Industrial Visit Report

Date of Visit : November 12, 2024

College: Shri Varshney College, Aligarh

Company To Visit : Pavna Industries Pvt. Ltd.

 Acknowledgment

I would like to convey my heartfelt gratitude to Pawna Industries for allowing

us to visit their facility and get great insights into their operations. The visit was

both informative and motivating, allowing us to grasp practical aspects beyond

theoretical understanding. I want to express my heartfelt gratitude to Shri

Varshney College for their continual advice and encouragement throughout the

visit. Their supervision ensured that we maximized our learning and made the

most of our experience. Their knowledge and professionalism made this visit

extremely instructive and memorable. Thank you for making this opportunity

both possible and meaningful.

  Table of Contents

 Introduction

 Pavna’s History

 Pavna’s Leadership Team

 Pavna’s Certifications

 Objectives of the Visit

 Description of the Visit

 Learning Outcomes

 Analysis and Observation

 Conclusion

 Recommendations

 Appendices

 Bibliography
 Introduction:

Pavna Group, founded in 1971 by the visionary Shri Pawan Jain, has a long

history of innovation and growth in the automobile industry. They have become

a key participant in South Asia, supplying parts to well-known original

equipment manufacturers. Okinawa, Tata, and Ola. Beginning with a dye

casting machine, Shri Pawan Jain's persistent efforts and fearless spirit have

propelled him to the pinnacle of success. As the years passed, he created an

aluminum dye casting process and established an unparalleled network across

India, including the south, Gujarat, Uttar Pradesh, Karnataka, Madhya Pradesh,

Rajasthan, and Delhi.

He passed his legacy beaten to Mr. Swapnil Jain who added golden feathers in

Pavna’s basket. He developed modified & digitalised Pavna units. Result of

this Pavna group is leading the automation market in South East Asia with his

eye on Global market.

This report provides a detailed account of an industrial visit conducted by

students of Shri Varshney College, Aligarh, to Pavna Industries, Aligarh, on

November 12 , 2024. The visit offered a comprehensive look into the workings

of this leading automotive component manufacturer.

 Company History

Pavna group, founded in 1971 by the visionary Shri Pawan Jain, boasts a rich

history of innovation and growth within the automotive sector . Driven by a

commitment to quality and competitive pricing, they have become a prominent

player in south asia , supplying parts to renowned original equipment

manufacturers .

Okinawa, Tata, And Ola . Beginning with a dye casting machine, is now

touching the zenith which was only possible with the tireless efforts and

dauntless spirit of Shri Pawan Jain. As the years rolled by, he himself

developed an aluminum dye casting machine and erected an unparallel network

in India including south , Gujrat, U.P, Karnataka, M.P. Rajasthan and Delhi.

He got a break when Bajaj Automobiles became the first O.E.M buyer from the

organization, with his efforts and quality products in best competitive price in

market he seal the deal, since then this is the USP of Pavna Group.

He passed his legacy beaten to Mr. Swapnil Jain who added golden feathers in

PAVNA’s basket. He developed modified & digitalised Pavna units. Result of

this Pavna group is leading the automation market in South East Asia with his

eye on Global market.

 Pavna's Certifications

All Pavna units boast ITAF and OHSAS certifications, demonstrating their

dedication to quality and safety standards.

 Objectives of the Visit

The visit aims to provide students with practical exposure to the operations and
management of an organization, bridging the gap between theoretical
knowledge and real-world application. By observing and interacting with
industry professionals, students will develop a deeper understanding of business
processes, organizational structure, and decision-making dynamics.

Key objectives include:

1. Gaining insights into the organization's operations, culture, and key

strategies.
2. Observing real-world applications of classroom theories such as marketing,
production, human resource management, and finance.
3. Understanding challenges faced by the organization and how they are
managed.
4. Enhancing students' analytical, observational, and critical thinking skills.
5. Encouraging students to interact with professionals, fostering networking and
interpersonal skills.
 Description of the visit:

The college visit focused on a deep dive into two specific units of Pavna

Industries : unit 3 and unit 4 .

Unit 3 - a high-volume production hub

Workforce: a massive team of approximately 800 workers.

Operation: 24-hour manufacturing divided into two shifts.

Production plant head: SG Rajput

Turnover: estimated at ₹150 crores (target: ₹200 crores in 2024)

Focus: a wide array of automotive components, including:

Key production: key making and key cutting processes.

Automotive components: Ignition switches, fuel tank

caps, fuel cocks, engine components.

New focus areas: introduction of AC , DC and Virtual

lock production.

Machinery: Multiple, Sophisticated machines with two workers assigned per

machine for efficient operation.

Clientele: a prestigious list of clients includes Bajaj , TVS , Mahindra Electric ,

Tata , and Ola.

 Unit 4 - casting expertise (established 2017):

Workforce: An estimated workforce of 300-400 workers.

Operation: single-shift operation with 8-hour workdays. Overtime work is

compensated with additional pay.

Bonus scheme: workers who complete 26 working days in a month receive a

bonus of ₹1000.

Working hours: 9:00 am to 6:00 pm

Focus on casting: unit 4 specializes in the casting process, where molten metal

is poured into molds to create specific components.

Standardized work hours: the single-shift operation with fixed working hours

allows for better work-life balance for employees compared to Unit 3's 24/7

operations.
 Network

With more than nine industrial facilities, the firm is well-represented throughout

India.

Over the years, he created his own aluminum dye casting equipment and

established an unparalleled network throughout India, encompassing Gujrat,

U.P., Karnataka, M.P., Rajasthan, Delhi, and the south. He received a break

when Bjajaj Automobiles became the company's first O.E.M. buyer. He sealed

the sale with his hard work and high-quality products at the most competitive

price in the market, and this has been the Pavna Group's USP ever since.

He gave his heritage to Mr. Swapnil Jain, who embellished Pavna's basket with

golden feathers. He created digitalized and modified Pavna units. As a result,

the Pavna group is currently dominating the South East Asian automation sector

while keeping an eye on the global market.

 Learning Outcomes of the Industrial Visit to Pavna Industries, Aligarh

The industrial visit to Units 1 and 2 of Pavna Industries provided an invaluable

learning experience for students, combining theoretical knowledge with hands-
on exposure to real-world industrial processes. This report highlights the
contribution of the visit to academic and practical knowledge and outlines key
takeaways across various functional areas such as marketing, human resources,
finance, and operations.

 Contribution to Academic and Practical Knowledge

(a) Academic Knowledge Enhancement

1. Integration of Theory with Practice:

Students observed how textbook concepts like production management, quality

control, and supply chain optimization are implemented in real-life
manufacturing processes.

2. Understanding Organizational Goals:

The focus on achieving a turnover target of ₹200 crores by 2024 and

diversifying into products like AC, DC, and virtual locks demonstrated strategic
goal-setting and planning.

3. Production and Automation:

Exposure to key-making, key-cutting, and automobile parts manufacturing
processes helped students understand industrial automation and its role in
improving efficiency and productivity.

(b) Practical Knowledge Acquisition

1. Operational Processes:

Students gained a first-hand understanding of production line activities,

machine operations, and workforce coordination.

2. Workforce Management:

The bonus system for workers and flexible shifts in Unit 4 highlighted strategies
to enhance employee motivation and productivity.

3. Client Relationship Management:

Working with major clients like Bajaj, TVS, Tata, Ola, and Mahindra Electric
showcased the importance of maintaining strong business relationships.

 Key Takeaways for Students

(a) Marketing

1. Client Partnerships:

Pavna Industries' association with leading companies like Tata, Bajaj, and Ola
highlighted the role of strong client partnerships in sustaining business growth.
2. Product Diversification:

The company’s aim to introduce AC, DC, and virtual locks emphasized the
importance of innovation and market expansion strategies.

3. Brand Positioning:

The company's reputation for manufacturing high-quality components like

ignition switches and fuel tank caps reinforced the significance of quality in
brand building.

(b) Human Resources (HR)

1. Workforce Management:

Unit 3’s 24-hour operations in two shifts demonstrated efficient workforce

planning for continuous production.

2. Employee Incentives:

The bonus system in Unit 4, rewarding employees for consistent attendance,

highlighted the importance of incentivizing workers to boost productivity.

3. Labor Welfare:

Extra payment for overtime work and a structured work schedule in Unit 4
reflected the organization’s commitment to labor welfare and compliance with
labor laws.
 (c) Finance

1. Turnover and Growth Goals:

Unit 3’s turnover of ₹150 crores and the target of ₹200 crores demonstrated the
role of financial planning and forecasting in driving organizational growth.

2. Cost Efficiency:

Efficient utilization of machinery and labor, with two workers assigned per
machine, emphasized cost optimization in manufacturing processes.

3. Capital Investment:

Investment in advanced machines and new product lines like AC and DC locks
illustrated strategic financial decisions to achieve long-term profitability.

(d) Operations

1. 24-Hour Production Cycle:

Unit 3’s round-the-clock manufacturing in two shifts showcased effective

operational planning to meet high production demands.

2. Casting Components in Unit 4:

Observing the production of grab handles, step holders, and coupling sprockets
gave insights into precision engineering and quality control processes.

3. Machine Utilization:

The assignment of two workers per machine for processes like key-making and
key-cutting highlighted the importance of balancing human and machine
efficiency.
4. Supply Chain Integration:

The production of components for leading automotive clients illustrated

seamless supply chain integration to meet client-specific requirements.

 Overall Benefits for Students

1. Comprehensive Industry Exposure:

Students gained a holistic understanding of manufacturing processes, from raw

material handling to finished product delivery.

2. Strategic Thinking:

Observing the company’s goals and operations provided insights into strategic
decision-making and goal alignment across departments.

3. Professional Insights:

Interaction with the Production Plant Head, SG Rajput, helped students

understand leadership roles and responsibilities in large-scale industrial
operations.

4. Career Inspiration:

The visit offered exposure to potential career opportunities in engineering,

production management, and operations within a dynamic industrial setup.

5. Enhanced Practical Knowledge:

By observing real-world applications of concepts like workforce management,
quality control, and client servicing, students were able to contextualize their
academic learning.
 Analysis and Observation

The visit to Pavna Industries, encompassing Units 1 and 2, provided a

comprehensive view of the company's manufacturing capabilities, operational
efficiency, workforce management, and strategic goals. This section outlines a
SWOT analysis of Pavna Industries, followed by detailed observations of its
business practices and processes.

 SWOT Analysis of Pavna Industries

 Strengths

1. Diversified Product Portfolio:

Pavna Industries manufactures a wide range of components, such as ignition

switches, fuel tank caps, fuel cocks, and engine components, catering to leading
clients like Bajaj, TVS, Mahindra Electric, Tata, and Ola.

2. Strong Client Base:

The company has established relationships with renowned automotive and

electric vehicle manufacturers, ensuring a steady revenue stream.

3. Operational Efficiency:

Unit 3 operates 24/7 with two shifts, supported by advanced machinery and an
efficient workforce allocation system (two workers per machine).
4. Experienced Leadership:

The strategic leadership of the Production Plant Head, SG Rajput, ensures

smooth operations and goal alignment.

5. Innovation-Driven Goals:

Plans to diversify into AC, DC, and virtual locks indicate a forward-looking
approach and a commitment to staying competitive in the market.

 Weaknesses

1. Labor-Intensive Operations:

While efficient, the reliance on manual labor (e.g., two workers per machine)
might slow down production scaling compared to fully automated processes.

2. High Dependency on Key Clients:

Although the company serves prominent brands, over-reliance on a few large

clients could pose risks if market dynamics or client preferences change.

3. Limited Visibility of Environmental Initiatives:

The visit did not highlight any specific focus on sustainability or eco-friendly
practices, which are increasingly important in today’s business landscape.

 Opportunities

1. Expansion into Emerging Markets:

The production of AC, DC, and virtual locks can help the company tap into
growing markets for advanced locking solutions.

2. Enhanced Automation:

Adopting advanced automation technologies could improve efficiency and

reduce dependency on manual labor.

3. Sustainability Integration:

Implementing environmentally friendly manufacturing practices can help attract

eco-conscious clients and align with global sustainability standards.

4. Diversification of Client Base:

Exploring new partnerships beyond the automotive sector can reduce

dependency on a single industry and open up additional revenue streams.

 Threats

1. Competition in Automotive Components:

The automotive components market is highly competitive, with many players

vying for market share.

2. Economic Fluctuations:

Market downturns or reduced demand in the automotive sector could impact the
company’s revenue.

3. Labor Challenges:
Over-dependence on manual labor increases vulnerability to labor strikes,
shortages, or rising wage demands.

4. Technological Advancements by Competitors:

Rivals adopting cutting-edge technologies could pose a challenge to Pavna’s

market position.
 Conclusion

The industrial visit to Pavna Industries, covering Units 1 and 2, was an

insightful experience that bridged the gap between academic learning and

practical industry exposure. Pavna Industries, with its extensive product

portfolio and strong client base, stands out as a leader in the automotive

components manufacturing sector.

Unit 3 demonstrated exceptional operational efficiency, with its 24-hour

production cycle supported by advanced machinery and a dedicated workforce.

The turnover of ₹150 crores and the ambitious target of ₹200 crores by 2024

underscore the company’s growth-oriented approach. Plans to diversify into AC,

DC, and virtual locks further illustrate its commitment to innovation.

Unit 4, established in 2017, showcased a structured approach to labor

management and productivity. Its focus on casting components for automotive

use, along with effective worker incentive systems, reflects an organizational

culture centered on quality and employee satisfaction.

The visit provided valuable insights into operational planning, workforce

management, and client relationship management, reinforcing key business

concepts. However, the company can enhance its operations by addressing

certain areas of improvement, such as automation and sustainability initiatives.

Recommendations:

To further strengthen its position and meet future challenges, Pavna Industries

should consider the following recommendations:

1. Enhance Automation:

Invest in advanced automation technologies to increase production efficiency

and reduce dependency on manual labor.

Automating repetitive tasks can also improve product consistency and reduce

operational costs in the long run.

2. Focus on Sustainability:

Implement environmentally friendly manufacturing practices, such as energy-

efficient machinery and waste reduction systems.

Highlight sustainability efforts in marketing and branding to appeal to eco-

conscious clients and stakeholders.

3. Expand Product Portfolio:

While diversifying into AC, DC, and virtual locks is a promising step, exploring

other high-demand areas, such as components for electric vehicles (EVs) and

renewable energy systems, can help future-proof the business.

4. Strengthen Workforce Training:

Regularly update training programs to ensure employees stay proficient in

handling new technologies and processes.

Introduce certifications or partnerships with technical institutes to upskill

workers.

5. Enhance Client Diversification:

Reduce dependency on automotive clients by targeting other industries, such as

home automation or industrial machinery.

Explore international markets to expand the client base and revenue streams.

6. Leverage Digital Marketing and Branding:

Increase visibility through an updated and detailed online presence, showcasing

achievements, innovations, and client testimonials.

Use social media and digital platforms to reach a broader audience and attract

potential partners.

7. Strengthen Data-Driven Decision Making:

Implement advanced analytics tools to monitor production efficiency, predict

maintenance needs, and analyze market trends for better strategic planning.
 Appendices

Entrance of Pavna Industries (Unit 3 and Unit 4)

Workers operating key cutting and key making machines in Unit 3

Production setup for ignition switches in Unit 3

Casting components setup in Unit 4

Charts, Graphs, or Data

1. Comparison of Workforce and Operations

Unit Year Number of Working Shift Type

Established workers Hours

Unit 3 2010 750-800 240 hours Continuous

(2 shifts)

Unit 4 2017 300-400 8 hours Single

(9:00 AM– Shift

6:00 PM)

2. Turnover and Goals (Unit 3)

Current Turnover: ₹150 Crores

2024 Target Turnover: ₹200 Crores

3. Production Goals (Unit 3)

Ongoing: Ignition switches, fuel tank caps, engine components, etc.

Future: AC, DC, and virtual locks production.

4. Ratios

Additional Notes

Bonus Policy (Unit 4):

Workers who work for more than 26 days in a month receive a ₹1000 bonus.

Overtime Policy:
Extra work hours beyond the standard shift of 9:00 AM to 6:00 PM are

compensated separately.

Machinery Details (Unit 3):

Each machine (key making, key cutting, etc.) is operated by two workers

simultaneously, ensuring precision and productivity.

Major Components Manufactured:

Unit 3: Ignition switches, fuel tank caps, fuel cocks, and engine components.

Unit 4: Casting components like grab handles, step holders, cover rear, coupling

with sprockets, etc.

References

1. Website: pavna.in

2. On-Site Observations during the visit to Units 3 and 4.

3. Discussions with SG Rajput (Production Plant Head, Unit 3).This layout

should effectively present the data and additional details for your industrial visit

report.
 Bibliography/References

1. Pavna Industries Official Website

Website: www.pavna.in

Information on production units, products, and company overview.

2. On-Site Observations

Direct insights and data collected during the industrial visit to Pavna Industries

Unit 1 and Unit 4 in Aligarh.

3. Discussions with Production Plant Head

Insights provided by SG Rajput, the Production Plant Head of Unit 1, regarding

workforce, turnover, and future goals.

4. Employee Interactions
Conversations with workers about shifts, payment structures, and production

operations in both units.

5. Company Client List and Product

Information on the company’s clients (e.g., Bajaj, TVS, Tata, Ola) and products

like ignition switches, fuel tank caps, and casting components observed during

the visit.

6. Unit 2 Documentation

Details on the establishment, workforce, working hours, and products (e.g., grab

handles, step holders, coupling components) as per the observations made at the

site.