1.

INTRODUCTION

For nearly 4 decades, Servall has partnered the pulp and paper industry worldwide, answering its need
for high performance, futuristic machinery. Today, Servall has earned itself the unique position of the
complete manufacturer. The quest for excellence in quality, design and engineering, manufacturing &
technology has spurred SERVALL’s electrifying growth over the years, enabling the company to
carve itself a prominent place in the world map of pulp and paper machinery up to 400 TPD
capacities. Servall have received ISO 9001 accrediation from TUV Nord. At Servall, the quest
for excellence is never – ending, driving the company to innovate, upgrade and develop. 500
employees are working in Servall.

YEAR OF ESTABLISHMENT: 1975

INDIAN MART MEMBER : Since 2012

NATURE OF BUSINESS : Manufacturer

LEGAL STATUS:

The legal status of the industry is limited liability. It is private limited company(51% of the shares by
own and remaining 49% from outsiders).

HOLDING COMPANY:

Servall comes under holding company and so it gets tax free dividends. Servall can control his own
policies and management.

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PRODUCT OR SERVICES:

1. Complete paper, board and kraft machines

2. Finishing house equipment

3. Drying cylinders and alloy cylinders for paper, food and chemical industries

4. Press rolls and suction rolls of Ultra High Nip Loads and extra large diameters.

5. Total solutions from servall offers total projects management and turnkey solutions, right
from concept and design to engineering, erection, execution & commissioning.

6. Total solutions are Servall’s way of saying to its customers: we’re with you, right through’.

The product line of the product produced in the company is based on product layout. The products
are:

 Head box
 Wire part
 Top former
 Dryer
 Combi-bi-nip press
 Calendar
 Pope reel
 Rebuilds
 Winders
 Sheet cutters
 Cylinder
 Suction couch roll
 Suction press roll

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ORGANISATION STRUCTURE:

PROPRITER

GENERAL MANAGER

ASSISTANT GENERAL MANAGER FACTORY MANAGER

HUMAN RESOURCE MANAGER PATTERNSHOP MANAGER

FINANCE MANAGER FOUNDRY MANAGER

PRODUCTION MANAGER MACHINE SHOP MANAGER

MARKETING MANAGER ASEMBLY MANAGER

STORES MANAGER

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 2. DEPARTMENTS

Every department has a unique position to control the activities performed in their department
in an organisation. When all the departments are co-ordinated and communicate the
department activities to each and every department, then it leads success to the organisation.
Such that, Servall have different departments and each department has separate rules to do the
departmental activities.

The various departments in servall’s are:

 Pattern shop
 Foundry
 Machine shop 1
 Machine shop 2
 Assembly
 Stores
 Design and project
 Production
 Quality control
 Human resource
 Finance
 Marketing

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 2.1 PATTERN SHOP

OBJECTIVES:

 The objective of the department is to make proper castings in the pattern shop with
the help of thermocole.
 Help to conserve material thereby avoiding wastage.

FUNCTIONS AND PROCESS:

The pattern shop is the place where various patterns required for castings are made. The
patterns are chipped in wood or made of aluminium as per the drawing given by the customer
or the design department.

A Thermocole pattern is used for single time use and is temporary. It becomes unwise to
make a wood or aluminium pattern for a part that is not going to be cast again and helps
conserve material thereby avoiding material wastage. The shop also has a cutting and
planning machine for easy working. By using these requirements the castings works are taken
place regularly. The pattern shop machines are plays a major role for manufacturing the basic
products.

Thus, the pattern shop works are taken place regularly in a predominant manner. The
problems are handled by pattern shop manager. He maintains the regular records done in the
pattern shop.

Pattern shop department is inter-relationship with foundry department. The casting made in
the department is send to the foundry for further process.

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 2.2 FOUNDRY

OBJECTIVES:

The objective of the department is to make proper moulding to make the product.

FUNCTIONS AND PROCESS:

Foundry is the place where the moulding has been made. The mould used here is carbon
dioxide mould. It is cheap and faster process for casting heavy machine parts up to 200 kgs.
The mould can be used only once unlike resin moulds (no bake system) where the sand can
be recycled and reclaimed. The mould consists of silica sand, 5% silicate oil and carbon
dioxide gas is passed through it for binding purpose.

An artificial drying machine is used in off seasons where natural drying cannot be achieved.
It can produce of 2 tonnes of sand per hour where the clay and other impurities and moisture
is removed by the heat produced in the burner. Through a pneumatic pipeline the dry sand is
transported to a hoffer where it stores 100 tonnes of sand. It is then sent to a 10 tonne hoffer
where certain additives are added such as 0.5% bentacoal which is required for core
collapsibility and 0.5% iron oxide to withstand heat, silicate oil and 1.5-1.8% carbon dioxide
gas for hardening and binding purpose.

The core box is made of wood and cast iron. Ladles of various capacity- 1 tonne to 15 tonnes
are available for pouring the molten metal into the mould. The furnace is a cupola which
produces 8 tonnes of metal per hour continuously. The fuel, coke is ignited and metal is
charged through bucket elevator. Based on the composition required appropriate weight of
pig iron, limestone, steel scrap, foundry scrap and coke is mixed. 1 charge of metal weighs
800 kgs. There are about 10 charges done. The mould pit that holds the mould of huge
cylinders and rolls is about 10 metres deep. A single casting weighs about 500 kgs to 22
tonnes. If spiral graphite iron is used it would be from 1 tonne to 10 tonnes.

Preheating of the container is done to avoid reduction of metal temperature. The containers
are made of metal and lined inside with bricks to withstand the heat. After moulds are made
using the patterns and cores, the other necessary elements such as runner, riser, sprue and in

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gates are provided for directing the metal flow. Spirit is coated on the mould and heated to
enhance the mould removal after solidification of metal. Smaller capacity ladles are called
shanks.

Inspection taken place where in the mould and castings are checked at various stages. The
mould has to include allowances such as machining, draft and shrinkage allowances are
mentioned in the drawing. If SG iron is required in the casting exothermic reaction. The
molten metal must be poured within 7-10 minutes in the mould and cooled or else it reverses
back to being cast iron. The temperature after melting is about 1450º C and it is check by
using a temperature stick. Slag removal powder is added to remove the slag floating on the
surface; the density is about 7.1-7.2 kg/mз. Volumetric analysis is done in the lab to check for
its composition. The holding ladle’s capacity is about 935 kgs.

The lab is equipped with, titrating apparatus, muffle furnace, polishing machine, metal
cutting machine, drilling machine, microscope and beam balance.

The finished product of the mould is send to the machine shop to undertake further process.
This department is linked with machine shop.

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 2.3 MACHINE SHOP

OBJECTIVES:

The objective of the machine shop is to make product by drilling and boring through various
machines.

FUNCTIONS AND PROCESS:

There are two machine shops are working in the machine shop department. The process flow
for a cylinder made of cast iron as follows:

OD turning-roughing

Riser cutting-parting

Steady cleaning

Facing

Drilling for gear wheel

Boring with gear

Finishing OD

Assembly

Hydrostatic testing

Grinding

Balancing

Rubber lining

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The drive side and tender side cover also machined and assembled to the cylinder. The pope
reel is made of mid steel and follows the same process flow. The OD of a cylinder is about
1500mm and ID is 1350mm.

The machines used in this department are:

 Planno miller
 Radial drilling
 Universal boring
 Union boring
 Floor type boring machine
 Shaper
 Balancing machine
 Grinding machine
 Vertical turret lather
 Cylinder bore
 Horizontal boring
 Universal drilling machine

After finishing the machine shop process, the semi-finished product is send to the assembly
department to assemble the semi-finished product to the finished product.

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 2.4 ASSEMBLY

OBJECTIVE:

The objective of the assembly department is to make semi-finished product into finished
product by assembling the product.

PROCESS AND FUNCTIONS:

Mock up assembly is done at the assembly shop. It is done to check for any variations that
can be corrected prior to the actual mounting in the customer’s place. This ensures that no
stone is left unturned in terms of the quality and precision of the parts assembled here. The
assembly department manager is responsible for the work made in this department. This
department is linked with stores department to keep the stock.

2.5 STORES DEPARTMENT

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OBJECTIVE:

The main objective of the stores department is to maintain the proper goods through
inspection.

FUNCTIONS AND PROCESS:

The inspection of bought out and sub contract items are done here. The stores also host a
plasma cutting machine which is programmable to cut of different counters. If stainless steel
is to be cut then water is filled completely in the machine to produce cooling effect.

The goods to be inspected are noted in the MIN- Material Inward Note where the product
specifications are checked with the required specifications.

The various types of inspection are:

1. Inward:
 Raw material
 Purchased items-standard readily available components
 Sub contract items-non standard manufacturing items.
2. Online/periodic process:

Stage wise inspection at machines on running are carried out.

3. Final inspection:

Before assembly, inspection of individual parts are taken place.

4. After assembly:

Inspection of the entire product taken place.

This department is linked with quality control department to check the quality of the product.

2.6 QUALITY CONTROL DEPARTMENT

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OBJECTIVE:

The objective of the quality control department is to maintain the proper quality of the
product.

FUNCTIONS AND PROCESS:

The quality control tools used in the quality control department are:

 Histogram
 Cause and effect diagram
 Run charts
 Control charts
 Pareto diagram
 Scatter diagram

Flow of work in planning:

Work order

Planning

Work based system number

Design

IE - routing

MRP running

Drawing released to fabrication, Subcontact, foundry.

2.7 PRODUCTION DEPARTMENT

OBJECTIVE:

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The objective of the production department is to maintain the proper production capacity and
to maintain the quality of the product.

FUNCTIONS AND PROCESS:

The paper manufacturing process has been made in the production department. The activities
made in the department are responsible to the production department manager. He has to note
each and every activity in the file case. He is responsible for the production department
works.

The paper machine manufacturing process is as follows:

Head box

Wire section

Press

Dryer

Calendar

Pope reel

Finishing section

Sheet cutters

Size Press

Head box:

The mixture of pulp and water enters into the head box where it is 96.6% water and 0.4%
pulp.

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Wire section:

This section helps in formation of fibres and their entanglement for better strength.

Press:

20% of water made of smaller diameter mild steel.

Dryer:

3 bar pressure, 120º C, and cylinders of large diameters are heated inside to enhance drying
process.

Calendar:

Calendar helps to remove wrinkling in the particle.

Pope reel:

Pope reel is used to make reeling of paper.

Finishing section:

Here, the rewinders took place. Machine width is placed to multiples of 700mm to give
standard paper size.

Sheet cutters:

Sheet cutters are used to cut the paper in the original size as the customer requirements.

Size press:

This gives a glassy finish by adding layers of starch.

The production department is inter-linked with finance department to enter the number of
products produced.

2.8 FINANCE DEPARTMENT

OBJECTIVE:

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The finance department of a business takes responsibility for organising the financial and
accounting affairs including the preparation and presentation of appropriate accounts, and the
provision of financial information for managers.

FUNCTIONS AND PROCESS:

The finance manager is responsible for the activities made in the finance department. He keep
the records for day to day transactions which has been made by the company.

Servall’s finance department keep certain records of financial transactions. They prepare
financial statement i.e. profit and loss account and balance sheet at the end of financial year.
Last year the company came across 4 crores as turnover. They are keeping the financial
statement in confidential.

The book keeping system maintained by the Servall is:

 Purchase journal
 Sales journal
 Ledger
 Debit note
 Credit note
 Demand draft
 Bank reconciliation statement

Purchase journal:

The day to day transactions regarding purchase of machinery or any other raw materials is
entered in the purchase journal. It is entered with the help of purchase bill. Purchase vouchers
also prepared for the purpose of creditors. The purchase journal includes:

a. Parties name and

Sales journal:

The day to day transactions regarding sale of machinery or raw materials are entered in this
book of accounts. This is entered with the help of bills invoice. It includes:

a. Invoice number
b. Date
c. Name of the party and
d. Amount and description of the product.

Ledger:

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Both the purchase and sales related ledger is maintained in the book of accounts. Here, both
the purchase and sales transactions is entered in the single book which is named as ledger. It
includes:

a. Name of the party

Debit note:

Debit note is prepared for purchase return, interest and commission which is received by the
company. It includes debit transaction details.

Credit note:

Credit note is prepared for sales return; interest and commission paid transactions are entered.

Bank reconciliation statement:

Servall has maintained bank reconciliation statement. They maintain their statement in Indian
Overseas Bank, Karamadai.

Hence, the finance department has inter-relationship with human resource department.

2.9 MARKETING DEPARTMENT

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OBJECTIVE:

The marketing details such as export and import and transportation, etc., are kept in the
marketing department as a report format.

FUNCTIONS AND PROCESS:

Servall’s excellence in worldwide exports. The export division is the pride of Servall, having
built up an impressive export portfolio that includes all the major paper producing nations of
the world. This division works in close association with Servall overseas agents to ensure
smooth, complete and timely commissioning, trouble-free operations and efficient service.
Today, this division has earned the company a coveted niche in the international paper
industry with its envious track record.

 Servall purchase raw materials from the local parties and they export to other
countries. Certain finished product is exported to other countries are:
 Over 1250 drying cylinders/ food dryers exported to Europe and Middle East.
 Complete dryer sections exported to South Africa and Germany.
 Complete head box is exported to Germany.
 Over-hauling and re-build services rendered in numerous paper and board plants are
exported to other foreign countries.
 As India’s first and only company to export over 1250 drying cylinders.
 Servall, the only company to design and develop a complete hydraulic head box
suitable for range of900 mpm for paper manufacturing.
 As the first Indian company to stall a multi-fourdrinier machine for 100000 TPA on-
line coated duplex board plant in India.

The clients include:

 BHEL
 Shanthi Gears
 L&T
 LMW
 Hyderabad Industries Limited
 Electro steels Castings Limited
 Sarvamangala Limited
 LNV Tech
 Dhanalakshmi controls & equipments

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After exporting or sale of product they send an enquiry to the suppliers and they get feedback
about the product. This information also recorded for future reference.The supplying and the
purchasing detail is maintained by the marketing manager in the books of accounts. Servall
handle a separate book to record this export and import transactions. It includes:

 Name of the supplier

This report is send to the finance department.

The transportation expenses and other miscellaneous expenses regarding these department
activities have been recorded by the department manager in the books of accounts of
marketing department.

2.10 HUMAN RESOURCE DEPARTMENT

OBJECTIVE:

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The objective of the human resource department is to deal with the overall functions of the
organisation.

FUNCTIONS AND PROCESS:

The Human Resource Department deals with overall functions of the organisation. First of
all, the Department is responsible for hiring members of staff; this will involve attracting
employees, keeping them in their positions and ensuring that they perform to expectation.
Besides, the Human Resource Department also clarifies and sets day to day goals for the
organisation. It is responsible for organisation of people in the entire Company and plans for
future ventures and objectives involving people in the Company. All the departments are
inter-linked with this department.

In sevall there are five officers working in the HR department. Each person have separate
work in the company. All the activities are wholly undertaken by the human resource
manager. He is responsible for the tasks done in human resource department.

As like in other company’s servall’s also maintain and doing certain activities. They are:

 Payroll
 Employee welfare
 Recruitment
 Training

Payroll: The payroll details includes pension fund(PF), allowances, deductions, gross pay
and net pay. Even though the company working under three shift, the gross pay is calculated
by number of hours worked by the employee.

Employee welfare: For each and every organisation employee welfare is important. Servall
has giving certain welfare facilities to the employees. They are:

a. Increment
b. Bonus
c. Promotion and Insurance

a. Increment:

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Increment is given to the employees who perform their work in an well versed manner.
Certain percentage is given as increment with the salary to encourage the employee for their
working performance.

b. Bonus:

Certain percentage is given as bonus to the employees which are the outcome of the profit
earned by the company. Bonus is given at the festival time. Sometimes this also can
encourage the employee to show their better performance in the work.

c. Promotion:

Promotion also given to the employee within the department he is worked or other
department in the company. It is based on the performance level of the employee.

d. Insurance :

Insurance scheme is also given to all the employees working in the company for their
welfare.

Requirement:

This is one of the most fundamental roles of the HR department. This is because this function
ensures that the Company under consideration selects the most skilful and competent person
from a sea of applicants at that time. This function involves evaluation of ability and
competency of potential employees in relation to what the Company needs. This role falls
under the Staffing role of management.

Training:

It is not necessarily a guarantee that a candidate who did well in the recruitment exercise is
the best in performing an organisation’s functions. New employees need orientation into the
Company’s functions and can also improve some inefficiency that these new employees may
have in relation to their skills. This is the purpose of placing them on training.

3. CONCLUSION

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Thus the training period undertaken at SERVALL ENGINEERING WORKS helped me to
understand the functioning of various departmental activities and processes of the company.
The training gave me in depth of knowledge and insight into the working of never seen. It is
very enlightening and helpful to my summer internship training.

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