been regularly receiving export awards for excellence from Export Promotion Council for Handicraft (EPCH) & Capexil, Kolkata. They work on maintain Industry’s leadership by enhancing their investment in skill upgradation, in equipments, in distribution and product development infrastructure and in upgrading technology and by subscribing to eco friendly raw materials and their renewable resourcing. the company has a very well equipped IT infrastructure with modern computers and software to further expand their deals into new markets and in new trade channels. All their factories are socially complied as per European standard. PRODUCT RANGE: • Gift Boxes •Exclusive Gifts •Desktop Accessories •Festival Gifts •Gift Items •Mementos •Show Piece •Wall Hangings •Wedding Gift •Wooden Exclusive Gifts •Wooden Photo Frame •Walkng Sticks
4 FACTORY INSTALLATIONS Unit 1- sawing and seasoning Unit II- violin parts Unit III- gifts and utility products Unit IV- jute and textile department Unit V- musical gifts and instruments Unit VI- horn and mother of pearl products Sister concern by Mr. Manish Gourisaria Different wings of Hitaishi: • Domestic wing- GJK shellex and Lions India • Export wing- Hitaishi Kk manufacturing company • Horn products- Harmony • Milk colony, Belgachai- jute • Madhyamgam- horn, metal, lining, finishing (unit-III), finishing / assembling and packaging of percussion items. • Salua- storage of violin parts and raw material- rosewood, ebony, box wood- imported from Theodore, Nigel. Finishing and dispatch of violin accessories. • BK Paul Avenue- main office. Violin components are collected, finished, packed na d dispatched. Jute sampling. • Canal Circular Road; Bidhan Nagar- Unit I, III, V, VI • Jagatpur- finishing unit of III, VI • Salkia- turning jobs, metal hardware ( hinges)
5 ABOUT UNIT III Established in 1990’s this division specialises in wooden products such as: o Corporate lines o Desktop accessories o Utility boxes for sweets, chocolates, tea bags and dates etc. o Gifts like photo frames, walking sticks, vanity boxes etc. o Cigar boxes o Wine requisites o Stationery items This unit is supervised by Mr.D.P Surekha who deals with major clients from international markets and domestic as well. He also plans and administers various departments, vendors and suppliers for raw material and semi-finished goods as well. Unit III has the highest contribution toward the company’s economy and is increasing every year. They ensure the quality of products to international standards that adds to the goodwill of the company. Hitaishi is purely an export house competing with Chinese manufactures, but it has always made its stand in the higher market segment due to its high finish and techniques and skilled labour. Continuous research and development undertaken by the sampling department has consequently delivered new and innovative product range for the international trade fairs.
6 FLOW OF WORK New Department
Customers Requirements
Sampling Department
Fairs
Some Changes By Clients
Placement Of Orders Getting Back To Clients
Final Order Placement
Planning Production
Finishing
Assembling
Packaging
Shipment
7 FACTORY LAYOUT
8 ABOUT WOOD NAME
COST CFT SOURCE
STRENGTH/ HARDNESS
GRAINS
WATER RE- TURNING CARVING CUTTING WEIGHT SISTANCE/ OIL CONTENT
MANGO
900
LOCAL
MEDIUM
VERY COARSE
REACTS WITH H2O
NO
NO
NO
RUBBER
1400
KERALA
HARD DENSE
MEDIUM COARSE
LIMITED REACTS,H2O
LIMITED
NO
NOT EASY MEDIUM ON MACHINE
BADAM
1900
LOCAL
VERY STRONG
FINE/ STIFF
MIN OIL
MEDIUM
EASY
EASY
MEDIUM
TEAK
2500
LOCAL
MEDIUM
VISIBAL COARSE
MORE OIL
GOOD
EASY
EASY
MEDIUM
RED SESHAM
2500
UPPER UP TOUGH, DENSE HIGH STRENGTH
HARD/ COARSE
LESS OIL
NOT EASY NOT EASY EASY
LAUREL
2000
LOCAL
HIGH STRENGTH
COARSE THICK FIBERS ACROSS GRAINS
HAS OIL
NOT EASY NO
NO PROB- VERY LEM HEAVY
EBONY
13000
S.AFRICA
HARD BUT BRITTLE
COARSE
HIGH
MEDIUM
MEDIUM
EASY
QUITE HEAVY
ROSE WOOD
6500
UP, AFRICA
HIGH
COARSE
MORE OIL
GOOD
EASY
EASY
HEAVY
LIGHT
HEAVY THAN MANGO
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NAME
COST CFT SOURCE
BOX WOOD
4500
CEDER (TOON)
STRENGTH/ HARDNESS
GRAINS
WATER RE- TURNING CARVING CUTTING WEIGHT SISTANCE/ OIL CONTENT
IN SMALL HAS PIECES STRENGTH
VERY FINE
LESS WATER RESISTANT
MEDIUM
EASY
EASY
MEDIUM
1600
LOCAL
SOFT
FINE
VERY MUCH HYDROSCOPIC
GOOD
EASY
EASY
LIGHT
BEECH WOOD
2300
CANADA
RIGID/ TOUGH
COARSE
LESSOIL
CAN BE
NO
HARD
HEAVY
PINE WOOD
1500
PANJAB
LESS
LESSOIL
VERY FLAT
NOT REA- EASY SIBLE
LIGHT
10 LINKS IN INDIAN MARKET Hitaishi –KK is basically an export company mainly dealing in the international market. In recent years, it has expanded its business and started catering into the domestic market. Clients like ITC, Titan, Fastrack and Vedic Village have bonded with Hitaishi in many projects. To create healthy terms with Hitaishi group of hotels, products like chauffers trays, wooden interiors and exterior panels, bins, menu plates, bathroom accessories have been made that would extend to other hotels further. Vedic village, a resort in Kolkata dealt for wooden interior panels with Hitaishi. Hitaishi has also connections with Malabar jewellers to make their display and gift boxes. It has also developed gift items, boxes invitation boxes, wedding gifts for various events of celebrities and business tycoons of the country as well.
11 INTERNATIONAL FAIRS The main sales of the company happen through fairs. Every year, company displays its new collection of products and handles new clients as well as get feedback from old ones. The fairs also alerts them about the changing trend in the market and also about their competitors. Fairs attented: • Spring Fair- Delhi (EPCH) Feb , March • Autumn Fair- Delhi (EPCH) October • Tendence Fair- Frankfurt (August) • Ambiente- Germany • Hongkong Fair • Birmingham Fair The fairs differ on the basis of space, type of clients, the taste of clients. The fairs help the company to keep a check on the upcoming Chinese products that have flooded the market with quality products at a lower price. The Delhi fair provides lots of space for display in comparison to others. The display at the fair is planned and props are designed for specific items The theme of the fair display has to be common for all departments. Buyers are invited to the fairs by forms or invitation. Some are even sent visuals of new products thus inviting them to have a look at the new range. In the fairs, the customers place order on the spot or take photo offers to their countries for reference and may place order later. Some even suggests and give requirements for new sample developments. Over the years Hitaishi has developed many regular clients and have maintained healthy terms with them.
12 SAMPLING DEPARTMENT Hitaishi KK is a customised product company. It has developed products according to the requirements of the customers and if needed makes necessary changes to the existing ones every year. Earlier the sampling process was headed by Mr. Ajit Pal, who passed away last year, but now it is done under the guidance of Mr. Narayan and Ms. Papiya and the labours of the sample workshop. Lots of innovation in products and techniques happened in last 5-6 years but it slowed down since last years. So the degree of new creation is at the scratch, but there is a team of creative people who are constantly coming up with new design modifications and sometimes new design altogether in the process of dealing with the clients requirements. These creations are done to showcase their collection the fairs. Once the products are developed they are named and so are the ranges so that the clients can identify with it. The sample department is also provided for individual clients as per their requirements. After the sample is approved, the final order is placed and depending on the quantity of shipment, dates are set with a minimum period of 40-45 days.
13 PRODUCTION FLOW Production work order is issued which ten departments who start there working according to the shipment date receives by Mr S.S Pal, who sees that none of the details are missed out and it complies with the design to the last detail. The technical drawing is prepared. The production starts its planningl after consulting the sawing department, which feeds the date when the wood will be available for production. With that date the planning starts production. The work flow on the floor has to be planned so that no machine is overworked and to prevent any breakdown. The production department indents wood to the seasoning department and sawing department. Sample Apporval Work Order Released Production
Sawing & Seasoning
Purchase
Drawing
Wood Purchase
Stores Check
Wood Identiphing
Sawed
Suppliers
Planning
Seasoned
Hardware Procured
Process
Production
Stores
Stores Insperation
Sample Inventory
R/M Inspection Stock Checked Received Goods Inspedted
Sample Sent To All Departments
Finishing
Inventory
Finishing
Finishing
Packaging
Engineering
Quality Check
Raw Product
Goods Packed
Preventive Maintenance
Inspection At All Stages
Finished To Meet Shipment Dates
Shipped
Machines Ready
Assembly Packing
14 SAWING DEPARTMENT The sawing department is under Mr. A. Dutta who has to make the wood available for production on time. If the wood is not available in the unit then it is purchased. The log required to be cut into small pieces and made ready for seasoning. Rubber wood is purchased in small pieces only.
Thin sheet of wood is cut into narrow planks
Slicing planks to be waxed and sent for seasoning
The sawing and seasoning department is in unit I. Earlier sawing used to happen inhouse but later they source from outside for maintainace purpose. But still some works are done inhouse if it is difficult to get it done from outside vendors.
15 SEASONING DEPARTMENT The wood pieces are kept in the seasoning chambers for few days to few weeks depending on the moisture content. In the chambers relative humidity is controlled by keeping it low and temperature is kept high at 40- 55 degree Celsius. If the surface hardens then the wood is subjected to moisture. The wood is checked for its moisture content regularly. • The standard is 8% moisture content for all goods. • For kadam, moisture content has to be 20% as it is difficult to turn if it goes below that level. • Teak is slowly seasoned. • Haldu for 57 days as it absorbs moisture. • Big blocks are not preferable as moisture escaping from end grains make them crack so they have to be waxed. • Woods up to 75-100 inch is vacuum dried. • Different wood has different reactions to water and heat and also have to be treated differently. • Bleaching is done to remove any spots on wood. Ex. Kadam wood is frequently bleached. • Ammonia fumigation is done to acquire uniform colour of wood. After seasoning the wood is sent to the production department.
Wood edeges waxed to prevent craks
Wood is seasoned in chambers
16 MANUFACTURING PROCESSES The entire range is made of using world class technology and ultra modern machines such as Molding, Cutting & Router, Wood drying, Seasoning & Sawing machine, Laser Machine, CNC Router etc. Due to our advance instruments and tools we are capable enough to manufacture the products having monthly capacity of Desktop Accessories - 50000, Photo Frame - 20000, Gift Boxes -20000, Mementos - 10000.
Circular saw machine to cut and palne the edges at 90 degree
Bandsaw machine-A bandsaw is a piece of machinery that is used to cut angled or curved shapes on a piece of wood. The band saw has the same function as a jigsaw only it is much larger and instead of moving the saw to cut the wood like on a jigsaw you move the wood around the blade.
Auto Sander- 2 people engaged at a time to feed in the wood and stack them continuosuly, while they get sanded on the top and bottom surfaces.
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The drop saw replaces the hand saw because it is much quicker and can cut or trim large piece of timber and the blade can also be turned at an angle for cutting things like mitre joints.
Manulal Ripper- he pieces are ripped on either side consdering the tolerance and requirement.
Edge Planar- the roller and the blade are set according to the required measurement and then the planks are fed in the machine. the roller hold the plank while it is plained along the edges.
Miter Machine- the jigd are set according to the angle required for miter joints and the planks are fd in the machine one by one. Generally cut an angle of 45 degree.
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Milling Machine- to make grooves of various depth and more than one grooves at a time.
Copy Turner- used to make circular objects with fine finish.
Drilling Machine- operates vertically to makes holes for various sizes and dept using various drill bits.
Miter machie -to make angular edges.
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Manual Sanding Flat bed Machine
The slot-cutting router bit, installed in a router table, allows you to cut slots for biscuits quickly and safely.
20 JOINTS
Adhesive joints•Urea formaldehyde: - it is a powder, which is mixed in distilled water to desired viscosity (ratio-3:1) and used. As its application is in making bongos so is also bongo glue. It is used for veneer pasting, applied on both sides, has to be clamped. Optimum drying time is 24 hrs, but the gue is stiff after 1 hr and joint can be declamped after 4 hrs. The excess glue has to be wiped within 25-30 minutes of application, as after drying its not possible.. the glue leaves just a thin line which is stainable but is hard to machine. •Araldite- good for joints where heat not required. It doesn’t give a mark but a visible unstainable joint is left. It can be used to make putty. Setting time is 25 mins which can be delayed by addiction of spirit and the viscosity can be changed. •Fevikwik- used for quick temporary joints. It leaves a mark and breaks from the joint area. •Foam tapes- used to hang small products, which have to be sprayed, and are difficult to hold. •Double- sided tape- it is a double side adhesive tape used to stick metals or labels on flat surface. It costs rs 700 for 50 metres. •Silicon glue- it is used for sticking glass as it is transparent when dry. •Chloroform- used to stick acrylic. •Fevicol- this is rubber based adhesive, which has to be clamped afterapplication. 24 hrs drying time is advisible, but after 4 hrs it can be declamped. It is used to stick certain ornaments in wood. Also used in putty for small gaps. Used on end grains in absence of wax.
21 DIFFERENT WOOD JOINTS
BUTT JOINT- are the easiest of all to make. Wood is butted face to edge or end to edge and nailed, screwed or dowelled together. End to edge joints can be joined with corrugated fasteners. Strength can be added by glueing the joining faces
MITER JOINT- are always cut to 45° in a mitre box so that they will form a 90° corner when joined. As no end wood is ever seen these are very neat joints but they are weak. Normally used for picture frames where they are nailed with panel pins
DOWEL JOINT-The end of a piece of wood is butted against another piece of wood. This is reinforced with dowel pins. This joint is quick to make with production line machinery and so is a very common joint in factory-made furniture.
FINGER JOINT- A form of box joint where the fingers are locked together by diagonal cuts. More secure than a finger joint. A lock joint is a good drawer joint because it holds together tightly as the drawer is moved
22 FINISHING PROCESS
23 FINISHING DEPARTMENT The finishing department is supervised under Mr. Sen. According to the finish and quality of the product, the work is distributed and raw material is indented or else prepared . There are 3 types of finishing done here: •Lustre •Lacquer •Burnt Lustre polish is done, but in the production unit only. There are mainly three types of lustre: •Red •White •Yellow The products once sanded lustre is applied over it by buffing machine. These products are directly sent to packaging. Lustre is done on products were grain has to be shown and the product is not highly priced.
Lustre finish is applied by buffing
24 LACQUER FINISH Lacquer is applied with spray equipment and dries very quickly. Lacquer intensifies grain and colour. It’s hard and has durable finish. Sealer is required to avoid stain from seeping into the wood, non-grain raising and water-based stains only, it must be thinned and many thin coats required. It is not used on mahogany and rosewood. At times stain is sprayed along with the lacquer. It takes minimum of 4 hrs to dry. PU is a synthetic resin varnish. Some require sealer and have a very tough finish. It’s non- yellowing, and gives glossy or satin finish. Easier to apply and dries quickly. It is incompatible with some sealers and stains. Some require special synthetic thinners. PU is used where tough finish is required. It is expensive than leather.
Hand sealer is applied that normally takes 4 hrs to dry.
The sealer is cut with 180 sand grit paper
Compressed air blow to remove minute dust & sealer is then sparyed using a sprayer. It takes approx. 3 hrs to dry.
Sealer is again sanded with hand
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Palm sanding of some products to give a uniform flat, smooth surface.
Some products are hand painted to remove grooves, stains or leftovers.
Inspection of goods before sent for colour spray
Melamine is sprayed , once the sealer cutting and colour testing is done
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Hand painting is done once melamine is sprayed and dried.
To give gloss finish the box is sanded with 600 grit sandpaper
After sanding and QC the product goes for lacquer coating
Once the lacquer is coated it is inspected. if approved goes for further assembly and if there is a defect it goes for putty repair.
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BURL EFFECT- in this finish the process is followed as in lacquer finish. The catch of burl finish is that when melamine is sprayed on sealer coat it is sanded and subjected to acetone which dissolves the surface colour leaving the white surface beneath giving it a burly effect.
Crackle: a paint effect that makes projects appear aged by creating cracks in the top layer of a painted object. Most often, people paint the base one colour (the colour of the cracks), apply the crackle, and then paint the top coat before finishing it with a sealant of some kind.
SCREEN PRINT- it should be done on the smooth side after the sealer coat on the polyester mesh. The mesh is coated with colour and sensitizer and kept for drying. Once dried the master pattern along with the coated mesh is subjected to light for 6-7 hrs. The pattern that has black looses colour on the mesh and hence the screen is created. The screen is adjusted according to the products to be printed. The ink gets smudged on the raw wood. A clear coat of lacquer is sprayed to protect the print. Once screen is created it can be used for 1000-10,000 products until the mesh gets blocked. Other different finishes can be given like the scratch look, antique look, leather look, stone look textures, etc.
28 ASSEMBLY
The products after finishing are assembled according to the sample. The good may be sent directly to packaging after assembly or go pack to post finishing as in cleaning, buffing etc. The different kinds of work done here are:
Inner and outer lining of the products- pre and post assembly.
BUTT HINGE
PIVOT HINGE
They also undertake sometypes of finishing work as well. Fixing of hinges, mahnets, laches, locks, acrylic etc all such surface workis done here.
L- HINGE
MORTISE HINGE
29 PACKAGING
This department is under Mr. U.C Jha. According to the product size, cut, shape, type, and mode of transport and according to the client’s demand its packaging is decided. The master carton cannot be heavier than 25 kg. As that the carrier rolls it, thus spoiling the carton and the goods. So, accordingly all the space and volume has to be calculated and ship’s space to be booked. Pack material used are bubble, foam, tissue wrap, soft tissue fabric and then small products boxes, with bar code and if asked company’s name. Final inspection of goods before dispatched is done here. The drop test of samples is also done here after packaging.
In case of dominoes game the pieces are sealed compactly in a plastic wrap
The box is wrapes in soft fabric along with tissue wrap and taped.
The wraped pieces are placed in the wooden box
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The tissue wrapped box is again wrapped in a foam sheet and packed in single individual boxes which is slightly bigger than the actaul product to provide breathing space.
The single boxes are stacked in the master carton vertically after trying the possible options to stack perfectly. It is then sealed along with the required information of the spiment to the company.
31 SHIPMENT
This department is controlled by Mr. Amitava Roy. When an order is received the they are thoroughly checked as to code number, price, and description and then Performa invoice is prepared. New clients have to give 35-40 % advance payment on the placement of order and the rest when the goods are shipped. Clients draw the LC on the exporter and the exporter as to compile with the entire requirement and if any discrepancy occurs then the exporter has to pay a fine. The goods are sent to the customs and the challan is made by the payment of a sum of Rs. 1500. The company pays charges up to FOB (Freight On Board)and after that the client has to bear. DOCUMENT OF LC: •Bills of exchange •Bills of lading •Proforma •Invoice •Packaging List •Certificate of Origin LC- letter of credit, it is a document drawn by the importer on the exporter in reference to the order placed. The importer parts in all the clauses of his requirements the mode of payment, the place of shipment etc. Products are even dispatched by air. This happens when the client needs the goods urgently. The airway charges depends on the weight or volume, whichever is higher. This is completely borne by the client.
32 PURCHASE DEPARTMENT
When the work order is received by the research and development department, they plan the amount of raw material, hardware, colour, and other accessories required an d forward the information to the purchase department stock indent. Depending on that the order is placed to the suppliers.
STORE MANAGEMENT
Inspection unit is under Mr. U. C Jha who checks the quality of the outgoing raw material and the incoming semi-finished products. The inspection is done with reference to some 10 samples randomly picked up. The products which are not up to the quality are not paid for. Depending on the usage of the product the stock is kept. The LIFO (Last In First Out) system is followed. A record of the quality of goods going out and coming in is kept on a bin bard that is updated regularly
MAINTAINANCE
This department is under Mr. Bhowmick who looks after mechanical maintenance, jigs, fixtures and drawing area section of the machinery. There are 3 types of maintenance followed: • Preventive • Predictive • Breakdown Preventive management safeguards the machine from frequent breakdown and ensures long life. It is done every month according to the requirement. The machines are lubricated if required parts may be changed. The record is maintained of each machine from the date of purchase. Predictive maintenance is done at the end of the year checking the record of the machine and depending on its requirements. Breakdown happens in a machine due to overload or over usage which cannot be predicted all the time so it is tried to repair them as quickly a s possible without hampering the production. The machines and tools are cleaned weekly mainly Saturday by the workmen and give the tools for sharpening. Jigs and fixtures are made by this department for any product requirements. The cost of maintenance goes in overheads. They give in their monthly budget to purchase department for their requirement including some amount for any unforeseen expenditure. They are called in for breakdowns from other factories. They encourage the use of dust collectors so as to control air pollution. Strict safety measures for labours are followed. The industry throws out solid waste to avoid water pollution. They also look after office maintenance, cleanliness and sanitation. Water tanks are cleaned every 15 days.
33 LABOUR MANAGEMENT The company has around 900- 1200 people working in house in the entire unit- including company staffs, labourers and contractual labourers. Unit III has around 100-120 people working at a time. After finishing includes more people involvement. In case of contractual labours the company pays the contractors who look after the welfare of the labourers. They also source work from Gutiarisharif – a regional craft centre 30-40 km away from Kolkata, thus aiding them as well. Facilities for the in-house labourers: • Increase in wage every year • Bonuses during durga puja • Medical help- treatment in good hospitals • Alternate year a trip for labourers of each unit with their families completely paid by the company • Holidays on certain occasions • Twice every month provided with soap and towels to all the labourers and a token for a healthy living • No child labour and encouraged
QUALITY CONTROL Hitaishi-KK is ISO 9002 certified craft company. It has QC systems as per ISO 9002 standards. Mr U.C Jha is quality management personnel who looks after that the company meets all the norms and standard required for an export company and ISO certified. There are quality checks at all the levels of production. There are supervisors at all levels to see that the production is carried out smoothly. Quality is not compromised at any levels. The goods coming from suppliers are inspected thoroughly and the rejected goods are not paid for. There is check of calibration tools every 6 months. The checking tools are calibrated in the testing house in New Airforce, under the Govt. Of West Bengal.
34 COST AND ACCOUNTING Unit III has various divisions such as department for purchase, inventory, marketing, accounts, production and planning, finishing, packaging, maintenance and shipping. The cost of each unit is estimated and then the total cost of production and sales price for the product line is determined. Thus, the cost of a product may be determined after assessing the various stages in the manufacturing process. To do so a particular cost sheet is maintained. 1- Raw material cost- being a primary cost, it includes the cost of sawing and seasoning and an added 25 % margin on the total raw material cost for the consideration of wastage. 2- Production cost- to evaluate the production cost it is important to evaluate the number of machines used in its production. Manufacturing and labour costs are two aspects of production costs. It includes cost of every aspect involved in the production from stage of raw material to the pre- finishing stages. Items such as electricity, machinery, rent, depreciation, etc are considered as machine overheads. If a special tool or a jig be required for a particular product it is added to the manufacturing overhead. If the production labour is involved the cost is accounted to the M/C. 3- Hardware cost- cost of all the hardware employed such as pins, hinges and dowels comes under components cost. 4- Finishing cost- calculated on the basis of area of product, the cost of elements includes labour, material and a certain percentage of waste and repairs. As in lacquer cost. 5- Packing cost- it includes all the packing material like tissue, sponge, bubble foam. Cotton, cartons. The labour cost is under the certified cost (salary). Other costs such as printing on cartons and touch-ups jobs before packing. 6- Transportation- as a part of overheads includes everything till FOB- approx 60% of total cost is taken as overhead. 7- Profit margin- a basic of 37 %on total cost of production is taken as the profit marginthat varies the quality and type of product line. The following is an estimated outline cost of each job in the production of a small scratch utility box.
THE MARKETING DEPARTMENT
The most crucial area of Hitaishi-KK, it is the control centre of the entire company. From arranging the various international fairs, securing buyers, maintaining public relation and client management, issuing work order, preparing deadlines, supervising the activities of the various departments to have an overview of the progress in the production, controlling costs to fixing a sales price for the product, the marketing department, must be aware of each aspect involved in the running of the company. While Mr. D.K Surekha, MD of unit III, oversees the development of all the departments, Mr. Bibhor.K.Sethi is responsible for dealing with the clients and managing work orders. Ms. Anancia Fernandes is responsible for correspondence with Hitaishi-KK’s numerous clients all over
35 ACCOUNTS DEAPRTMNET
This department manages cash transactions arising from payment of wages and salaries, payment to contractors, suppliers and vendors etc. Bills received are recorded and forwarded to the head office where all the bills are cleared. To enable convenient recording, all the departments are well computerised and connected through WIFI following tally systems. Security issues to see the smooth working, cameras are installed in each units which allows a continuous check of work done.
US •Ralph Lauren •Restoration Hardware •Interlude Home •Roost •Wisteria •Chico’s •TJX Group •Fender Group •West Music MIDDLE-EAST •Home-Center •Gazzaz •Nadia EUROPE/UK •Gewa Music •Percussion Plus •Marks & Spencers •Harrods OTHERS •Nakano (Japan) •Takashimaya (Japan) •Hollywood Home (China) •Markor Chain stores (China) •Cecelia Dale (Brazil)
CLIENTELE
36 INTERNSHIP PROJECTS Project- 1 Client- Middle East Contry(Nadia) Project Brief- The aim of the project was to design 20� square gift boxes for the festivles of Diwali and Ramangan for the Middle East countries Specification- It should hav motief of middle east country,It should look high-end, Explore with material. BOXES WITH DIFFERENT OPENINGS
The box is made in 3ds max and editing is done in Photoshop
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Project-2 Client-ENT Specialist Project Brief- The aim of the project was to design a Table Top accessory for an ENT specialist Specification- Sould not be much bigger ( max hight 5�), Sould have some utelity.
HIGHT- 9 cm WIDTH- 5 cm DEPTH- 0.5 cm MATERIAL USED- Rubber wood The design of this table top is inspired by the form of human ear. The logic behind taking this kind of inspiraion is to crating some differnt in same product watch. The clintal for this product is the doctor for ENT specilist. As the product is small and compect so this can be a great item for gifting.
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Project-3 Client-Duro Flex Project Brief- The aim of the project was to design some Table Top accessory from flexible plywood Specification- The finishing of the product sould be raw.
SLIPNOTE HOLDER
PENSTAND
DESKTOP ORGANIZER
39 SWOT ANALYSIS
STRENGTH •Unique product range that caters to high end international market. •Kolkata is a city with easy availability of cheap labour, good communication and transport system. •There is always an easy availability of raw materials. •Ancestral business. •Goodwill of the customers developed in recent years. •Large scale industry with good labour force. •Encourages new design talents and innovations. •Systematic work flow and strong quality level. WEAKNESS •Too many work orders are passed at a time that hampers the production and causes delay in meeting the deadline •Miscommunication leading to delay at each step. At some level work order are not followed and compared with the actual. •Absenteeism. May be due to lack of motivation or regular check. •Mismanagement in cost. The estimated cost in the starting if surpasses the sampling cost it creates an issue and worsens if not tallied. •Delay in raw material indent and therefore delay in sampling and shipment will effect the goodwill of Hitaishi. •Unorganised floor management. OPPURTUNITY •No company to beat Hitaishi-KK at such a level. •Variety of material exploration options. •Slight motivation among the employees can boost up the company. •Great demand of such products in the international market. •Skilled employees. •Increase inventories. •Get as much as production in-house. THREATS •Great competition in the international market from Chinese and Italian companies. •At times becomes tidies to make up to all the standards. •Safeguard company’s employees •Rising cost of raw material – wood •Less availability •Changing patterns of wood and less innovation in wood science creates problems to cope up with the desired standard of the clients •Wood being a versatile material, decorative wooden products are a challenge to replace with alternatives.
40 FEED BACK
The feedback for the industry is a basic observation that are major drawbacks, affecting work allover. • There is a lot of delay in the shipment which leaves a bad impression on customers. • Lot of absenteeism causing delay in work. • Sample department not organised. It constantly requires supervision. • The samples are lost and their whereabouts are not known. • If the production at times is slow less work should be taken. • In the sample department the labours are less and the pressure is more. • Great scope of new techniques and product range. • Should follow proper quality control measures • Proper promotion and marketing will enhance the company image.
REALIZATION
The two months internship at Hitaishi KK of Kolkata was a very good learning experience. Earlier designing to me was self acceptance and self- satisfaction but here it changed from self acceptance to customer and market acceptance. Here my designs got reviews on how production friendly it will be, how well or not will it be accepted in the market and how feasible and economical it is. Earlier mass production was least considered. In the industry, to cater to a mass market is a major factor to be considered and factors like industrial engineering has to be focused on because at times it becomes the designer’s job to get the jigs and fixtures done to get the desired product output. I got more material sensitive to make the product stand in the competitive market and make it as one of the regular product. The entire work flow in the company. Starting from raw material ti shipments all depends upon the product. It’s the duty of the designer to involve in every step of sample development. Mainly to understand the areas where the company is lagging behind in terms of production and get alternatives.
41 CONCLUSION
I am very much thankful to Mr. O.P Prahaladka for giving me this opportunity of going through this great experience. The 2 months internship has changed my perspective about a lot of things. It has helped me in my learning process to a huge extent. I could watch and learn the working very close quarters, how such an organization runs in sync. The team work, the understanding, the cooperation, everything has helped me grow on the whole. The internship was of rigorous hard work and helped me to deal things with patience.
BIBLIOGRAPHY
The later information is collected while working in the industry , some from their official website • www.hitashi.com