PRODUCTION PLANNING AND CONTROL IN
THE AUTO-ELECTRICAL INDUSTRY
A SUMMER INTERNSHIP REPORT
Registration No: 11504778
In partial fulfillment of Summer Internship for the award of the degree of
MASTER OF BUSINESS ADMINISTRATION (HONS)
School of Business
LOVELY PROFESSIONAL UNIVERSITY Phagwara, Punjab
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I, Subham Chauhan, hereby declare that this internship project report entitled
Production planning and control has been completed based on actual study carried out
by me during my 45 days internship program at Lucas TVS Limited, Rudrapur.
I am presenting an authentic report of my work to School Of Business at Lovely
Professional University, Phagwara carried out at Lucas TVS Limited, Rudrapur for the
partial fulfilment of the requirement of the Master of Business Administration degree
programme of Lovely Professional University, Phagwara
This Study based report is original and information, data and fact furnished there in are
actual based on study carried out by me.
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The satisfaction and euphoria that accompany the successful completion of any task
would be incomplete without the mention of the people made it possible and whose
guidance and encouragement.
The project is the part & parcel of M.B.A. Degree. Its my great privilege to be
associated with Lucas TVS Limited - leaders in Automotive Filters and Auto-
Electrical Equipments. The kind of expression of Lucas TVS Limited. Global &
professional attitude is what, I desired before joining. I would like to take this
opportunity to thank all the people who helped in the completion my industrial training
& in the completion of this project.
I acknowledge my deepest thanks to Mr. D. D. Satyawali (Human Resource Head)
at Lucas TVS Limited, Rudrapur for all his care & encouraging words & giving
suggestions at the crucial stages of this project.
I deliberate my profound sense of gratitude of Mr. Sunit Kumar Chauhan
(Production Head), who have rendered constant guidance, advice and help as & when,
needed to complete this project work successfully.
I am thankful to Mrs. Neeru Sidana (Assistant Professor, School of Business) for her
exertions and persistent assistance during my internship at Lucas TVS.
I am deeply indebted to my dear parents, friends whose blessings and inspirations have
brought me up to this stage of my career.
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This report is mainly focused on production planning and control towards optimizing
the resources to enhance the productivity and effective labour utilisation and to
improve the quality for better customer satisfaction. In my summer training I have
targeted Alternator (SIA114) main assembly line in Lucas TVS Limited. Normally in
this internship important motive is to give information to the plant head of the
company and production manager. After giving information to the line in charge then
we ask some question for production planning and controlling purpose like what the
production losses and the quality problems in the assembly of alternator and from
where they tried to get the solutions and up to what extend they got their problem
troubleshooting in failure of production planning and corrective and preventive action
for the quality issues. Collection of data from the quality gate (Final Dispatch) and
pre-dispatch inspection used in this report is primary and secondary. Primary data of
this project is to explore awareness among the operators and supervisors about the data
of production losses and quality problems to discuss certain best practices towards
enhancing the productivity and effective labour utilization (ELU). Arising out of the
productivity loss and secondary objective of this project is, to aware the operators and
supervisor about the product quality towards customer satisfaction.
As per the study and feedback from the operators, they are not much aware about the
productivity losses and the customer dissatisfaction about the quality and delivery. But
after giving information to the operators and line in-charge they said it is very useful
for them and said whenever they get some problem regarding the productivity and the
quality or any loss in production they will definitely minimize the 4M (Man, Machine,
Material & Method) losses and also many of the lines are facing the problems related
with the production and quality losses so there is large potential of the customer
dissatisfaction for Lucas TVS Limited.
As every other study, this study also has certain limitations. Some of the information
taken is secondary so the information taken can be wrong. The operators or supervisors
while providing the information may be bias.
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OBJECTIVE OF THE PROJECT
To study the Need and Management of Supply Chain Management of the
organization and the potential benefits of doing so.
To identify the strategic, tactical, and operations issues in supply chain
To define the term inventory and list the major reasons for holding inventories and
list the main requirements for effective inventory management.
To study the production planning and controlling process of Lucas TVS and the
techniques by which the former can enhance its productivity.
To gain real world experience of production and operations within the organization.
To enhance the skills and gain experience of being a true professional.
To understand the day to day functioning of a department within the organization.
To deal with various problems of customer and their enquiry.
To apply the various theoretical concepts in practical way within the organization.
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TABLE OF CONTENTS
S.No CONTENTS PAGE No.
1 Profile Study of Organization 13-19
Industry Analysis 14
Preliminary Understanding of the industry 15-16
Nature of demand and supply 16-19
2 History of Company 20-26
Global Expansion 25-26
3 Introduction of the Company 27-42
Mission and Vision 30-31
Life and Work Culture 33-35
Specialized Products Lucas TVS Offers 36-40
Customers of Lucas TVS 41-42
4 Organization Structure 43-48
Organization Hierarchy Under Plant 44
Organization Hierarchy Under Production 45
Awards and Recognitions 46
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Quality Policy 47-48
5 Learning From the Internship 49-67
Supply Chain Management 50-52
Production Planning 53-55
Production Scheduling 55-57
Production Monitoring 57-59
Quality Control 60-61
Pre-Dispatch Inspection 61-65
Inventory management 65-67
6 SWOT Analysis 68-74
Competitors Analysis 71-73
7 Customer Satisfaction Towards Lucas TVS
Need of the Study 76
Objective of the Study 76-77
Review of the literature 77-78
Research Methodology 79-80
8 Data Analysis and Interpretation 81-94
9 Findings and Recommendations 95-97
10 Conclusions 98-99
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11 References 100-101
12 Questionnaire 102-104
LIST OF TABLES
S.No TABLES PAGE No.
Table 3.1 Customers of Lucas TVS 42
Table 4.1 Awards and Recognitions 46
Table 5.1 Suppliers of Lucas TVS 52
Table 5.2 Cell log Sheet 54
Table 5.3 Day-Wise Breakdown 55
Table 5.4 Shift Breakdown 56
Table 5.5 Production Monitoring 63
Table 5.6 4Ms Reason 63
Table 5.7 4Ms Breakdown 64
Table 5.8 Kaizen Result Layout 65
Table 8.1 Variables Validity 82
Table 8.2 Order Validity 82
Table 8.3 Order Quantity Validity 83
Table 8.4 Order Delivery Validity 84
Table 8.5 Order Fulfilment Validity 85
Table 8.6 Package Rating Validity 86
Table 8.7 Defected Items Per Lot Validity 87
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Table 8.8 Problems in AEC Validity 88
Table 8.9 Problems in EFIP Validity 89
Table 8.10 Component Rating Validity 90
Table 8.11 KMOs Test Significance 91
Table 8.12 Communalities Extraction 92
Table 8.13 Variance Explanation 92-93
Table 8.14 Component Matrix 93
Table 8.15 Rotated Component Matrix 93
LIST OF FIGURES
S.No FIGURES PAGE NO
Fig 1.1 Engine Electrical Components 14
Fig 2.1 Customers Welcome in Lucas TVS 23
Fig 3.1 The Founder of Lucas TVS 28
Fig 3.2 Certifications 29
Fig 3.3 Plant Outlook 33
Fig 3.4 Plant Interior Layout 33
Fig 3.5 Health & Safety Policy 34
Fig 3.6 Energy Policy 34
Fig 3.7 Norms and Ethics 35
Fig 3.8 Alternator 37
Fig 3.9 Location of Alternator in Engine 37
Fig 3.10 Starter Motor 38
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Fig 3.11 Location of Starter Motor in Engine 38
Fig 3.12 Wiper Motor 39
Fig 3.13 Location of Wiper Motor in